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TECHNICAL FIELD
[0001] The present invention relates to a high-speed evaporator defrost system for defrosting refrigeration coils of evaporators in a short period of time without having to increase compressor head pressure.
BACKGROUND ART
[0002] In refrigeration systems found in the food industry to refrigerate fresh and frozen foods, it is necessary to defrost the refrigeration coils of the evaporators periodically, as the refrigeration systems working below the freezing point of water are gradually covered by a layer of frost which reduces the efficiency of evaporators. The evaporators become clogged up by the build-up of ice thereon during the refrigeration cycle, whereby the passage of air maintaining the foodstuff refrigerated is obstructed. Exposing foodstuff to warm temperatures during long defrost cycles may have adverse effects on their freshness and quality.
[0003] One method known in the prior art for defrosting refrigeration coils uses an air defrost method wherein fans blow warm air against the clogged-up refrigeration coils while refrigerant supply is momentarily stopped from circulating through the coils. The resulting defrost cycles may last up to about 40 minutes, thereby possibly fouling the foodstuff.
[0004] In another known method, gas is taken from the top of the reservoir of refrigerant at a temperature ranging from 80° F. to 90° F. and is passed through the refrigeration coils, whereby the latent heat of the gas is used to defrost the refrigeration coils. This also results in a fairly lengthy defrost cycle.
[0005] U.S. Pat. No. 5,673,567, issued on Oct. 7, 1997 to the present inventor, discloses a system wherein hot gas from the compressor discharge line is fed to the refrigerant coil by a valve circuit and back into the liquid manifold to mix with the refrigerant liquid. This method of defrost usually takes about 12 minutes for defrosting evaporators associated with open display cases and about 22 minutes for defrosting frozen food enclosures. The compressors are affected by hot gas coming back through the suction header, thereby causing the compressors to overheat. Furthermore, the energy costs increases with the compressor head pressure increase.
[0006] U.S. Pat. No. 6,089,033, published on Jul. 18, 2000 to the present inventor, introduces an evaporator defrost system operating at high speed (e.g., 1 to 2 minutes for refrigerated display cases, 4 to 6 minutes for frozen food enclosures) comprising a defrost conduit circuit connected to the discharge line of the compressors and back to the suction header through an auxiliary reservoir capable of storing the entire refrigerant load of the refrigeration system. The auxiliary reservoir is at low pressure and is automatically flushed into the main reservoir when liquid refrigerant accumulates to a predetermined level. The pressure difference between the low pressure auxiliary reservoir and the typical high pressure of the discharge of the compressor creates a rapid flow of hot gas through the evaporator coils, thereby ensuring a quick defrost of the refrigeration coils. Furthermore, the suction header is fed with low-pressure gas to prevent the adverse effects of hot gas and high head pressure on the compressors.
SUMMARY OF INVENTION
[0007] It is a feature of the present invention to provide a high-speed defrost refrigeration system that operates a defrost of evaporators at low pressure.
[0008] It is a further feature of the present invention to provide a high-speed defrost refrigeration system having a compressor dedicated to defrost cycles.
[0009] It is a still further feature of the present invention to provide a high-speed defrost refrigeration system having a low-pressure defrost loop.
[0010] It is a still further feature of the present invention to provide a method for defrosting at high-speed refrigeration systems with low-pressure in the evaporators.
[0011] It is a still further feature of the present invention to provide a method for operating a high-speed defrost refrigeration system having a compressor dedicated to defrost cycles.
[0012] According to the above features, from a broad aspect, the present invention provides a defrost refrigeration system of the type having a main refrigeration circuit, wherein a refrigerant goes through at least a compressing stage, wherein the refrigerant is compressed to a high-pressure gas state to then reach a condensing stage, wherein the refrigerant in the high-pressure gas state is condensed at least partially to a high-pressure liquid state to then reach an expansion stage, wherein the refrigerant in the high-pressure liquid state is expanded to a first low-pressure liquid state to then reach an evaporator stage, wherein the refrigerant in the first low-pressure liquid state is evaporated at least partially to a first low-pressure gas state by absorbing heat, to then return to the compressing stage. The defrost refrigeration system comprises a first line extending from the compressing stage to the evaporator stage and adapted to receive a portion of the refrigerant in the high-pressure gas state. A first pressure reducing device on the first line reduces a pressure of the portion of the refrigerant in the high-pressure gas state to a second low-pressure gas state. Valves stop a flow of the refrigerant in the first low-pressure liquid state to at least one evaporator of the evaporator stage and direct a flow of the refrigerant in the second low-pressure gas state to release heat to defrost the at least one evaporator and thereby change phase at least partially to a second low-pressure liquid state. A second line directs the refrigerant having released heat to at least one of the compressing stage and the condensing stage.
[0013] According to a further broad feature of the present invention, there is provided a defrost refrigeration system of the type having a main refrigeration circuit, wherein a refrigerant goes through at least a first compressor in a compressing stage, wherein the refrigerant is compressed to a high-pressure gas state to then reach a condensing stage wherein the refrigerant in the high-pressure gas is condensed at least partially to a high-pressure liquid state to then reach an expansion stage, wherein the refrigerant in the high-pressure liquid state is expanded to a first low-pressure liquid state to then reach an evaporator stage, wherein the refrigerant in the first low-pressure liquid state is evaporated at least partially to a first low-pressure gas state by absorbing heat, to then return to the compressing stage. The defrost refrigeration system comprises a first line extending from the compressing stage to the evaporator stage and is adapted to receive a portion of the refrigerant in the high-pressure gas state. Valves stop a flow of the refrigerant in the first low-pressure liquid state to at least one evaporator of the evaporator stage and direct a flow of the portion of the refrigerant in the high-pressure gas state to release heat to defrost the at least one evaporator and thereby change phase to a second low-pressure liquid state. A dedicated compressor is adapted to receive an evaporated gas portion of the refrigerant in the second low-pressure liquid state. The dedicated compressor is connected to the condensing stage for directing a discharge thereof to the condensing stage.
[0014] According to a still further broad feature of the present invention, there is provided a method for defrosting evaporators of a refrigeration system of the type having a main refrigeration circuit, wherein a refrigerant goes through at least a compressing stage, wherein the refrigerant is compressed to a high-pressure gas state to then reach a condensing stage, wherein the refrigerant in the high-pressure gas state is condensed at least partially to a high-pressure liquid state to then reach an expansion stage, wherein the refrigerant in the high-pressure liquid state is expanded to a first low-pressure liquid state to then reach an evaporator stage, wherein the refrigerant in the first low-pressure liquid state is evaporated at least partially to a first low-pressure gas state by absorbing heat, to then return to the compressing stage. The method comprises the steps of i) stopping a flow of the refrigerant in the first low-pressure liquid state to at least one evaporator of the evaporator stage; ii) reducing a pressure of a portion of the refrigerant in the high-pressure gas state to a second low-pressure gas state; and iii) directing the portion of the refrigerant in the second low-pressure gas state to the at least one evaporator to release heat to defrost the at least one evaporator and thereby changing phase at least partially to a second low-pressure liquid state.
[0015] According to a still further broad feature of the present invention, there is provided a method for defrosting evaporators of a refrigeration system of the type having a main refrigeration circuit, wherein a refrigerant goes through at least a compressing stage having at least a first compressor, wherein the refrigerant is compressed to a high-pressure gas state to then reach a condensing stage, wherein the refrigerant in the high-pressure gas state is condensed at least partially to a high-pressure liquid state to then reach an expansion stage, wherein the refrigerant in the high-pressure liquid state is expanded to a first low-pressure liquid state to then reach an evaporator stage, wherein the refrigerant in the first low-pressure liquid state is evaporated at least partially to a first low-pressure gas state by absorbing heat, to then return to the compressing stage. The method comprises the steps of i) stopping a flow of the refrigerant in the first low-pressure liquid state to at least one evaporator; ii) directing a portion of the refrigerant in the high-pressure gas state to the at least one evaporator to release heat to defrost the at least one evaporator and thereby changing phase at least partially to a second low-pressure liquid state; and iii) directing an evaporated gas portion of the refrigerant in the second low-pressure gas state to a dedicated compressor, the dedicated compressor being connected to the condensing stage for directing a discharge thereof to the condensing stage.
[0016] According to a still further broad feature of the present invention, there is provided a defrost refrigeration system of the type having a main refrigeration circuit, wherein a refrigerant goes through at least a compressing stage, wherein the refrigerant is compressed to a high-pressure gas state to then reach a condensing stage, wherein the refrigerant in the high-pressure gas state is condensed at least partially to a high-pressure liquid state to then reach an expansion stage, wherein the refrigerant in the high-pressure liquid state is expanded to a first low-pressure liquid state to then reach an evaporator stage, wherein the refrigerant in the first low-pressure liquid state is evaporated at least partially to a first low-pressure gas state by absorbing heat, to then return to the compressing stage. The defrost refrigeration system comprises a first line extending from the compressing stage to the evaporator stage and adapted to receive a portion of the refrigerant in the high-pressure gas state. Valves are provided for stopping a flow of the refrigerant in the first low-pressure liquid state to at least one evaporator of the evaporator stage and directing a flow of the refrigerant in the high-pressure gas state to release heat to defrost the at least one evaporator and thereby changing phase at least partially to a second low-pressure liquid state. A second line is provided for directing the refrigerant having released heat to the compressing stage, and pressure control means in the second line for controlling a pressure of the refrigerant reaching the compressing stage.
[0017] According to a still further broad feature of the present invention, there is provided a defrost refrigeration system of the type having a main refrigeration circuit, wherein a refrigerant goes through at least a compressing stage, wherein the refrigerant is compressed to a high-pressure gas state to then reach a condensing stage, wherein the refrigerant in the high-pressure gas state is condensed at least partially to a high-pressure liquid state to then reach an expansion stage, wherein the refrigerant in the high-pressure liquid state is expanded to a first low-pressure liquid state to then reach an evaporator stage, wherein the refrigerant in the first low-pressure liquid state is evaporated at least partially to a first low-pressure gas state by absorbing heat, to then return to the compressing stage. The defrost refrigeration system comprises a first line extending from the compressing stage to the evaporator stage and adapted to receive a portion of the refrigerant in the high-pressure gas state. Valves are provided for stopping a flow of the refrigerant in the first low-pressure liquid state to at least two evaporators of the evaporator stage and directing a flow of the refrigerant in the high-pressure gas state to release heat to defrost the at least two evaporators and thereby changing phase at least partially to a second low-pressure liquid state. A second line is provided for directing the refrigerant having released heat in the at least two evaporators to the compressing stage. Temperature monitor means are adapted to monitor an average temperature of the refrigerant in the second line and to reverse an action of the valves when the temperature reaches a predetermined value to re-establish the flow of the refrigerant in the first low-pressure liquid state to the at least two evaporators of the evaporator stage.
[0018] According to a still further broad feature of the present invention, there is provided a defrost refrigeration system of the type having a main refrigeration circuit, wherein a refrigerant goes through at least a compressing stage, wherein the refrigerant is compressed to a high-pressure gas state to then reach a condensing stage, wherein the refrigerant in the high-pressure gas state is condensed at least partially to a high-pressure liquid state to then reach an expansion stage, wherein the refrigerant in the high-pressure liquid state is expanded by an expansion valve to a first low-pressure liquid state to then reach an evaporator stage, wherein the refrigerant in the first low-pressure liquid state is evaporated at least partially to a first low-pressure gas state by absorbing heat, to then return to the compressing stage. The defrost refrigeration system comprises a first line extending from the compressing stage to the expansion stage and adapted to receive a portion of the refrigerant in the high-pressure gas state. Valves are provided for stopping a flow of the refrigerant in the first low-pressure liquid state to at least one evaporator of the evaporator stage and directing a flow of the refrigerant in the high-pressure gas state around the expansion valve to the at least one evaporator of the evaporator stage to release heat to defrost the at least one evaporator and thereby changing phase at least partially to a second low-pressure liquid state, to then be directed to the compressing stage.
[0019] According to a still further broad feature of the present invention, there is provided a defrost refrigeration system of the type having a main refrigeration circuit, wherein a refrigerant goes through at least a compressing stage having at least a first and a second compressor, wherein the refrigerant is compressed to a high-pressure gas state to then reach a condensing stage, wherein the refrigerant in the high-pressure gas state is condensed at least partially to a high-pressure liquid state to then reach an expansion stage, wherein the refrigerant in the high-pressure liquid state is expanded to a first low-pressure liquid state to then reach an evaporator stage, wherein the refrigerant in the first low-pressure liquid state is evaporated at least partially to a first low-pressure gas state by absorbing heat, to then return to the compressing stage. The defrost refrigeration system comprises a first line extending from the first compressor to the evaporator stage and adapted to receive at least a portion of discharged low-pressure refrigerant from the first compressor. Valves are provided for stopping a flow of the refrigerant in the first low-pressure liquid state to at least one evaporator of the evaporator stage and directing a flow of the discharged low-pressure refrigerant to release heat to defrost the at least one evaporator and thereby changing phase at least partially to a second low-pressure liquid state. A second line is provided for directing the refrigerant having released heat to the evaporator stage.
BRIEF DESCRIPTION OF DRAWINGS
[0020] A preferred embodiment of the present invention will now be described with reference to the accompanying drawings in which:
[0021] [0021]FIG. 1 is a block diagram showing a simplified refrigeration system constructed in accordance with the present invention;
[0022] [0022]FIG. 2 is a schematic view showing a refrigeration system constructed in accordance with the present invention;
[0023] [0023]FIG. 3 is an enlarged schematic view of an evaporator unit of the refrigeration system;
[0024] [0024]FIG. 4 is an enlarged schematic view of an evaporator unit in accordance with another embodiment of the present invention;
[0025] [0025]FIG. 5 is a block diagram showing a simplified refrigeration system constructed in accordance with another;
[0026] [0026]FIG. 6 is a block diagram showing a simplified refrigeration system constructed in accordance with still another embodiment of the present invention; and
[0027] [0027]FIG. 7 is a schematic view showing the refrigeration system of FIG. 6.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] Referring to the drawings, and more particularly to FIG. 1, a refrigeration system in accordance with the present invention is generally shown at 10 . The refrigeration system 10 comprises the components found on typical refrigeration systems, such as compressors 12 (one of which is 12 A, for reasons to be described hereinafter), a high-pressure reservoir 16 , expansion valves 18 , and evaporators 20 . The refrigeration system 10 is shown having a heat reclaim unit 22 , which is optional. In FIG. 1, the refrigeration system 10 is shown having only two sets of evaporator 20 /expansion valve 18 for the simplicity of the illustration. It is obvious that numerous other sets of evaporator 20 /expansion valve 18 may be added to the refrigeration system 10 .
[0029] The compressors 12 are connected to the condenser units 14 by lines 28 . A pressure regulator 21 is in the line 28 but is not in operation during normal refrigeration cycles, and is thus normally open to enable refrigerant flow therethrough. High-pressure gas refrigerant is discharged from the compressors 12 and flows to the condenser units 14 through the line 28 . A line 30 diverges from the line 28 by way of three-way valve 32 . The line 30 extends between the three-way valve 32 and the heat reclaim unit 22 . A line 34 connects the condenser units 14 to the high-pressure reservoir 16 , and a line 36 links the heat reclaim unit 22 to the high-pressure reservoir 16 . The condenser units 14 are typically rooftop condensers that are used to release energy of the high-pressure gas refrigerant discharged by the compressors 12 by a change to the liquid phase. Accordingly, refrigerant accumulates in the high-pressure reservoir 16 in a liquid state.
[0030] Evaporator units 17 are connected between the high-pressure reservoir 16 and the compressors 12 . Each of the evaporator units 17 has an evaporator 20 and an expansion valve 18 . The expansion valves 18 are connected to the high-pressure reservoir 16 by line 38 . As known in the art, the expansion valves 18 create a pressure differential so as to control the pressure of liquid refrigerant sent to the evaporators 20 . The outlet of the evaporators 20 are connected to the compressors 12 by lines 48 . The compressors 12 are supplied with low-pressure gas refrigerant via supply lines 48 . The expansion valves 18 control the pressure of the liquid refrigerant that is sent to the evaporators 20 , such that the liquid refrigerant changes phases in the evaporators 20 by a fluid, such as air, blown across the evaporators 20 to reach refrigerated display counters (e.g., refrigerators, freezers or the like) at low refrigerating temperatures.
[0031] Refrigerant in the refrigeration system 10 is in a high-pressure gas state when discharged from the compressors 12 . For instance, a typical head pressure of the compressors is 200 Psi. The compressor head pressure obviously changes as a function of the outdoor temperature to which will be subject the refrigerant in the condensing stage. The high-pressure gas refrigerant is conveyed to the condenser units 14 and, if applicable, to the heat reclaim unit 22 via the line 28 and the line 30 , respectively.
[0032] In the condenser units 14 and the heat reclaim unit 22 , the refrigerant releases heat so as to go from the gas state to a liquid state, with the pressure remaining generally the same. Accordingly, the high-pressure reservoir 16 accumulates high-pressure liquid refrigerant that flows thereto by the lines 34 and 36 , as previously described.
[0033] The compressors 12 exert a suction on the evaporators 20 through the supply lines 48 . The expansion valves 18 control the pressure in the evaporators 20 as a function of the suction by the compressors 12 . Accordingly, high-pressure liquid refrigerant accumulates in the line 38 to thereafter exit through the expansion valves 18 to reach the evaporators 20 via the lines 43 in a low-pressure liquid state. The typical pressure at an outlet of the expansion valve 18 is 35 Psi. During a refrigeration cycle, the refrigerant absorbs heat in the evaporators 20 , so as to change state to become a low-pressure gas refrigerant. Finally, the low-pressure gas refrigerant flows through the line 48 so as to be compressed once more by the compressors 12 to complete the refrigeration cycle.
[0034] As frost and ice build-up are frequent on the evaporators, the evaporators 20 are provided with a defrost system for melting the frost and ice build-up. Only one of the evaporator units 17 is shown having defrost equipment, for simplicity of the drawings. It is obvious that all evaporator units 17 can be provided with defrost equipment. One of the evaporators 20 is supplied with refrigerant discharged from the compressors 12 by a line 106 having a pressure regulator 108 therein. The pressure regulator 108 creates a pressure differential in the line 106 , such that the high-pressure gas refrigerant, typically around 200 Psi, is reduced to a low-pressure gas refrigerant thereafter, for instance at about 110 Psi. The pressure regulator 108 may include a modulating valve in line 106 . In the event that the pressure in the evaporator 20 is lower than that of the refrigerant conveyed thereto by the line 106 in a defrost cycle, the modulating valve portion of the pressure regulator 108 will preclude the formation of water hammer by gradually increasing the pressure in the evaporator 20 . This feature of the pressure regulator 108 will allow the refrigeration system 10 to feed the evaporators 20 with high-pressure refrigerant, although it is preferred to defrost the evaporators 20 with low-pressure refrigerant. On the other hand, the modulating action can be effected by the valves 118 .
[0035] Valves are provided in the evaporator units 17 so as to control the flow of refrigerant in the evaporators 20 . A valve 114 is provided in the line 38 . The valve 114 is normally open, but is closed during defrosting of its evaporator unit 17 . A valve 116 is positioned on the line 48 and is normally open. The line 106 merges with the line 48 between the valve 116 and the evaporator 20 . The line 106 has a valve 118 therein. A line 112 , connecting a low-pressure reservoir 100 to the evaporator 20 , has a valve 120 therein. The valves 118 and 120 are closed during a normal refrigeration cycle of their respective evaporators 20 .
[0036] In a normal refrigeration cycle, refrigerant flows in the line 38 through the valve 114 , to reach the expansion valves 18 . A pressure drop in refrigerant is caused at the expansion valve 18 . The resulting low-pressure liquid refrigerant reaches the evaporators 20 , wherein it will absorb heat to change state to gas. Thereafter, refrigerant flows through the low-pressure gas refrigerant line 48 and the valve 116 therein to the compressors 12 .
[0037] During a defrost cycle of an evaporator 20 , the valves 118 and 120 are open, whereas the valves 114 and 116 are closed. Accordingly, the expansion valve 18 and the evaporator 20 will not be supplied with low-pressure liquid refrigerant from the line 38 , as it is closed by valve 114 . During the defrost cycle, low-pressure gas refrigerant accumulated in the line 106 , downstream of the pressure regulator 108 , is conveyed back into the evaporator 20 through the portion of line 48 between the valve 116 and the evaporator 20 . As the valve 116 is closed and the valve 118 is open. The closing of the valve 116 ensures that refrigerant will not flow from the line 106 to the compressors 12 . As the low-pressure gas refrigerant flows through the evaporator 20 , it releases heat to defrost and melt ice build-up on the evaporator 20 . This causes a change of phase to the low-pressure gas refrigerant, which changes to low-pressure liquid refrigerant. Thereafter, the low-pressure liquid refrigerant flows through the line 112 and the valve 120 to reach the low-pressure reservoir 100 . The low-pressure reservoir 100 accumulates liquid refrigerant at low pressure.
[0038] The low-pressure reservoir 100 is connected to the compressors 12 by a line 126 . The line 126 is connected to a top portion of the reservoir 100 such that evaporated refrigerant exits therefrom. As the low-pressure reservoir 100 accumulates low-pressure liquid refrigerant, evaporation will normally occur such that a portion of the reservoir above the level of liquid refrigerant will comprise low-pressure gas refrigerant. The pressure in the low-pressure reservoir 100 is typically as low as 10 Psi.
[0039] However, with the present invention a compressor is dedicated for discharging the low-pressure reservoir 100 , whereas the other compressors receive refrigerant exiting from the evaporators 20 . Reasons for the use of a dedicated compressor will be described hereinafter. Accordingly, as shown in FIG. 1, the compressor 12 A will be dedicated to discharging the low-pressure reservoir 100 . A line 128 diverges from the line 126 to reach the compressor 12 A. A valve 130 is in the line 128 , whereas a valve 132 is in the line 126 . During operation of the dedicated compressor 12 A, the valve 132 is closed, whereas the valve 130 is open.
[0040] A bypass line 134 and a check valve 136 therein are connected from the line 48 to the compressor 12 A. The pressure in the lines 126 and 128 is generally lower than in the line 48 . The check valve 136 therefore enables a flow of refrigerant therethrough such that the inlet pressure at the compressors 12 and the dedicated compressor 12 A is generally the same.
[0041] In order to flush the liquid refrigerant in the low-pressure reservoir 100 such that the latter does not overflow, a flushing arrangement is provided for the periodic flushing of the low-pressure reservoir 100 . The flushing arrangement has a line 140 having a valve 142 therein diverging from the line 28 and connecting to the low-pressure reservoir 100 . The line 140 diverges from the line 28 upstream of the pressure regulator 21 , such that high-pressure gas refrigerant can be directed from the compressors 12 directly to the low-pressure reservoir 100 .
[0042] A line 144 having a valve 146 extends from the low-pressure reservoir 100 to the line 28 downstream of the pressure regulator 21 , and upstream of the three-way valve 32 . A line 148 having a valve 150 goes from the low-pressure reservoir 100 to the high-pressure reservoir 16 . A periodic flush of the low-pressure reservoir 100 is initiated by creating a pressure differential (e.g., 5 psi) in the line 28 .
[0043] The valve 142 is opened while the valves 130 and 132 are simultaneously closed, if they were open. Accordingly, high-pressure gas refrigerant can be directed to the low-pressure reservoir 100 , but will be prevented from reaching the compressors 12 and 12 A. One of the valves 146 and 150 is opened, while the other remains closed. If the valve 146 is opened, a mixture of gas and liquid refrigerant will flow through the line 144 and to the line 28 downstream of the pressure regulator 21 . It is pointed out that the pressure differential caused by the pressure regulator 21 will create this flow. If the valve 150 is opened, the gas/liquid refrigerant will flow through the line 148 to reach the high-pressure reservoir 16 , in this case having a lower pressure than the low-pressure reservoir 100 , by the insertion of compressor discharge in the low-pressure reservoir 100 via line 140 , and by the pressure drop caused by the pressure regulator 21 .
[0044] When the defrost cycle has been completed, the valves are reversed so as to return the defrosted evaporator 20 to the refrigeration cycle. More specifically, the valves 114 and 116 are opened, and the valves 118 and 120 are closed. It is preferred that the valve 116 be of the modulating type (e.g., Mueller modulating valve, www.muellerindustries.com), or a pulse valve. Accordingly, a pressure differential in the line 48 between upstream and downstream portions with respect to the valve 116 will not cause water hammer when the valve 116 is open. The pressure will gradually be decreased by the modulation of the valve 116 . Furthermore, the refrigerant reaching the compressors 12 via the line 48 will remain at advantageously low pressures. Although in the preferred embodiment of the present invention the refrigerant defrosting the evaporators 20 will be at generally low pressure because of the pressure regulator 108 , the refrigeration system 10 of the present invention may also provide high-pressure refrigerant to accelerate the defrosting of the evaporators 20 , whereby the modulation of the valve 116 is preferred when a defrosted evaporator 20 is returned to the refrigeration cycle. It is obvious that equivalents of the valve 116 can be used, and such equivalents will be discussed hereinafter.
[0045] In the warmer periods, such as summer, the flushing is directed to the condenser units 14 via the line 144 , such that the liquid content of the flush cools the condenser units 14 . In the cooler periods, the flush is directed to the high-pressure reservoir 16 . When the flush is completed, for instance, when the liquid level in the low-pressure reservoir 100 reaches a predetermined low level, the flush is stopped by the closing of the valves 142 and 146 or 150 and the deactivation of the pressure regulator 21 . The valves 130 or 132 can also be opened if defrosting of one of the evaporators 20 is required.
[0046] It is obvious that the control of valve operation is preferably fully automated. As mentioned above, the flushing of the low-pressure reservoir 100 can be stopped by the low-pressure reservoir 100 reaching a predetermined low level. Similarly, the flush of the low-pressure reservoir 100 can be initiated by the refrigerant level reaching a predetermined high level in the low-pressure reservoir 100 . Similarly, the valve operation for controlling the defrost of evaporators 20 , namely the control of valves 114 , 116 , 118 , 120 , 130 and 132 , is fully automated. For the flushing of the low-pressure reservoir 100 , and in the defrost cycles, an automation system may also be programmed to do periodic flushing or defrost cycles, respectively. It also has been thought to provide a pump (not shown) to pump the liquid refrigerant in the low-pressure reservoir 100 to the line 28 or to the high-pressure reservoir 16 .
[0047] It is an advantageous feature to have a dedicated compressor 12 A. It is known that compressors are not adapted to receive liquids therein. However, as the defrost cycles produce a change of phase of gas refrigerant to liquid refrigerant, there is a risk that liquid refrigerant reaches the compressors 12 . It is thus important that the low-pressure reservoir 100 does not overflow, whereby the flushing can be actuated, as described above, upon the low-pressure reservoir's 100 reaching a predetermined high level of refrigerant. An alarm system (not shown) can also be provided in order to shut-off the compressors in the event of a low-pressure reservoir overflow. The alarm can be used to shut-off the compressors such that liquid refrigerant cannot affect the compressors. However, this involves a risk of fouling the foodstuff in the refrigeration display counters. The use of a dedicated compressor 12 A, isolated from the other compressors 12 , can prevent the shutting down of all compressors or the liquid from reaching the compressors. As described above, the valve 132 is shut during the use of the dedicated compressor 12 A such that the low-pressure reservoir 100 is isolated from the compressors 12 . On the other hand, the alarm (not shown) can be connected to the valve 130 in order to shut-off the valve 130 when an overflow of the low-pressure reservoir 100 is detected. The compressor 12 A will then be supplied with gas refrigerant from the line 48 through the check valve 136 .
[0048] The defrosting of one of the evaporators 20 can be stopped according to a time delay. More precisely, a defrost cycle of an evaporator 20 can be initiated periodically and have its duration predetermined. For instance, a typical defrost portion of a defrost cycle can last 8 minutes for low pressures of refrigerant fed to the evaporators 20 and can be even shorter for higher pressures. Thereafter, a period is required to have the defrosted evaporator 20 returned to its normal refrigeration operating temperature, and such a period is typically up to 7 minutes in duration. It is also possible to have a sensor 152 positioned downstream of the evaporator 20 in a defrost cycle, that will control the duration of the defrost cycle of a respective evaporator 20 by monitoring the temperature of the refrigerant having defrosted the respective evaporator 20 . A predetermined low refrigerant temperature detected by the sensor 152 could trigger an actuation of the valves 114 , 116 , 118 and 120 , to switch the respective evaporator 20 to a refrigeration cycle 20 .
[0049] It is known to provide the sensor 152 . However, these sensors have been previously provided after each evaporator 20 . Accordingly, this proves to be a costly solution. Furthermore, in systems wherein defrost is effected for a few evaporators simultaneously, these evaporators are often synchronized to return back to refrigeration cycles only once all temperature sensors reach their predetermined low limit. This causes unnecessarily lengthy defrost cycles. The sensor 152 of the present invention is thus preferably positioned so as to measure an average temperature of the defrost refrigerant of all evaporators defrosted simultaneously. In consequence thereof, fewer sensors 52 are necessary and the operation of defrost cycles is more efficient.
[0050] It is obvious that the various components enabling the defrost cycle can be regrouped in a pack so as to be provided on site as a defrost system ready to operate. This can simplify the installation of the defrost system to an existing refrigeration system, as the major step in the installation would be to connect the various lines to the defrost system.
[0051] Now that the refrigeration system 10 has been described with reference to a simplified schematic figure, a refrigeration system 10 ′ is shown in FIGS. 2 and 3 in further detail. It is pointed out that like numerals will designate like elements. Furthermore, the refrigeration system 10 ′ illustrated in FIGS. 2 and 3 comprises additional elements to the refrigeration system 10 , and these additional elements are common to refrigeration systems but have been removed from FIG. 1 for clarity purposes.
[0052] As seen in FIG. 2, the compressors 12 and 12 A are connected to the line 28 , which has a discharge header 24 to collect the discharge of all compressors 12 and 12 A. Although not shown, it is common to have an oil separator that will remove oil contents from the high-pressure gas refrigerant in the line 28 . The three-way valve 32 is preferably a motorized modulating valve that will prevent water hammer when stopping a supply of refrigerant to the heat reclaim unit 22 .
[0053] The refrigeration system 10 ′ has a high-pressure liquid refrigerant header 40 and a suction header 44 . The high-pressure liquid refrigerant header 40 is in the line 38 and thus connected to the high-pressure reservoir 16 to supply refrigerant to the evaporators 20 . The suction header 44 is connected to inlets of the compressors 12 by the lines 48 . Refrigerant accumulates in the suction header 44 in a low-pressure gas state, and is conveyed through the lines 48 to the compressors 12 by the pressure drop at the inlets of the compressors 12 .
[0054] Numerous evaporator units 17 extend between the high-pressure reservoir 16 and the suction header 44 , but only one is fully shown in FIG. 2 for clarify purposes. Each of the evaporator units 17 has an evaporator 20 and an expansion valve 18 . The expansion valves 18 are connected to the high-pressure liquid refrigerant header 40 by the lines 38 , and to the evaporators 20 by the lines 43 . As mentioned above, the expansion valves 18 create a pressure differential so as to control the pressure of liquid refrigerant sent to the evaporators 20 . The expansion valves 18 control the pressure of the liquid refrigerant that is sent to the evaporators 20 as a function of a fluid that is blown on the evaporators 20 (e.g., air), such that the liquid refrigerant changes phases in the evaporators 20 by the fluid, blown across the evaporators 20 to reach refrigerated display counters (e.g., refrigerators, freezers or the like) at low refrigerating temperatures.
[0055] The compressors 12 exert a suction on the evaporators 20 through the suction header 44 and the lines 48 . The expansion valves 18 control the pressure in the evaporators 20 as a function of the suction by the compressors 12 . Accordingly, high-pressure liquid refrigerant accumulates in the line 38 and the high-pressure liquid refrigerant header 40 to thereafter exit through the expansion valves 18 to reach the evaporators 20 in a low-pressure liquid state.
[0056] In the refrigeration system 10 ′, the defrost system has a low-pressure gas header 102 and a low-pressure liquid header 104 . The low-pressure gas header 102 is supplied with refrigerant discharged from the compressors 12 by a defrost line 106 . As mentioned previously, the pressure regulator 108 creates a pressure differential, such that the high-pressure gas refrigerant is reduced to a low-pressure gas refrigerant thereafter. The low-pressure gas header 102 and the low-pressure liquid header 104 are connected by the evaporator units 17 . As seen in FIG. 3, the valve 114 is provided on the line 38 , with the line 112 connected to the line 38 between the expansion valve 18 and the valve 114 . The valve 114 is normally open, but is closed during defrosting of its evaporator unit 17 . The valve 116 is positioned on the line 48 and is normally open. The line 106 merges with the line 48 between the valve 116 and the evaporator 20 . The line 106 has the valve 118 therein, and the defrost outlet line 112 has the valve 120 therein. The valves 118 and 120 are closed during a normal refrigeration cycle of their respective evaporators 20 . A check valve 122 is provided parallel to the expansion valve 18 . It is pointed out that the check valve 122 is not shown in FIG. 1, yet the refrigeration system 10 of FIG. 1 and the refrigeration system 10 ′ of FIG. 2 operate in an equivalent fashion. The check valve 122 enables the use of the line 43 and a portion of the line 38 for defrost cycles, and this reduces the number of pipes going to the evaporators 20 . Furthermore, the check valves 122 will facilitate the adaptation of a defrost system to an existing refrigeration system.
[0057] Although, as illustrated in FIG. 3, the line 106 is preferably connected to the line 48 to feed the evaporator 20 with refrigerant, whereas the line 112 is connected to the line 38 to provide an outlet for the refrigerant after having gone through the evaporator 20 , it is pointed out that the lines 106 and 112 can be appropriately connected. As shown in FIG. 4, the line 106 is connected to the line 38 , whereas the line 112 is connected to the line 48 . In doing so, the check valve 122 of FIG. 3 is replaced by a solenoid valve 122 ′ that will allow refrigerant to bypass the expansion valve 18 to reach the evaporator 20 .
[0058] Therefore, as seen in FIGS. 2 and 3, in a normal refrigeration cycle, refrigerant flows in the line 38 through the valve 114 . The check valve 122 blocks flow therethrough in that direction of flow of refrigerant, such that refrigerant has to go through the expansion valve 18 to reach the evaporator 20 via the line 43 . Thereafter, refrigerant flows through the line 48 , including the valve 116 and the suction header 44 , to reach the compressors 12 .
[0059] During a defrost cycle of one of the evaporators 20 , the valves 118 and 120 are open, whereas the valves 114 and 116 are closed. Accordingly, the expansion valve 18 and the evaporator 20 will not be supplied with low-pressure liquid refrigerant from the line portion 38 , as it is closed by valve 114 . During the defrost cycle, low-pressure gas refrigerant is conveyed from the line 106 to the evaporator 20 through a portion of the line 48 . The valve 116 is closed and the valve 118 is open. As the valve 116 is closed, refrigerant will not flow from the line 106 to the suction header 44 . As the low-pressure gas refrigerant flows through the evaporator 20 , it releases heat to defrost and melt ice build- on the evaporator 20 . This causes a change of phase to the low-pressure gas refrigerant, which changes to low-pressure liquid refrigerant. The check valve 122 will allow refrigerant to accumulate upstream thereof, such that the refrigerant in the evaporator 20 has time to release heat to melt the ice build-up on the evaporator 20 . The check valve 122 will open above a given pressure, such that low-pressure liquid refrigerant can flow through the line 38 to the line 112 and the valve 120 to reach the low-pressure liquid header 104 and the low-pressure reservoir 100 .
[0060] The low-pressure reservoir 100 is connected to the suction header 144 by the line 126 . The line 126 is connected to a top portion of the reservoir 100 such that evaporated refrigerant exits therefrom.
[0061] The compressor 12 A has its own portion 44 A of the header 44 . The portion 44 A is separated from the suction header 44 . The line 128 extends from the line 126 to the suction header portion 44 A. A valve 130 is in the line 128 , whereas the valve 132 is in the reservoir discharge line 126 . During operation of the dedicated compressor 12 A, the valve 132 is closed, whereas the valve 130 is open. The line 134 and the check valve 136 therein merge with the line 128 such that the dedicated compressor 12 A can be supplied with refrigerant from the suction header 44 to operate at a same pressure as the compressors 12 . [ 0062 ] A line 160 provides a valve 162 parallel to the valve 130 . The line 160 has a small diameter, and is used to lower the pressure of the gas refrigerant coming from the low-pressure reservoir 100 after a flush of the low-pressure reservoir 100 has been performed.
[0062] A plurality of check valves 164 and manual valves 166 are provided through the refrigeration system 10 ′ to ensure the proper flow direction and allow maintenance of various parts of the refrigeration system 10 ′.
[0063] The refrigeration system 10 of the present invention is advantageous, as it provides a defrost system that can readily be adapted to existing refrigeration systems. The valve configuration in the evaporator units 17 , as shown in FIG. 3, provides for the use of existing pipe of typical refrigeration systems for defrost cycles. Also, the evaporators 20 only receive low-pressure refrigerants therein, as opposed to known defrost systems, and this ensures that most types of evaporators are compatible with the present invention. For instance, aluminum coils of an evaporator may not be specified for high refrigerant pressures that are typical to known defrost systems. Finally, the dedicated compressor 12 A is a safety feature that will prevent costly failures and breakdown of all compressors 12 , and thus reduces the risks of fouling foodstuff.
[0064] In FIG. 5, there is shown an alternative to the low-pressure reservoir 100 . In the refrigeration system 10 ′ of FIG. 5, the line 112 is connected to the line 48 , downstream of the valve 116 , for directing refrigerant directly to the compressors after having defrosted the evaporator 20 . The refrigeration system 10 ′ is similar to the refrigeration system 10 of FIG. 1, whereby like elements will bear like numerals. Pressure control means 180 are provided in the line 112 , downstream of the valve 120 . The pressure control means 180 will ensure that defrosting refrigerant reaching the compressors 12 is at a pressure generally similar to that of the refrigerant flowing to the compressors 12 after a refrigeration cycle. The pressure control means 180 may consist of any one of outlet regulating valves, modulating valves, pulse valves and a liquid accumulator, and may also consist in a circuit having heat exchangers (e.g., roof-top radiators) and expansion valves, that will reduce the refrigerant pressure and change the phase thereof. In the case where the pressure control means 180 are outlet regulating valves, these may be positioned directly after the evaporators 20 , or just before inlets of compressors 12 , to prevent liquid refrigerant from reaching the compressors 12 and to control the pressure of refrigerant supplied thereto. A liquid accumulator would preferably be positioned between suction headers (not shown) so as to ensure that no liquid refrigerant is fed to the compressors 12 . Considering that the refrigerant having defrosted an evaporator 20 will be generally liquid, the liquid accumulator prevents excessive liquid refrigerant from blocking the lines. The pressure control means 180 will enable the compressors 12 to operate at low pressures, i.e., independently from the pressure of refrigerant at the outlet of the defrost evaporators. Therefore, more evaporators can be defrosted at a same time as the compressor inlet pressure is generally independent from the number of evaporators in defrost, whereby such simultaneous defrosting will not substantially increase the energy costs of the compressors 12 .
[0065] As mentioned previously, typical defrost periods with the refrigeration system 10 of the present invention are of 8 minutes for the evaporator 20 to reach the highest temperature, and 7 minutes for returning back to an operating temperature. Therefore, a total of 15 minutes is achievable from start to finish for a defrost period with the refrigeration system 10 of the present invention.
[0066] Referring to FIGS. 6 and 7, another configuration of the refrigeration system 10 ″ is shown, wherein gas refrigerant is sent to defrost the evaporators 20 at a lower pressure than gas refrigerant sent to the condensing stage. The dedicated compressor 12 A′ collects low pressure gas refrigerant from a suction header 204 that also supplies the other compressors 12 in refrigerant. However, the compressor 12 A′ is the only compressor supplying evaporators in defrost cycles, whereby its discharge pressure can be lowered. This is performed by having line 106 ′ connected to the evaporators 20 by valve 116 closing to direct refrigerant via line 48 thereto (shown connected to only one line 48 in FIG. 6 but obviously connected to all lines 48 of all evaporators 20 requiring defrost). A portion of the refrigerant discharged by the compressor 12 A′ can be sent to the condensing stage, via line 106 ″ that converges with the line 28 . A valve 200 (e.g., a three-way modulating valve), controls the portions of refrigerant discharge going to the lines 106 ′ and 106 ″.
[0067] Thereafter, the refrigerant exiting from the defrosted evaporators 20 is injected into the evaporators 20 in a refrigeration cycle. Line 112 ′ collects liquid refrigerant exiting from the evaporators 20 in defrost, and converges with the line 38 upstream of the expansion valves 18 , such that the liquid refrigerant can be injected in the evaporators 20 in the refrigeration cycle. A valve 202 (e.g., pressure regulating valve) ensures that a proper refrigerant pressure is provided to the line 38 , and compensates a lack of refrigerant pressure by transferring liquid refrigerant from the high pressure reservoir 16 to the line 38 . The combination of the dedicated compressor 12 A′ (i.e., low pressure refrigerant feed to the defrost evaporators, also achievable by the refrigeration system of FIG. 1) and the valve 202 enable the injection of low pressure refrigerant, which exits from the defrost cycle, in the evaporator units 17 . Previously, reinjected defrost refrigerant had to be conveyed to the condensing stage to reach adequate conditions to be reinjected into the evaporation cycles. As seen in FIG. 7, a subcooling system 204 can be used to ensure the proper state of the refrigerant reaching the evaporator units 17 . With the refrigeration system 10 ″ of FIGS. 6 and 7, the defrost refrigerant can be reinjected in the evaporator units 17 at pressures as low as 120 to 140 Psi for refrigerant 22 , and 140 to 160 Psi for refrigerant 507 and refrigerant 404 , even though the refrigerant 22 is up to about 220 to 260 Psi in the condenser units 14 , and the refrigerant 507 and the refrigerant 404 are up to about 250 to 340 Psi.
[0068] Although the refrigeration system 10 of the present invention enables the defrosting of the evaporators 20 at high pressure, it is preferable that the pressure regulator 108 reduce the pressure of the refrigerant fed to the evaporators 20 in defrost cycles. In such a case, less refrigerant is required to defrost an evaporator, whereby a plurality of evaporators 20 can be defrosted simultaneously.
[0069] It is within the ambit of the present invention to cover any obvious modifications of the embodiments described herein, provided such modifications fall within the scope of the appended claims.
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A defrost refrigeration system having a main refrigeration system and comprising a first line extending from a compressing stage to an evaporator stage and adapted to receive refrigerant in high-pressure gas state from the compressing stage. A first pressure reducing device on the first line is provided for reducing a pressure of the refrigerant in the high-pressure gas state to a second low-pressure gas state. Valves are provided for stopping a flow of the refrigerant in a first low-pressure liquid state from a condensing stage to evaporators of the evaporator stage and directing a flow of the refrigerant in the second low-pressure gas state to release heat to defrost the evaporators and thereby changing phase at least partially to a second low-pressure liquid state. A second line is provided for directing the refrigerant having released heat to the compressing stage, the condensing stage or the evaporator stage.
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[0001] This application claims the priority of U.S. Provisional Application 60/626,037, filed on Nov. 8, 2004.
[0002] The present invention relates to methods and devices for drying lumber.
[0003] Combustible gases are produced by landfills. The quality of this gas as an energy source varies, for example with the age of the landfill or with the placement of the source collection wells. Where the energy content is 460 BTU/ft 3 or higher, it may be practical to operate electricity producing turbines or engines. Lower energy content gas or gas that is not produced in sufficient quantity to make energy production practical is often ignited in a flare to reduce its noxious odor content and/or to reduce pollutants from entering the atmosphere.
[0004] Because there has been a use for higher quality landfill gas, little attention has been paid to secondary uses for the heat provided by burning the gas. Because the focus for lower quality gas has been on odor reduction, little attention has been paid to uses compatible with its low energy content. Similarly, where landfills produce insufficient quality gas for energy production, little attention has been paid to uses compatible with its low energy content. Thus, it has not been recognized that landfill gas provides an excellent, cost effective source of heat for drying lumber.
SUMMARY OF THE INVENTION
[0005] In one embodiment, the invention provides a method of drying lumber comprising: igniting landfill gas to directly or indirectly create a heated gas or heat exchange medium; and directing the heated gas into an enclosure containing lumber to be dried or directing the heat exchange medium into a heat exchanger located within the enclosure.
[0006] In another embodiment the invention provides a lumber drying plant comprising: a kiln adapted to dry lumber; and a heater for the kiln comprising one or more of:
an electric generation turbine or engine adapted to be fueled with landfill gas and cooled with a second heat exchange medium, and means to heat the kiln with the second heat exchange medium when heated by the engine, or a furnace adapted to be fueled by landfill gas and to heat a third heat exchange medium, and means to heat the kiln with the third heat exchange medium when heated by the furnace.
[0009] In still another embodiment, the invention provides a lumber drying plant comprising: a kiln adapted to dry lumber; a flare adapted to combust landfill gas; and a heater for the kiln comprising one or more of:
a flare heat exchanger adapted to collect heat from the flare into a heat exchange medium, and means to heat the kiln with the heated heat exchange medium, or an electric generation turbine or engine adapted to be fueled with landfill gas and cooled with a second heat exchange medium, and means to heat the kiln with the second heat exchange medium when heated by the turbine or engine, or a furnace adapted to be fueled by landfill gas and to heat a third heat exchange medium, and means to heat the kiln with the third heat exchange medium when heated by the furnace.
In some embodiments, the plant has plumbing adapted to direct the atmosphere from the kiln to the flare. The “second” heat exchange medium can be given a different identifier, such as “generator” heat exchange medium. Similarly, the “third” heat exchange medium can be identified, for example, as the “furnace” heat exchange medium.
[0013] In another embodiment the invention provides a lumber drying plant comprising: a kiln adapted to dry lumber; heat exchange piping within the kiln; and conduits adapted to be stacked within the lumber and quick release couple to the heat exchange piping.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1-5 show various illustrative wood-drying plants.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Shown in FIG. 1 is an illustrative wood-drying plant 100 . Kiln 110 receives heated gas through klin-inlet pipe 112 . An optional air circulation system 111 A (e.g., ducts and baffles, blowers, and the like) distributes heated air through the kiln 110 . In the illustrated embodiment, air is directed into flare heat exchanger 130 by blower 133 and heat exchanger-inlet pipe 134 . The heat exchanger 130 exchanges heat from flare 140 , which is fueled from air inlet 141 and landfill gas inlet 142 . Optionally, kiln-outlet pipe 113 directs exhaust from the kiln 110 to the flare 140 , thereby reducing Volatile Organic Compounds (VOC) in the kiln exhaust.
[0016] It should be recognized that the air circulation system of wood-drying plant 100 can be replaced by a kiln heat exchange system, such as a system of baffled conduits that radiate heat. Accordingly, the heated fluid provided by the flare heat exchanger 130 can be gas or another heat exchange medium. If a kiln heat exchanger is used with heated gas from a flare heat exchanger, this heat exchange medium can be directly exhausted (not shown), or exhausted into the kiln exhaust with other gases from the kiln. Since the atmosphere in the kiln should be exchanged as its water content increases, the gas from the flare heat exchanger can provide fresh atmosphere that may not require as much heating as might external air.
[0017] The combusted gas of the flare itself can be used directly to provide the heat and atmosphere for the kiln.
[0018] The flare heat exchanger can serve to add to the detention time of combustible molecules in the combustion zone of a flare. Thus, the flare heat exchanger can, in addition to providing heat for drying lumber, increase the environmental quality of the landfill's gas byproduct.
[0019] As shown in the illustrative wood-drying plant 200 of FIG. 2 , kiln-outlet pipe 213 is joined to air inlet 241 at junction 243 . Hardware can be provided such that, for example, all of the kiln-outlet gas is consumed in the flare, supplemented with atmosphere as needed. The heat exchanger 230 can have, for example, an upper segment 231 of heat exchange piping located above the flare 240 , and a lower segment 232 that provides heat exchange piping about the periphery of the flare 240 . (Elements in different figures numbered with the same last two digits and, if present, last letter, are analogous to one another; and hence are not redundantly named here.)
[0020] In another embodiment, illustrative wood-drying plant 300 ( FIG. 3 ) acquires heat from the coolant used in the generator turbines or engines of a landfill gas to electric generation facility 350 . Heated coolant is delivered to heat exchanger 311 B with outlet pipes 353 , then returned with inlet pipes 354 . Landfill gas is provided to the turbines or engines via landfill gas inlet 352 . Exhaust from the kiln can be optionally delivered to the turbines or engines with exhaust inlet 355 , which in this illustration is joined to kiln-outlet pipe 313 at junction 314 . Kiln outlet pipe 3313 is, for example, joined to air inlet 341 at junction 343 . Hardware can be provided such that, for example, all of the kiln-outlet gas is consumed in the turbines or engines, supplemented with atmosphere from air inlet 357 (joined at junction 356 ) as needed. Hardware, and optionally automation tools, can be provided so that kiln-outlet gas is directed to flare 330 when or to the extent landfill gas to electric generation facility 350 is not available to consume that gas.
[0021] The flare can be operated concurrently with the landfill gas to electric generation facility, for example using gas from wells producing lower quality gas. Thus, in embodiments in which VOCs from the kiln are combusted, in some such embodiments these VOCs are combusted solely or primarily in the flare.
[0022] It should be recognized that flare 340 (or any other flare) can be fitted with heat exchanger that can provide heated gas or other heat exchange medium to the kiln. Where a flare is used in conjunction with a landfill gas to electric generation facility, it can be the primary heat source for the kiln, a supplemental heat source, or, as in FIG. 3 , a non-contributor to kiln heat.
[0023] The engines (typically diesel) or turbines used in a landfill gas to electric generation facility typically do not well tolerate changes in rpms. Thus, fuel feed should be maintained at approximately the same rate and quality. Thus, the landfill gas to electric generation facility should be adapted to run at the rates provided at the troughs of the variations in a landfill's gas production. Of course, with the season and other variables, the rate may be adjusted by bringing engines on or off line. Nonetheless, an excess of gas is typically produced which may or may not be buffered by storage (though usually storage is impractical). Thus, a supplemental flare is often of additional use in combusting gas and thereby reducing odor. In some cases, odor reduction alone is not enough to motivate use of the flare. In these cases supplemental income from additional wood drying capacity and tax credits for energy production can provide further motives for cleaning the gas byproduct.
[0024] In a further embodiment, illustrative wood-drying plant 400 ( FIG. 4 ) acquires heat from a furnace 460 , fueled with landfill gas inlet 462 . Heated heat exchange medium (such as steam) is delivered to heat exchanger 411 B from furnace 460 (such as, without limitation a boiler) with outlet pipes 463 , then returned with inlet pipes 464 . Furnace exhaust 461 can be piped to junction 443 . Furnace exhaust 461 can be directed on a path that conveys heat therein into the kiln 410 . For example, the exhaust can be upwardly coiled through the kiln. The furnace is illustrated in a heat utilization-efficient location within the kiln, but this location is optional.
[0025] In this and other embodiments, the kiln heat exchanger can be replaced with an air circulation system, with the furnace operating to heat air or other gas as the heat exchange medium. “Air” in this and other embodiments can be replaced with another gas, though atmospheric air is typically the economical choice.
[0026] As illustrated in FIG. 5 , kiln-outlet pipes 513 can manifold exhaust from multiple outlets 514 . The manifolding can be done at a low level, such as below ground, to help collect cooler gas from the kiln 510 . In this embodiment, as in the others, gas can be pushed through pipes as needed, such as by fan operated by control hardware. Doors 515 for inserting and removing lumber can be, for example, placed between outlets 514 .
[0027] In certain embodiments, the landfill gas used has an energy content of 450 BTU/ft 3 or less, 440 BTU/ft 3 or less, 430 BTU/ft 3 or less, 420 BTU/ft 3 or less, 410 BTU/ft 3 or less, or 400 BTU/ft 3 or less.
[0028] In certain embodiments, combusted landfill gas is used directly to heat the lumber. In other embodiments, such combusted landfill gas is passed through a heat exchange arrangement and conveys heat to a second gas or other heat exchange medium. For example, the landfill gas may be combusted with excess oxygen provided to increase combustion efficiency. In some embodiments, the excess oxygen may not be desirable in the drying kiln. Thus, the combusted landfill gas can be used to heat another gas, such as one with lower oxygen content. A second gas can also have lower water content, increasing its effectiveness in drying lumber. Any gas to be used to fill the kiln can be passed through a condensing unit that lowers water content.
[0029] VOCs are generated by the drying process. However, in most instances the rate of generation is small enough that VOC do not raise substantial issues. As one option, however, the VOCs can be combusted catalytically or thermally, optionally using heat from the combustion of landfill gas.
[0030] In certain embodiments, the drying kiln is placed at or near the landfill. For example, the kiln is located close enough to the landfill to make piping the landfill gas to the kiln practical. For example, the kiln can be located 5 miles or less from the gas production at the landfill. Or, the kiln can be located 4 miles or less, 3 miles or less, 2 miles or less, 1 miles or less, 0.5 miles or less, from gas production. In certain embodiments, the gas and resulting heated gas are conveyed with conduit such as pipe, avoiding the use of storage tanks.
[0031] A further advantage of drying methods according to the invention is that within wide limits heated gas production can be generated and utilized at a rate matching the need to flare the landfill gas. With greater production, heated gas flow through the kiln is increased, thereby more uniformly distributing heat and drier air. At lower production rates, drying may not be as fast, but the process more efficiently utilizes the heat content of the landfill gas.
[0032] When stacked for drying the wood is typically separated by spacers, which can be pieces of the lumber to be dried, waste lumber, or another material. Drying can occur on a rack adapted for hoisting or carting in an out of the kiln. Lumber on such a rack will typically be stacked with supplemental spacers. To convey heat exchange medium more directly into the stack, some of the spacers or elements of the rack can be conduits for the heat exchange medium. Such conduits can be constructed of a heat-conductive material such as aluminum. The conduits can be adapted to quick-release couple to piping for heat exchange medium.
[0033] A “serpentine” pathway for an exhaust from a furnace is one that doubles (or more) the length of the direct pathway (within the kiln) from the furnace to the farthest wall of the kiln from the furnace.
[0034] Publications and references, including but not limited to patents and patent applications, cited in this specification are herein incorporated by reference in their entirety in the entire portion cited as if each individual publication or reference were specifically and individually indicated to be incorporated by reference herein as being fully set forth. Any patent application to which this application claims priority is also incorporated by reference herein in the manner described above for publications and references.
[0035] While this invention has been described with an emphasis upon preferred embodiments, it will be obvious to those of ordinary skill in the art that variations in the preferred devices and methods may be used and that it is intended that the invention may be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications encompassed within the spirit and scope of the invention as defined by the claims that follow.
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Provided, among other things, is a method of drying lumber comprising: igniting landfill gas to directly or indirectly create a heated gas or heat exchange medium; and directing the heated gas into an enclosure containing lumber to be dried or directing the heat exchange medium into a heat exchanger located within the enclosure.
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This is a national stage application of PCT/IB96/00530 filed May 30, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and a device for the initial flushing of a blood treatment apparatus.
2. Description of the Related Art
It is known that before commencing dialysis treatment, the dialyser has to be flushed and filled (procedure referred to as priming) by passing a flushing solution through the compartments of the dialyser. Various methods have been proposed for carrying out this flushing. For example, U.S. Pat. No. 5,004,548 describes a method which consists in connecting the outlet of the dialyser's blood compartment to the inlet of the dialysis liquid compartment, and in circulating in series, through the blood compartment and the dialysis liquid compartment, a sterile physiological saline solution issuing from a bag. The outlet of the dialysis liquid compartment is connected to a bag for collection and discharge of the flushing liquid.
In a known flushing method, the flushing liquid is not recovered in a collecting bag, but is eliminated via the dialysis apparatus' pipes for discharge of used liquid. For this purpose, the outlet connection piece of the dialysis liquid compartment is connected, by way of a conduit and an electromagnetic valve, to a discharge pipe provided in the dialysis apparatus in proximity to the outlet of an ultrafilter. At the same time, a dialysis liquid is circulated through the ultrafilter, so that the liquid for flushing the dialyser and the dialysis liquid in preparation are thus discharged together in the discharge pipe.
The advantage of this solution is that it permits considerable savings to be made, by omitting the collecting bag and avoiding the expenses involved in disposing of the latter, and it permits an improvement in the flushing of the dialyser. In addition, there is no risk of the dialyser or of the sterile parts of the apparatus being contaminated by the non-sterile liquid since there is complete separation of the sterile and non-sterile parts of the apparatus.
To ensure satisfactory flushing of the dialyser, any air bubbles present on the membrane of the dialyser have to be eliminated. To do this at the present time, the person charged with performing the dialysis gently taps the dialyser so that the bubbles dislodge from the membrane and are discharged with the flushing liquid.
An object of the invention is to perfect the flushing method indicated above, in such a way as to render it completely automatic, while at the same time retaining the advantages of the known flushing method described hereinabove.
SUMMARY OF THE INVENTION
To achieve this object, the invention provides a method for flushing a blood treatment apparatus, which has a first compartment and second compartment separated by a semi-permeable membrane, consisting in:
setting up a flushing circuit by connecting an inlet of one compartment to a flushing liquid source, and an outlet of this compartment to discharge means;
circulating flushing liquid through the flushing circuit;
the method being characterized in that it consists in creating pressure waves at time intervals in the flushing circuit in such a way as to dislodge air bubbles adhering to an inner wall of the blood treatment apparatus and to discharge these air bubbles in the flushing liquid.
According to one characteristic of the invention:
the flushing liquid is made to circulate by pumping means arranged on the flushing circuit on the inlet side (or outlet side, respectively) of the compartment; and in that
the pressure waves are created by alternately opening and closing occlusion means which are arranged on the flushing circuit on the outlet side (or inlet side, respectively) of the compartment.
In one embodiment of the invention, the opening and closing of the occlusion means are controlled as a function of a pressure Pi measured in a flushing circuit section located between the pumping means and the occlusion means.
In another embodiment of the invention, the opening and closing of the occlusion means are controlled in accordance with a predetermined time sequence.
The invention also provides a device for flushing a blood treatment apparatus, which has a first compartment and second compartment separated by a semi-permeable membrane, this device comprising a flushing circuit which has:
means for supplying flushing liquid to at least one compartment;
pumping means for circulating the flushing liquid through the flushing circuit;
means for discharging the flushing liquid which has been used;
characterized in that it comprises means for creating pressure waves at time intervals in the flushing circuit in such a way as to dislodge air bubbles adhering to an inner wall of the blood treatment device and to discharge these air bubbles in the flushing liquid.
According to one characteristic of the invention, the means for creating pressure waves comprise:
occlusion means for selectively prohibiting the circulation of liquid in the flushing circuit, these occlusion means being situated downstream (or upstream, respectively) of the membrane apparatus, while the pumping means are situated upstream (or downstream, respectively) of the membrane apparatus;
control means for controlling the opening and closing of the occlusion means in such a way as to create pressure waves in the flushing circuit.
In one embodiment of the invention, the control means are intended to control the opening and closing of the occlusion means as a function of the pressure measured in a section of the flushing circuit located between the pumping means and the occlusion means.
In another embodiment of the invention, the control means are intended to control the opening and closing of the occlusion means in accordance with a predetermined time sequence.
Other advantages and characteristics of the invention will become evident on reading the description of a preferred embodiment of the invention, this description being given by way of non-limiting example and with reference to the attached drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of the hydraulic circuit of a dialysis machine,
FIG. 2 illustrates the course of the curves for certain measured variables in the circuit in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a diagrammatic representation of the hydraulic circuit of a dialysis machine 1 connected to a dialyser 2 for the flushing procedure. The connection pieces and the elements which do not play a part in the flushing method according to the invention have been omitted in the figure.
The dialyser 2 comprises a blood compartment 3 and a dialysis liquid compartment 4 which are separated by a semi-permeable membrane 5. The blood compartment 3 has an inlet 7 and an outlet 8; the dialysis liquid compartment 4 has an inlet 9 and an outlet 10. The inlet 7 of the blood compartment 3 is connected to a bag 14 of flushing liquid (sterile physiological saline solution) by means of an arterial line 11 equipped with a peristaltic pump 12 (blood pump) and an expansion chamber 13; the outlet 8 of the blood compartment is connected to the inlet 9 of the dialysis liquid compartment by means of a venous line 15 equipped with a bubble trap 16 and a pipe section 17. The outlet 10 of the dialysis liquid compartment is connected to the outlet of an ultrafilter 22 (junction point 19) by means of a connecting pipe 18 equipped with a sensor 20 for pressure Pi and with an electromagnetic valve 21.
The ultrafilter 22 is divided by a semi-permeable membrane 23 into two chambers: an inlet chamber 24 and an outlet chamber 25. The inlet chamber 24 has an inlet 26 connected to a unit 28 for preparation of dialysis liquid, and an outlet 30 connected to a branch pipe 31 equipped with an electromagnetic valve 32. The outlet chamber 25 has an outlet 33 connected to the connecting pipe 18 and to a discharge pipe 34.
The discharge pipe 34 includes a first pipe section and a second pipe section which are linked via a connection piece 48. The first section, which is connected directly to the outlet 33 of the ultrafilter 22, is equipped with a first electromagnetic valve 35. The second section is equipped with a gear pump 36 and with a second electromagnetic valve 40. A pipe section equipped with a pressure sensor for P0 and with a third electromagnetic valve 38 is arranged bypassing the pump 36.
The branch pipe 31, one end of which is connected to the outlet 30 of the first chamber of the ultrafilter 22, is connected at its other end to the discharge pipe 31, downstream of the second electromagnetic valve 40.
FIG. 1 also shows diagrammatically various clamps and various connection pieces on the tubing. In particular, on the arterial line 11, between the blood pump 12 and the bag 14, there is a clamp 43, and an analogous clamp 44 is arranged on the venous line 15 downstream of the bubble trap 16. A connection piece 45 is provided in order to connect the venous line 15 to the pipe section 17; a connection piece 46 is provided in order to connect the pipe section 17 to the inlet 9 of the dialysis liquid chamber of the dialyser 2; a connection piece 47 is provided in order to connect the outlet 10 of the dialysis liquid chamber 4 to the connecting pipe 18; and the connection piece 48 arranged on the discharge pipe 34 is provided in order to connect the second section of the discharge pipe 34 to the inlet 9 of the dialysis liquid chamber, at the end of the flushing procedure, so as to proceed with dialysis.
A sensor 50 for arterial pressure AP is connected to the expansion chamber 13, and a sensor 51 for venous pressure VP is connected to the bubble trap 16.
The valve 21 on the connecting pipe 18 has the function of ensuring total protection of the dialyser 2 from any contamination of the dialysis liquid during the flushing operation. The valve 21 is activated in such a way that the pressure in the connecting pipe 18 always remains greater than the pressure in the discharge pipe 34, and in such a way that the dialysis liquid being prepared cannot flow back towards the dialyser 2. To this end, the pressures Pi and P0, measured by means of the pressure sensors 20, 37 in the connecting pipe 18 and in the discharge pipe 34, are monitored in a continuous manner by a control and activation unit 55, and the valve 21 is opened and closed as a function of their respective values. The first electromagnetic valve 35 is constantly open in order to permit the discharge of the dialysis liquid being prepared during the flushing procedure, and it is closed when the dialysis is in progress. The valves 32, 38 and 40 serve to close or open the corresponding pipes as a function of predetermined safety conditions. The control unit 55, which receives the pressures Pi and P0 measured by the sensors 20 and 37, controls all the valves of the circuit (in particular valve 21).
The flushing method proceeds as follows. To start with, the electromagnetic valve 21 is closed and the first valve 35 on the discharge pipe 34 is open. After the connection of the hydraulic circuit in the manner described and represented, the arterial pump 12 is started up and suctions the flushing liquid (physiological saline solution) from the bag 14 and forces it into the arterial line 11 and into the blood compartment 3 of the dialyser 2, as is represented by the arrows in FIG. 1. The liquid then flows into the venous line 15 and the pipe section 17 and enters the dialysis liquid compartment via the inlet 9. Thus, the flushing liquid circulates in the two compartments 3 and 4 of the dialyser in the same direction, from the bottom upwards, which facilitates the discharge of the air contained in the dialyser 2.
After the dialysis liquid compartment 4 has been flushed, the liquid flows into the connecting pipe 18, and this brings about an increase in the pressure in this pipe, the valve 21 being closed. When the pressure prevailing in the connecting pipe 18, as measured by the sensor 20, exceeds a predetermined threshold (for example 80 mmHg), the opening of the valve 21 is controlled by the unit 55. The flushing liquid then flows into the discharge pipe 35 where the pump 36 causes it to circulate with the dialysis liquid under preparation. Thereafter, the valve 21 remains activated as a function of the pressure, but its state (open/closed) no longer depends on the absolute value of the pressure in the connecting pipe 18: it is then a function of the pressure difference ΔP between the pressure Pi prevailing in the connecting pipe 18 and the pressure P0 prevailing in the discharge pipe 34, so that the flushing liquid flows permanently into the discharge pipe 34 (which eliminates the risk of the dialysis liquid under preparation coming into contact with the dialyser 2).
In practice, when ΔP=Pi-P0<30 mmHg, the valve 21 is closed, and when ΔP>50 mmHg, the valve 21 is opened. The curve of the pressures Pi and P0 in the tubes 18 and 34 resulting from this control can be seen in FIG. 2 where (starting from t≈350 s) one can see an undulating progression of the two pressures, due to the continuing opening and closing of the valve 21. FIG. 2 also shows the course of the pressure curve VP in the venous line 15.
Activating the valve 21 in the manner which has just been explained causes a series of pressure waves inside the dialyser 2, in the venous line 15 and in the connecting pipe 18, which facilitates the dislodging of the air bubbles, clinging to the membrane of the dialyser 2 and to the walls of the pipes, and their discharge.
At the end of the flushing procedure, the receptacle 14 is uncoupled from the arterial line 11, which can then be connected to the vascular circuit of a patient by means of a cannula. The pipe section 17 is disconnected from the dialyser 2 and is uncoupled from the venous line 15, which can then be connected to the vascular circuit of the patient by means of a cannula. The first valve 35 is closed, the connection piece 48 serving to connect the two sections of the discharge pipe 34 is opened, and the second section of the discharge pipe 34 is connected to the orifice of the dialysis liquid compartment to which the pipe section 17 was connected previously. In this way, during the dialysis session, the dialysis liquid issuing from the second chamber of the ultrafilter 22 flows into the connecting pipe 18, into the compartment 4 (in a direction counter to that of the arrow in FIG. 1) and into the discharge pipe 34.
The present invention is not limited to the embodiments which have been described and illustrated, and it is open to variations. In particular, the method which has been described can just as well be implemented when the flushing liquid is not discharged into the discharge pipe used for the dialysis liquid under preparation, and when two independent flushing circuits are used for flushing the two compartments of the dialyser. Moreover, the opening and closing of the valve 21 arranged on the connecting pipe can be controlled as a function of parameters other than the pressure prevailing in the pipes, in particular as a function of a predetermined time sequence, the valve 21 being opened and closed during predetermined time intervals.
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A method and apparatus are disclosed for flushing a blood treatment apparatus. The blood treatment apparatus has a first compartment and second compartment separated by a semipermeable membrane substantially impermeable to gas. A flushing circuit is set up by connecting an inlet of the blood treatment apparatus to a flushing liquid source and an outlet of the blood treatment apparatus to a discharge pipe. Liquid is circulated through the flushing circuit in pressure waves. These pressure waves dislodge air bubbles adhering to an inner wall of the blood treatment apparatus and discharge the air bubbles in the flushing liquid.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and a circuit for removing noise signals from video signals by means of adaptive median filtering.
2. Description of the Related Art
German Patent Application P 43 26 390.9, corresponding to U.S. Pat. No. 5,519,453 (Atty. docket PHD 93-105), proposes a method of removing noise signals from video signals by means of a motion adaptive filtering, in which uniformly distributed noise as well as also pulse noise must be eliminated.
In addition, German Patent DE 40 14 971 A1, corresponding to U.K. Patent GB 2,246,265 (PHD 90-246 GB), discloses a circuit arrangement for median filtering of video signals produced during scanning of a film, by means of which, interferences due to dust and scratches must be reduced.
Characteristic of the interferences and of the efficiency of the method described is a limited local expansion of the interference to a few related picture elements, to one line at a maximum.
SUMMARY OF THE INVENTION
The present invention has therefore for its object to provide a method and a circuit for removing noise signals from video signals, enabling the masking of errors of very large-sized disturbed picture areas, for example, due to excessively stained or highly scratched films.
This object is accomplished in that the picture content is always classified into stationary, moving, undisturbed and disturbed picture areas and that contiguous thereto, error masking, by means of temporal median filtering, is only effected in the disturbed and stationary picture areas.
The method according to the invention has the advantage that large-sized interferences in stationary picture areas of films can optimally be suppressed without large extra costs or design efforts.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention is shown in the drawings and described in greater detail in the following description. In the drawings:
FIG. 1 is a block circuit diagram for putting the method of the invention into effect;
FIG. 2 shows a time diagram for deriving control signals;
FIGS. 3a and 3b are graphical representations of the picture interferences in a system of coordinates;
FIGS. 4a and 4b are block circuit diagrams of two alternative arithmetic-logic units;
FIGS. 5a and 5b are graphic representations of picture interferences in a further system of coordinates;
FIG. 6 is a block circuit diagram of a further arithmetic-logic unit;
FIG. 7 shows a time diagram of the signals shown in FIG. 6; and
FIG. 8 shows a time diagram of the signals present in the pulse width-discriminator of FIG. 6.
CORRESPONDING COMPONENTS IN THE FIGURES HAVE BEEN GIVEN THE SAME REFERENCES.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the block circuit diagram shown in FIG. 1 for putting the method in accordance with the invention into effect, a digital video signal (luminance and/or chrominance signal) which is preferably derived during film scan, is applied via a terminal 1 to two series-arranged (frame or field) picture stores 2, 3, so that three consecutive pictures N-1, N, N+1 are simultaneously available. The video signals x, y, z of these three pictures are now applied, on the one hand, to the inputs X, Y, Z of an arithmetic-logic unit 4 for producing a control signal K, and, on the other hand, to the inputs X, Y, Z of a median filter 5, each via a delay section 6, 7, 8 for propagation time matching to the control signal K. If the picture at the input Y is considered to be the actual picture N, then the preceding picture N-1, at the input Z, and the subsequent picture N+1, at the input X, are available.
The output of the median filter 5 is connected to one input of a change-over switch 9, at whose other input the video signal Y of the picture N is present. The change-over switch 9 is switched by means of the control or switching signal K, which is produced in the arithmetic-logic unit 4 and is available at its output. In the arithmetic-logic unit 4, a classification of the picture content of the three simultaneously available pictures in moving, stationary, disturbed and undisturbed picture areas is performed and a switching signal K is only produced for the disturbed and stationary picture areas. Thereby the switch 9 is switched in such a manner that in only the disturbed and stationary areas of the picture N the output signal of the median filter 5 arrives at the output 11, while, for all the other picture areas, the signal Y of the picture N is directly conveyed to the output 11. It is of course a condition for the function of error masking by the median filter 5 that the neighboring pictures N-1 and N+1 are in this position free from errors.
The classification of the picture content for deriving the control signal K will now be described with reference to FIG. 2. Let the picture content be characterized by the objects A, B and C. Object A comprises all the quiescent picture details, object B represents a disturbed picture area, which only occurs in picture N, and object C defines a picture portion moving from left to right.
In order to establish the differences between the pictures, the differences in the video signals y-x and y-z are computed. The amount of the differences is considered in German Patent Application P 43 26 390.9, corresponding to U.S. Pat. No. 5,519,453 (Atty. docket PHD 93-105), to be a motion signal and is used for controlling (switching off) the median filter, so as to prevent motional streaking. It then happens that the object B, i.e., the interference in the picture N, is also mis-interpreted as motion and that the median filter would be switched off.
It is however the object of the method according to the invention to energize the median filtering operation precisely in this case. Therefore, a criterium to distinguish between object B (interference) and C (motion) is searched for. A feature of the interference is that the object B occurs non-recurrently in the picture N. This has for its result that in the picture N, it holds for the two differential signals y-x and y-z that: y-=y-z or x=z, respectively. This can be interpreted as follows: when a non-recurrent interference occurs in the picture N, the two motion detectors respond to the same extent, and there is no difference between picture N-1 and picture N+1, that is to say x-z=0.
FIG. 3a illustrates this fact graphically. All the singular picture interferences are located on a 45°-straight line in a system of coordinates, at which y-z is plotted on y-x. Since always a certain noise component is superimposed on real picture signals, the difference between the pictures N-1 and N+1 will not be accurately equal to zero. It is therefore convenient, to define, instead of the strict straight scratch line, a tolerance area by |x-z|<S1. The threshold value S1 is determined by the peak value of the noise amplitude to be expected and can be set from the exterior or automatically, as is, for example, described in German Patent Application P 43 19 343.9, corresponding to U.S. Pat. No, 5,485,222 (Atty. docket PHD 93-083).
This tolerance range is shown in FIG. 3b. White scratches are located in the first quadrant of the coordinate system, whereas black scratches are located in the third quadrant. The distinguishing feature may, for example, be the sign of the difference y-x. In the environment of the origin of the coordinates, the tolerance field defined by S1 does not provide a sharp criterion for interferences, as here, all the stationary or slightly mobile picture areas, respectively, are shown. For this reason, a second condition is added, namely, both differential signals y-x and y-z must have a value greater than S2. Graphically, this means that a noise signal must have a given lowest contrast S2, to be recognizable as such.
FIG. 4a shows a circuit for an arithmetic-logic unit for deriving the control signal K. The following three conditions can therefore be formulated:
1. Contrast condition wherein |y-x|>S2 and |y-z|>S2,
2. Detection of white or black noise wherein y-x>0 or y-x<0,
3. Difference between noise and motion wherein
(a) |x-z|<S1 means noise, no motion (consequently the control signal K is delivered),
(b) |x-z|>S1 means no noise, but motion.
The median value of the video signals is only then switched to the output 11 by means of the control signal K when the conditions 1, 2 and 3(a) are satisfied.
The circuit of the arithmetic-logic unit 4 therefore consists of a first and a second comparator circuit 12 and 13, whose inputs are connected to the input and to the output of the first picture store 2 and to the input and to the output of the second picture store 3, respectively. In this situation, according to the differential value and absolute value formation of the input signals applied, a comparison to the threshold value S2 takes place, a signal then being supplied only when this threshold value S2 is exceeded. The outputs of the comparator circuits 12 and 13 are connected to the inputs of an AND-circuit 14, whose output is connected to the first input 15 of a further AND-circuit 16.
A third and a fourth comparator circuit 17 and 18 are connected to the input and to the output of the first picture store 2. In the comparator circuits 17 and 18 a differential signal y-x is formed, the comparator circuit 17 then supplying a signal when the differential value exceeds zero and the comparator circuit 18 then supplying a signal when the differential value is less than zero. These so-called identification signals "white" or "black", respectively, are supplied in the event of white or black scratches, respectively. In the case of a black or a white scratch, a logic "one" is formed at one of the inputs of a change-over switch 19. This change-over switch 19 then transfers the signal corresponding to the interference to the second input 21 of the further AND-circuit 16.
A fifth comparator circuit 22 is connected to the input of the first picture store 2 and to the output of the second picture store 3, respectively, a comparison to the threshold value S1 being effected after the differential value and the absolute value of the signals x and z have been formed. In this situation, a signal is only supplied when the absolute value is less than this threshold value S1. The output of this fifth comparator circuit 22 is connected to the third input 23 of the further AND-circuit 16. A control signal K can only be taken from the output 24 of this AND-circuit 16 when a logic "one" is present at each of the three inputs 15, 21 and 23.
FIG. 4b shows a circuit of the arithmetic-logic unit 4 with an alternative contrast condition: |y-x+y-z|>S3, instead of the first contrast condition in accordance with FIG. 4a. Instead of the comparator circuits 12 and 13, a comparator circuit 26 is used in FIG. 4b, whose inputs are connected to the inputs of the first picture store 2 and of the second picture store 3, as well as to the output of the second picture store 3, for which reference is also made to the corresponding time diagram in FIG. 2.
The FIGS. 5a and 5b are a graphical interpretation thereof. The threshold values S1 and S3 define tolerance fields which are located in a system of coordinates U, V which are rotated through 45° and extend parallel to the axis. For the rotated coordinates, the following transformation equations apply: U=2y-x-z and V=x-z.
The circuit of FIG. 4b has the advantage that using the contrast condition |2y-x-z|>S3 or |U|>S3, respectively, the interference (object B) versus the motion (object C) is eliminated to a greater extent, as can be seen from the time diagram shown in FIG. 2. It is also easy to see from this time diagram that the control signal K only changes to logic "one" in the case when it holds that:
S1 is not exceeded, consequently no motion, and
S2 is exceeded (contrast condition), or
S3 is exceeded (alternative contrast condition), respectively.
FIG. 6 shows an improved circuit for producing the control signal K, which is based on the principle of the circuit shown in FIG. 4b, i.e., the signal processing is effected in the rotated U/V-system of coordinates. This has the advantage that the U-signal basically contains the noise signal components, while, in the V-signal, basically the motion components are contained. An additional dual-channel signal processing for U and V has for its aim to separate the components noise and motion to a still better extent from each other and to remove unwanted noise components from them.
During processing of the U-signal in the upper signal channel 27, there is first provided a circuit 29 for forming the differential value, whose inputs are connected to the inputs and outputs x, y, z, respectively, of the picture stores 2, 3, whereafter, after the differential values between the output and input signals y-x of the first picture store 2, and between the input and output signals y-z of the second picture store 3 have been formed, the differential values are added together. The output of this circuit 29 is connected to each of the inputs of two comparator circuits 31, 32, in which a comparison of the output signal U of the circuit 29 for forming the differential value to the positive value or the negative value, respectively, of the threshold value S3 is performed, and a signal is supplied only when the signal U exceeds the positive or less than the negative value, respectively, of the threshold value S3, respectively.
The outputs of the comparator circuits 31, 32 are each connected to an input of two AND-circuits 33, 34, which serve as gate circuits. To that end, a control signal "only white" or "only black", respectively, is always applied to the second inputs of the AND-circuits 33, 34. If both black and white scratches are detected, both control signals have logic value "one". The outputs of the AND-circuits 33, 34 are each connected to an input of an OR-circuit 35, whose output is connected via a pulse-width discriminator 36 to the first input 37 of a further AND-circuit 38.
For processing the V-signal in the lower channel 28, there is first provided a circuit 39 for forming the differential value and the absolute value, whose inputs are connected to the input of the first picture store 2 and to the output of the second picture store 3. Consequently, the difference between the signal x and the signal z is formed in the circuit 39 and thereafter its absolute value, so that a signal |V | can be taken from the output of the circuit 39. The |V |-signal is applied, via a subsequent H/V-transversal filter 41, which acts as a low-pass filter, as signal M to a comparator circuit 42, wherein a comparison to the threshold value S1 is effected and a signal M1 is supplied only when this threshold value is exceeded. The output signal M1 is applied, via a H/V-min-filter 43, for the purpose of signal expansion, and a H/V-max-filter 44, for the purpose of signal narrowing, to the inverting input 45 of the AND-circuit 38, from whose output the control signal K can be taken.
As has already been mentioned in the foregoing, the interferences are mapped in the ideal case on the straight line x=z, i.e., V=x-z=0 is located on the U-axis. Because of noise superimposed thereon, the V-component is not accurately equal to zero, for which reason the tolerance field having a width 2 S1 had to be inserted. By a bi-dimensional low-pass filtering of the V-components in the horizontal and the vertical direction by means of the filter 41, it is possible to decrease the required threshold value S1 to a significant extent, so as to obtain thereby an improved selectivity for the noise components. For this purpose it is absolutely sufficient to simply form a mean value over approximately three lines and seven picture elements.
Contrary to the circuit shown in FIG. 4b, the subsequent comparator circuit 42 checks whether the filtered signal |x-z| is higher than the adjusted threshold value S1. If so, then accordingly, there is no interference, only motion. The preceding low-pass filtration has the side effect that the motion signal is expanded. The advantage this provides will be explained with reference to the time diagrams of FIG. 7.
FIG. 7 once again shows the three objects A (quiescent picture content), B (disturbed picture content) and C (mobile picture content). In contradistinction to FIG. 2, the object C now moves very rapidly. This has for its consequence that the motion signal |x-z| has a gap in its center. Without further measures, the fast-moving object C would erroneously be interpreted as being an interference and would consequently be filtered out. By expanding the motion signal with the aid of the low-pass filter 41, the gap is already reduced to some extent, as can be seen from signal M1. It is therefore obvious to expand the motion signal M1 still further. This is accomplished by the H/V-min-filter 43. The H/V-min-filter 43 projects from a bi-dimensional window, formed by a series of picture elements and lines, its minimum input value at the output. Since the input signal M1 only consists of one bit, the min-function represents a simple OR-operation on the values of the filter window. The size of the window depends on the maximum motional speed of the mobile objects or on the maximum shift from one picture to the next but one picture.
On film reproduction, this value is twice as high as with video signals, because of the low picture recording frequency of 24 frames/s. In practical tests, a filter window of approximately 5 lines * 21 picture elements proved to be sufficient for film reproduction. As horizontal motion generally dominates and, for example, due to moving of the camera, occurs much more often, this explains the comparatively small vertical filtering over only 5 lines.
In the processing of video signals, the filter window may be reduced to 3 lines * 11 picture elements. It is, however, a condition that simultaneously, the picture delay members 2, 3 for the generation of three video signals x, y, z are switched over from frame delay to field delay.
FIG. 7 shows, at the signal M2, how in this manner the gap in the motion signal is closed. It shows, at any rate, also the significant widening of the motion signal, which extends far outside the range of the object C. This unwanted signal expansion is eliminated by the subsequent H/V-max-filter 44, but the gap remains closed. The H/V-max-filter 44 represents a logic AND-operation on the input signal via a bi-dimensional field. The filter window can be chosen slightly greater compared with the preceding min-filtering, to also contribute to compensating for the expansion of the motion signal by the low-pass filter 41. The motion signal M3 thus obtained is used with the opposite polarity as an enable signal for the upper signal channel 27.
When the arithmetic-logic unit described in FIG. 6 is used, disturbed picture areas of any optional size can be replaced. In the extreme case, a single black picture in a sequence of white pictures can be completely suppressed. This is, however, not necessary in actual practice. The interferences rather extend over a limited number of associated picture elements and, depending on the cause, have each a given local effect. This may be purely in the horizontal direction (drop-out of picture elements, high-frequency pulses, clamping interferences) or only in the vertical direction (film-run scratches) but may also be planar (film dust, film dirt). It is therefore good policy to limit the noise signal E1 to the anticipated size, using the pulse-width discriminator 36 shown in FIG. 6. Thus, it can furthermore be prevented that a very rapidly moving object C effects over a large area an inadvertent triggering of the control signal K, cf. the signal |2y-x-z| in FIG. 7.
FIG. 8 illustrates, on the basis of a time diagram, the principle of such a suppression circuit (for the sake of simplicity only in the horizontal direction). A median filter 46 acts in the example over 5 picture elements. That is to say, it supplies from its output a signal only when, at the input, more than half the number of picture elements, consequently at least 3 picture elements, have logic "one" value. The signal sequence E2 may be interpreted as a low-pass filtered version of the input signal E1, as only the low frequency (wide) pulses are transferred by the median filter. In order to obtain a high-pass filtered version of the input signal sequence, in which the wide pulses are suppressed, the output signal E2 of the median filter 46 must be subtracted from the input signal E1. Since the signals E1 and E2 are binary signals, the subtraction can be represented by means of an AND-operation E1 & !E2 which can be performed by an AND-circuit 48.
So as to realize the bi-dimensional discriminator 36, the filter window of the median filter 46 must be adjustable to a maximum size of 9 lines * 21 picture elements, in order to suppress the most significant interferences which may be anticipated in actual practice. A further four completely disturbed lines can, for example, be restored therewith, or perpendicularly extending interferences up to 10 picture elements wide or planar interferences which extend over a total of 94 picture elements. For less serious interferences, the filter window can be reduced stepwise, for example, to 7 lines * 15 picture elements, 5 lines * 11 picture elements or 3 lines * 7 picture elements. Also, other combinations can be suitable, for example, 5 lines * 1 picture element, when the input signal has horizontal clamping interferences of a width of two lines. For the case in which extremely large-sized picture interferences are yet to be processed, it must be possible to switch the pulse-width discriminator 36 completely off, it then holding that E3=E1. For the AND-operation of the signals E1 and E2, a delay time matching T2, corresponding to the transit time delay of the median filter 46, is required, for which the delay member 47 is provided. Likewise the signals E3 and M3 for generating the control signal K must have equal transit times.
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A method of and a circuit for removing noise signals from video signals by adaptive median filtering which masks errors in large-size disturbed picture areas caused by dirt and dust during scanning of the film. In this method, the picture content is always classified in stationary, moving, undisturbed and disturbed picture areas. Subsequent thereto, error masking is only effected by temporal median filtering in only the disturbed, stationary picture area.
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FIELD OF THE INVENTION
[0001] The present disclosure relates generally to integrated circuits and methods of manufacturing integrated circuits. More particularly, the present disclosure relates to a semiconductor having a tensile strained substrate and a method of making such a semiconductor.
BACKGROUND OF THE INVENTION
[0002] Semiconductor manufactures utilize a wide variety of techniques to improve the performance of semiconductor devices, such as metal oxide semiconductor field effect transistors (MOSFETs). FIG. 1 shows a conventional MOSFET device. The MOSFET of FIG. 1 is fabricated on a semiconductor substrate 10 within an active area bounded by shallow trench isolations 12 that electrically isolate the active area of the MOSFET from other IC components fabricated on the substrate 10 .
[0003] The MOSFET is comprised of a gate electrode 14 that is separated from a channel region in the substrate 10 by a thin first gate insulator 16 such as silicon oxide or oxide-nitride-oxide (ONO). To minimize the resistance of the gate 14 , the gate 14 is typically formed of a doped semiconductor material such as polysilicon.
[0004] The source and drain of the MOSFET are provided as deep source and drain regions 18 formed on opposing sides of the gate 14 . Source and drain suicides 20 are formed on the source and drain regions 18 and are comprised of a compound comprising the substrate semiconductor material and a metal such as cobalt (Co) or nickel (Ni) to reduce contact resistance to the source and drain regions 18 . The source and drain regions 18 are formed deeply enough to extend beyond the depth to which the source and drain suicides 20 are formed. The source and drain regions 18 are implanted subsequent to the formation of a spacer 28 around the gate 14 and gate insulator 16 which serves as an implantation mask to define the lateral position of the source and drain regions 18 relative to the channel region beneath the gate.
[0005] The gate 14 likewise has a silicide 24 formed on its upper surface. The gate structure comprising a polysilicon material and an overlying silicide is sometimes referred to as a polycide gate.
[0006] The source and drain of the MOSFET further comprise shallow source and drain extensions 26 . As dimensions of the MOSFET are reduced, short channel effects resulting from the small distance between the source and drain cause degradation of MOSFET performance. The use of shallow source and drain extensions 26 rather than deep source and drain regions near the ends of the channel helps to reduce short channel effects. The shallow source and drain extensions are implanted prior to the formation of the spacer 22 , and the gate 14 acts as an implantation mask to define the lateral position of the shallow source and drain extensions 26 relative to the channel region 18 . Diffusion during subsequent annealing causes the source and drain extensions 26 to extend slightly beneath the gate 14 .
[0007] One option for increasing the performance of MOSFETs is to enhance the carrier mobility of silicon so as to reduce resistance and power consumption and to increase drive current, frequency response and operating speed. A method of enhancing carrier mobility that has become a focus of recent attention is the use of silicon material to which a tensile strain is applied.
[0008] “Strained” silicon may be formed by growing a layer of silicon on a silicon germanium substrate. The silicon germanium lattice is generally more widely spaced than a pure silicon lattice as a result of the presence of the larger germanium atoms in the lattice. Because the atoms of the silicon lattice align with the more widely spread silicon germanium lattice, a tensile strain is created in the silicon layer. The silicon atoms are essentially pulled apart from one another. The amount of tensile strain applied to the silicon lattice increases with the proportion of germanium in the silicon germanium lattice.
[0009] Relaxed silicon has six equal valence bands. The application of tensile strain to the silicon lattice causes four of the valence bands to increase in energy and two of the valence bands to decrease in energy. As a result of quantum effects, electrons effectively weigh 30 percent less when passing through the lower energy bands. Thus the lower energy bands offer less resistance to electron flow. In addition, electrons encounter less vibrational energy from the nucleus of the silicon atom, which causes them to scatter at a rate of 500 to 1000 times less than in relaxed silicon. As a result, carrier mobility is dramatically increased in strained silicon as compared to relaxed silicon, offering a potential increase in mobility of 80% or more for electrons and 20% or more for holes. The increase in mobility has been found to persist for current fields of up to 1.5 megavolts/centimeter. These factors are believed to enable a device speed increase of 35% without further reduction of device size, or a 25% reduction in power consumption without a reduction in performance.
[0010] An example of a MOSFET using a strained silicon layer is shown in FIG. 2. The MOSFET is fabricated on a substrate comprising a silicon germanium layer 30 on which is formed an epitaxial layer of strained silicon 32 . The MOSFET uses conventional MOSFET structures including deep source and drain regions 18 , shallow source and drain extensions 26 , a gate oxide layer 16 , a gate 14 surrounded by spacers 28 , 22 , silicide source and drain contacts 20 , a silicide gate contact 24 , and shallow trench isolations 12 . The channel region of the MOSFET includes the strained silicon material, which provides enhanced carrier mobility between the source and drain.
[0011] One detrimental property of strained silicon MOSFETs of the type shown in FIG. 2 is that the band gap of silicon germanium is lower than that of silicon. In other words, the amount of energy required to move an electron into the conduction band is lower on average in a silicon germanium lattice than in a silicon lattice. As a result, the junction leakage in devices having their source and drain regions formed in silicon germanium is greater than in comparable devices having their source and drain regions formed in silicon.
[0012] Another detrimental property of strained silicon MOSFETs of the type shown in FIG. 2 is that the dielectric constant of silicon germanium is higher than that of silicon. As a result, MOSFETs incorporating silicon germanium exhibit higher parasitic capacitance, which increases device power consumption and decreases driving current and frequency response.
[0013] Therefore, the advantages achieved by incorporating strained silicon into MOSFET designs are partly offset by the disadvantages resulting from the use of a silicon germanium substrate.
[0014] Thus, there is a need for a MOSFET fabrication process in which silicon is strained by the highly compressive deposition of layers on top of the silicon. Further, there is a need to increase tensile strain in a silicon MOSFET without changing a silicon germanium layer. Even further, there is a need to increase carrier mobility using strained silicon.
SUMMARY OF THE INVENTION
[0015] An exemplary embodiment relates to a method for forming a metal oxide semiconductor field effect transistor (MOSFET). The method includes providing a substrate having a gate formed above the substrate and performing at least one of the following depositing steps: depositing a spacer layer and forming a spacer around a gate and gate insulator located above a layer of silicon above the substrate; depositing an etch stop layer above the spacer, the gate, and the layer of silicon; and depositing a dielectric layer above the etch stop layer. At least one of the depositing a spacer layer, depositing an etch stop layer, and depositing a dielectric layer comprises high compression deposition which increases in tensile strain in the layer of silicon.
[0016] Another exemplary embodiment relates to a method for forming a metal oxide semiconductor field effect transistor (MOSFET) including providing a substrate comprising a layer of silicon germanium having a layer of silicon material formed thereon, and at least one of a gate insulating layer formed on the silicon layer, and a gate conductive layer formed on the gate insulating layer. The method also includes patterning the gate conductive layer and a gate insulating layer to form a gate and gate insulator over the silicon layer; forming a spacer around the gate and gate insulator; forming an etch stop layer above the spacer, and the gate, and forming an interlevel dielectric layer above the etch stop layer in a highly compressive deposition process that compresses the layer of silicon, causing increased tensile strain therein.
[0017] Another exemplary embodiment relates to a method of processing a transistor comprising providing a gate above a silicon layer where the gate has spacers located proximate lateral sidewalls of the gate; forming an etch stop layer above the gate, and spacers, where the etch stop layer is formed in a high compression deposition causing strain in the silicon layer; and forming a dielectric layer above the etch stop layer, where the dielectric layer is formed in a high compression deposition causing strain in the silicon layer.
[0018] Other principle features and advantages of the invention will become apparent to those skilled in the art upon review of the following drawings, the detailed description, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The exemplary embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like numerals denote like elements, and:
[0020] [0020]FIG. 1 is a schematic cross-sectional view representation of a conventional MOSFET formed in accordance with conventional processing;
[0021] [0021]FIG. 2 is a schematic cross-sectional view representation of a strained silicon MOSFET device formed in accordance with the conventional processing used to form the MOSFET of FIG. 1;
[0022] [0022]FIGS. 3 a - 3 e are schematic cross-sectional view representations of structures formed during production of a MOSFET device in accordance with an exemplary embodiment; and
[0023] [0023]FIG. 4 is a process flow encompassing an exemplary embodiment and alternative embodiments.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0024] [0024]FIGS. 3 a - 3 i illustrate structures formed during fabrication of a strained silicon MOSFET in accordance with an exemplary embodiment. FIG. 3 a shows a structure comprising a layer of silicon germanium 40 having an epitaxial layer of silicon 42 formed on its surface. The silicon germanium layer 40 preferably has a composition Si 1-x Ge x , where x is approximately 0.2, and is more generally in the range of 0.1 to 0.3.
[0025] The silicon germanium layer 40 is typically grown on a silicon wafer. Silicon germanium may be grown, for example, by chemical vapor deposition using Si 2 H 6 (disilane) and GeH 4 (germane) as source gases, with a substrate temperature of 600 to 900 degrees C., a Si 2 H 6 partial pressure of 30 mPa, and a GeH 4 partial pressure of 60 mPa. SiH 4 (silane) may be used in alternative processes. Growth of the silicon germanium material may be initiated using these ratios, or alternatively the partial pressure of GeH 4 may be gradually increased beginning from a lower pressure or zero pressure to form a gradient composition. The thickness of the silicon germanium layer may be determined in accordance with the particular application. The upper portion of the silicon germanium substrate 40 on which the strained silicon layer 42 is grown should have a uniform composition.
[0026] The silicon layer 42 is preferably grown by chemical vapor deposition (CVD) using Si 2 H 6 as a source gas with a partial pressure of 30 mPa and a substrate temperature of approximately 600 to 900 degrees C. The silicon layer 42 is preferably grown to a thickness of 200 nm.
[0027] As further shown in FIG. 3 a , a gate insulating layer 44 is formed on the silicon layer 42 . The gate insulating layer 44 is typically silicon oxide but may be another material such as oxide-nitride-oxide (ONO). An oxide may be grown by thermal oxidation of the strained silicon layer, but is preferably deposited by chemical vapor deposition.
[0028] Formed over the gate insulating layer 44 is a gate conductive layer 46 . The gate conductive layer 46 typically comprises polysilicon but may alternatively comprise another material such as polysilicon implanted with germanium.
[0029] Overlying the gate conductive layer 46 is a bi-layer hardmask structure comprising a bottom hardmask layer 48 , also referred to as a bottom antireflective coating (BARC), and an upper hardmask layer 50 . The bottom hardmask layer 48 is typically silicon oxide (e.g. SiO 2 ) and the upper hardmask layer 50 is typically silicon nitride (e.g. Si 3 N 4 ).
[0030] The silicon germanium substrate also has formed therein shallow trench isolations 52 . The shallow trench isolations may be formed by forming trenches having tapered sidewalls in the silicon germanium layer 40 and silicon layer 42 , performing a brief thermal oxidation, and then depositing a layer of silicon oxide to a thickness that is sufficient to fill the trenches, such as by low pressure CVD (LPCVD) TEOS or atmospheric pressure ozone TEOS. The silicon oxide layer is then densified and planarized such as by chemical mechanical polishing or an etch back process, leaving shallow trench isolations 52 that are approximately level with the surface of the silicon layer 42 .
[0031] [0031]FIG. 3 b shows the structure of FIG. 3 a after patterning of the gate conductive layer and gate insulating layer to form a gate 54 and a self-aligned gate insulator 56 . Patterning is performed using a series of anisotropic etches that pattern the upper hardmask layer 50 using a photoresist mask as an etch mask, then patterns the lower hardmask layer 48 using the patterned upper hardmask layer 50 as an etch mask, then patterns the polysilicon using the patterned lower hardmask layer 48 as an etch mask, then patterns the gate insulating layer using the gate 54 as a hardmask. As shown in FIG. 3 b , the thickness of the lower hardmask layer 48 is chosen such that after patterning of the gate insulating layer, a portion of the lower hardmask layer remains on the gate as a protective cap 58 .
[0032] [0032]FIG. 3 c shows the structure of FIG. 3 b after formation of spacers 60 around the gate 54 , the gate insulator 56 and the protective cap 58 . The spacers 60 are preferably formed by deposition of a conformal layer of a protective material, followed by anisotropic etching to remove the protective material from the non-vertical surfaces to leave the spacers 60 . The spacers 60 are preferably formed of silicon oxide or silicon nitride.
[0033] In an exemplary embodiment, the conformal layer used in forming the spacers 60 is deposited using a plasma enhanced chemical vapor deposition (PECVD) process. This PECVD process is preferably a high compression deposition that adds tensile strain to the silicon layer 42 . High compression deposition can be achieved by biased RF power resulting in higher ion bombardment and compression to the silicon layer 42 .
[0034] [0034]FIG. 3 d shows the structure of FIG. 3 c after deposition of an etch stop layer (ESL) 63 conformally over the gate 54 , the protective cap 58 , the spacers 60 , and the silicon layer 42 . In an exemplary embodiment, the etch stop layer 63 is deposited in a PECVD process with high compression as to increase tensile strain in the silicon layer 42 . High compression deposition can be achieved with increased ion bombardment.
[0035] [0035]FIG. 3 e shows the structure of FIG. 3 d after deposition of an interlevel dielectric (ILD) layer 65 . The ILD layer 65 is conformally deposited over the etch stop layer 63 . Preferably, the ILD layer 65 is deposited in a highly compressive PECVD process. The high compression deposition increases compression in the silicon layer 42 adding tensile strain and, thereby, enhancing carrier mobility.
[0036] Other layers can be deposited, such as a liner layer or another spacer layer. Such additional layers can also be deposited with high compression deposition techniques as to increase the tensile strain in the silicon layer 42 .
[0037] While the processing shown in FIGS. 3 a - 3 e represents a presently preferred embodiment, a variety of alternatives may be implemented. Accordingly, a variety of embodiments in accordance with the invention may be implemented. In general terms, such embodiments encompass a MOSFET that includes a strained silicon channel region on a silicon germanium layer, and source and drain regions formed in silicon regions that are provided at opposing sides of the gate. The depth of the source and drain regions does not extend beyond the depth of the silicon regions, thus reducing the detrimental junction leakage and parasitic capacitance of conventional silicon germanium implementations.
[0038] In an alternative embodiment, a diffusion furnace can be used after processing SiGe to process non-SiGe material by running a wet oxidation clean-up cycle. This wet oxidation cycle includes a high temperature H 2 O oxidation to convert Ge to Ge-oxide, which is volatile. Such a process can be repeated to reduce contamination to below detection limits.
[0039] In another alternative embodiment, the strained-Si technology can be combined with fully-depleted silicon on insulator (SOI). However, a challenge exists in that the strained silicon is supported by an underlying SiGe layer and the strain may disappear when the SiGe is removed. The strain can be maintained by introducing a single-crystal high-k material that has a similar lattice constant with SiGe. For example, 20% SiGe can be achieved with DySiO 3 or GdSiO 3 .
[0040] In another alternative embodiment, an epoxy seal or a seal of another suitable material is applied to the top surface of a silicon die. By modifying the properties of the seal material, the stress in the silicon die can be modified to induce tensile stress. As discussed above tensile stress improves carrier mobility, improving device speed. Another way of increasing tensile stress is by using a dome-shaped metal substrate on which the die can be placed. The dome shape can be manufactured by stamping or etching. The dome shape provides a physical stress to the silicon die, resulting in tensile stress.
[0041] [0041]FIG. 4 shows a process flow encompassing the preferred embodiment of FIGS. 3 a - 3 e , the aforementioned alternatives and other alternatives. Initially, a substrate is provided in an operation 80 . The substrate includes a layer of silicon germanium having a layer of silicon formed thereon. The substrate further includes a gate insulator formed on the strained silicon layer and a gate formed on the gate insulator. A spacer layer is deposited and a spacer is formed around the gate and gate insulator in an operation 82 . In an exemplary embodiment, the spacer layer is deposited in a highly compressive fashion causing compression and, thus, tensile strain in the silicon layer below.
[0042] An etch step layer is provided conformally above the gate, spacer, and silicon layers in an operation 84 . In an exemplary embodiment, the etch stop layer is deposited in a high compression fashion, increasing the tensile strain in the silicon layer. An interlevel dielectric layer (ILD) layer is deposited above the etch stop layer in an operation 86 . Alternatively, any layer material can be deposited. In an exemplary embodiment, the ILD layer is deposited in a high compression PECVD process. A high compression deposition can be utilized with at least one of the depositions of operations 82 , 84 , and 86 . Alternatively, the high compression deposition can be used in all three operations 82 , 84 , and 86 . In an operation 88 , the structure is processed including formation of any of a variety of features, such as contacts for source and drain regions, metal interconnection, IMD layers, and passivation layer.
[0043] It will be apparent to those having ordinary skill in the art that the tasks described in the above processes are not necessarily exclusive of other tasks, but rather that further tasks may be incorporated into the above processes in accordance with the particular structures to be formed. For example, intermediate processing tasks such as formation and removal of passivation layers or protective layers between processing tasks, formation and removal of photoresist masks and other masking layers, doping and counter-doping, cleaning, planarization, and other tasks, may be performed along with the tasks specifically described above.
[0044] The process described in the description of exemplary embodiments need not be performed on an entire substrate such as an entire wafer, but rather may be performed selectively on sections of the substrate. Thus, while the embodiments illustrated in the figures and described above are presently preferred, it should be understood that these embodiments are offered by way of example only. The invention is not limited to a particular embodiment, but extends to various modifications, combinations, and permutations that fall within the scope of the claimed invention and equivalents.
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An exemplary embodiment relates to a method for forming a metal oxide semiconductor field effect transistor (MOSFET). The method includes providing a substrate having a gate formed above the substrate and performing at least one of the following depositing steps: depositing a spacer layer and forming a spacer around a gate and gate insulator located above a layer of silicon above the substrate; depositing an etch stop layer above the spacer, the gate, and the layer of silicon; and depositing a dielectric layer above the etch stop layer. At least one of the depositing a spacer layer, depositing an etch stop layer, and depositing a dielectric layer comprises high compression deposition which increases in tensile strain in the layer of silicon.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to gas turbine operation and, more particularly, to a system and method for controlling gas turbine operation in a closed-loop manner based on estimated stress levels at key locations within the turbine.
[0002] Typical gas turbine operating control schedules are open-loop in nature, derived from extensive analysis of simulated thermal and mechanical stress levels in rotating components, and designed so that these nominal stresses are not exceeded during operation. As an example, a possible startup schedule for a gas turbine is shown in FIG. 1. The schedule includes turbine speed versus time and is used by the turbine speed controller as a reference. As the machine accelerates from startup, both mechanical and thermal stresses build up. Mechanical stresses are primarily due to aerodynamic reactions as well as rotational and centrifugal forces. Thermal stresses arise from differential thermal expansion within turbine metal parts. These thermal stresses result from sources of heat within the turbine that are not uniform, and hence different metal parts heat up at different rates. When two parts that are secured together expand at different rates, or even a single part that is massive enough that separate regions of the part expand at varying rates, mechanical deformation and severe stressing may result. Once these parts attain a substantially uniform temperature, however, the stress levels decrease.
[0003] Since peak stress levels cannot be allowed to exceed limits dictated by material integrity as well as ultimate component life, it is important that the machine is operated in such a manner that the stress levels are kept below these limits at all times. In the case of machine startup, this is achieved by “holding” the turbine at certain predetermined points in its startup cycle to allow the heat to “soak” in. FIG. 1 shows two such hold points at 50% and 85% of full speed. Hold points and hold times are typically derived from extensive off-line analysis that attempt to predict stress patterns using accurate, but very high order finite-element models.
[0004] To account for machine-to-machine variations as well as inaccuracies in the models, safety margins are built into the operating schedules. Better performance could be obtained from the machine in terms of quicker startups and the like if stresses could be measured or estimated on-line. Measuring such stress levels on rotating components, however, is prohibitively expensive.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In an exemplary embodiment of the present invention, a method of operating a gas turbine includes the steps of (a) measuring at least one measurable temperature (T MEAS ) in the gas turbine; (b) using heat conduction and convention equations to estimate a first critical temperature (T 1 ) and a second critical temperature (T 2 ) based on T MEAS ; and (c) controlling the gas turbine based on T 1 and T 2 .
[0006] In another exemplary embodiment of the invention, a method of estimating critical stress in a gas turbine includes the steps of (a) measuring at least one measurable temperature (T MEAS ) in the gas turbine; (b) using heat conduction and convection equations to estimate a first critical temperature (T 1 ) and a second critical temperature (T 2 ) based on T MEAS ; and (c) estimating the critical stress in real time according to a stress model prediction based on the difference between T 1 and T 2 .
[0007] In still another exemplary embodiment of the invention, a system is provided for estimating critical stress in a gas turbine. The system includes a probe that measures at least one measurable temperature (T MEAS ) in the gas turbine. A processor receives input from the probe and uses heat conduction and convection equations to estimate first and second critical temperatures based on T MEAS . The processor includes a memory storing a stress model prediction algorithm and estimates the critical stress in real time based on a difference between T 1 and T 2 using the stress model prediction algorithm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a graph showing a possible startup schedule for a gas turbine;
[0009] [0009]FIG. 2 is a schematic illustration of the system of the present invention;
[0010] [0010]FIG. 3 is a graph showing a real-time stress model prediction compared with a stress level predicted by finite-element models; and
[0011] [0011]FIG. 4 is a control schematic of the system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] With the system of the present invention, a simple on-line model is used to estimate stress at one or more key locations in the gas turbine, and this stress estimate is used to control the machine. As a first exemplary application of the invention, the typical startup schedule is modified to provide an estimate of stress and hence operate the machine in a regulated fashion.
[0013] An important location in the compressor rotor where material stress limits operation has been identified using validated physics-based models. Extensive finite element analysis has also shown that this stress is strongly influenced by (1) the difference in temperature at two related points in the rotor, (2) the speed of the machine, and (3) the flow rate of air through the compressor, with the first factor being the most significant.
[0014] [0014]FIG. 2 is a schematic illustration of the system of the present invention. The temperatures T 1 and T 2 are internal operating temperatures that are used to estimate stress values within the turbine. These internal temperatures, however, cannot be measured. The invention incorporates a model 10 that uses simple heat conduction and convection equations. In one example, the two temperatures are estimated by solving the following set of ordinary differential equations (using standard off the shelf software):
T 1 t = - k 1 ( T 1 - T MEAS ( 1 ) ) - k 2 ( T 1 - T 2 ) T 2 t = - k 3 ( T 2 - T 1 ) - k 4 ( T 2 - T MEAS ( 2 ) )
[0015] The measured temperatures TMEAS 1 and TMEAS 2 12 are shown as the first part of the model 10 in FIG. 2, and for example are air temperature measurements obtained around the component where the stress is being estimated. The model 10 is dynamic in nature, i.e. the model evolves over time. The temperatures 12 are input into a low-order dynamic temperature estimator 14 , which is used to determine estimated values for T 1 and T 2 . The constants k 1 -k 4 are obtained from material properties such as coefficient of thermal conductivity, convective heat transfer coefficient, metal density, etc., as well as geometric properties such as length and thickness of the components. Subsequently, a non-linear static model or low-order non-linear stress estimator 22 inputs the determined temperatures T 1 and T 2 , machine speed 16 , pressure 18 , and temperature 20 measurements in the compressor to estimate stress.
[0016] The following is an example of a static model that links the temperatures (T 1 and T 2 ), machine speed (S), and air pressure (P) to the peak stress (SEQ) at a particular critical location of the turbine:
SEQ= a 1 ( T 1 - T 2 )+ a 2 S n +a 3 P m
[0017] where a 1 , a 2 , a 3 , m and n are predetermined constants.
[0018] This model can be obtained from physics-based principals or from nonlinear regression analysis. In one example, where the latter was used to obtain the model, the values in the equation were: a 1 =0.4; a 2 =0.005; a 3 =0.1; n=2; and m=0.5. These numbers can vary depending on the location of the critical stress point.
[0019] [0019]FIG. 3 illustrates an example of how the real-time stress model prediction with the stress model 10 of FIG. 2 compares with the conventionally-determined stress level as predicted by the finite-element analysis model. The numerical values of stress have been normalized with respect to an arbitrary number and do not necessarily represent the stress level for the startup schedule in FIG. 1. The dotted line is the real-time stress model prediction (per the stress model 10 in FIG. 2), while the solid line represents the generally more accurate finite element analysis generated stress value. It can be seen from FIG. 3 that the real time stress model prediction almost identically matches the finite element analysis generated stress value.
[0020] Once the stress values have been determined using the low-order non-linear stress estimator 22 discussed above, operation of the turbine can be controlled in real time. Limits on stress level for safe operation of a gas turbine have been previously determined. These limits can be used to automatically control the startup (or other operating condition) of the machine without an open-loop schedule. One possible control schematic is illustrated in FIG. 4. The model 10 continuously estimates the stress at the key location. If there is more than one location where the stress level is critical, similar models 10 A, 10 B can be developed to estimate these stresses using the stress model 10 discussed above with reference to FIG. 2.
[0021] A maximum 24 of all these estimates is then compared against the limit, which is shown as being a constant in FIG. 4 but could be a function of other system parameters. A margin of safety is subtracted from this limit to accommodate modeling errors and other unknown variations. Reference number 26 designates the limit minus the margin of safety. While it is assumed in this detailed description that the limit is the same (whether constant or derived) for all locations, this does not necessarily have to be the case. Different limits can be incorporated for different locations. In this case, the differences between the stress levels and the individual limits (and corresponding safety margins) will be compared against each other to determine the maximum error.
[0022] In operation, if the estimated stress exceeds the modified limit, a negative error signal e is generated that is multiplied by a gain k and subtracted from the measured machine acceleration. This new value is used, along with existing limiting values, to reduce the rate of increase in speed (i.e., the acceleration) of the turbine. This reduction in acceleration leads to a reduction in the differential temperature and thus to a lower value for stress. This continues until the stress is lower than the modified limit, whereby the error signal e now becomes positive. In this event, the measured acceleration is then modified in the positive direction, thus raising the existing limit and allowing the speed to increase faster (i.e., at a higher acceleration). A filter 28 is included in the feedback path to filter the acceleration signal. The choice of the constant a in the filter 28 as well as the gain k is determined by using standard control engineering practice to maintain adequate performance and stability margin. These constants will be different for differently constructed machines.
[0023] In an alternative embodiment, other control methods can be implemented that function in essentially the same way but without the continuous control feature as described above. For example, a logical block could be added to the existing control algorithm that would receive the signal e (in FIG. 4) and hold the machine at the current speed whenever e is negative (to allow the stress to decrease) and allow it to accelerate along the normal startup schedule when e is positive.
[0024] With this system, real time stress levels can be estimated at key locations within the turbine, and a gas turbine can be controlled in a closed-loop manner based on the estimated stress levels.
[0025] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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Critical stress in a gas turbine can be estimated using one or more readily measurable temperatures in the gas turbine. First and second critical temperatures can be estimated based on the at least one measurable temperature using heat conduction and convection equations. Subsequently, the critical stress can be estimated in real time according to a stress model prediction based on the difference between the critical temperatures, and possibly the rotational speed of the turbine, and some parameter, such as air pressure, that is indicative of air flow around the turbine component. Operation of the gas turbine can thus be controlled using the estimated critical temperatures.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] Not Applicable
REFERENCE TO A MICROFICHE APPENDIX
[0002] Not Applicable
TECHNICAL FIELD OF INVENTION
[0003] The present invention generally relates to the field of augmented reality (AR) systems and apparatus that deploy a camera to capture in real time the physical world environment and then enhance the camera view by adding one or more layers of computer-generated virtual information. Specifically the invention pertains to an AR system that allows a user or the user's prop or pet to enter into an AR environment and become a part of and interact with the virtual information overlay. More particularly the invention relates to an AR kiosk wherein a user or group of users from the audience are positioned at a predefined spot in front of the camera to interact with one or more computer generated layers and records and sends via Internet an AR video of such interaction to one or more user specified destinations for future use and sharing with friends and family.
PRIOR ART
[0004] Augmented Reality, abbreviated to AR, is a new type of digitized human-environment that combines real-world visuals and virtual-world images such as computer graphics to enhance user experience. In other words, augmented reality systems combine a real environment with virtual objects, thereby effectively interacting with users in real time. With this technology the field of view of a user is enriched with computer-generated contextual information.
[0005] Augmented reality has been widely used in various fields of application such as the entertainment field and the TV broadcast industry. A very common example that no one can miss is the TV weather broadcast where the forecaster appears in front of a weather chart that keeps changing naturally. AR technology allows a person to see or feel a real world integrated with computer-generated virtual world. The “real world” is the environment that a user can see, feel, hear, taste, or smell using the user's own senses, while the “virtual world” is a computer-generated environment stored in a storage medium and presented as an overlay of image, audio, video, or text information. Most ARs require a marker system to associate the virtual world to the real world. But AR content can also be triggered either manually when a live target object is positioned within video camera's field of view, or automatically by means of face or form recognition, or by means of one or more gestures.
[0006] Recently Chen et al, in US App Pub No. 20120162256 disclosed a machine-implemented AR method to enable a user to virtually try on a selected garment. In another recent disclosure Hong US Pub No. 20120166578 provided an augmented reality (AR) system for providing a user with a friend recommendation list corresponding to the interest and/or tendency of the user based on AR history information of the location.
[0007] In U.S. Pat. No. 8,002,619, Gagner et al disclosed an augmented reality wagering game system. Dunko in U.S. Pat. No. 8,170,222 disclosed a device and method for providing augmented reality enhanced audio. Baronoff in US App Pub No. 20120122570 described an AR system of multiplayer story-based gaming environment. Adhikari et al have disclosed several embodiments pertaining to AR, such as a computer program AR interface for video (US App Pub No. 20120113142), position identification system (US Pub No. 20120113143), an AR system for providing guide information related to the selected features (US App Pub No. 20120113144), a mobile AR system for surveillance and rescue operations (US App Pub No. 20120113145), an AR interface for video tagging and sharing (US App Pub No. 20120113274), an AR system for product identification and promotion (US App Pub No. 20120116920) and an AR system for supplementing and blending data (20120120101).
BACKGROUND OF THE INVENTION
[0008] AR is a new industry that is still evolving. Based on technological variations in implementing AR experience, the following segments of global AR market are appearing to be branching out:
1. Mobile AR—Most Mobile AR applications introduced in recent times claim to be AR Browsers. Prominent examples are Aurasma, Layar, Metaio, Wikitude, so on and so forth. 2. Desktop AR—Most examples of desktop AR are web-based product promo or demo apps that deploy the computer webcam for camera view and mostly Adobe Flash—based browser plugins. Those in this market segment are mostly advertising and multimedia companies that are catering to big corporations on fee-for-service basis. Installable desktop AR applications are there, but not available on commercial scale. 3. Big Screen AR—Big screen AR applications have recently appeared in public places such as malls, railway stations, trade shows, auditoriums, etc. Big Screen AR applications don't have to depend on any particular Operation System or Browser. They can use either browser plugins or especially designed installable applications.
[0012] In a co-pending application, these inventors disclosed a novel Mobile AR application. That invention filled the gap by creating mobile AR stakeholders, incentivizing their participation, and bringing them on a single platform. It created AR communities around very tightly knit, centrally controlled contiguous public places or community centers by engaging all the AR stakeholders and commercially rewarding every stakeholder's participation.
[0013] However, Non-Mobile AR does not have these dependencies, and as such can reach the masses without having to download any AR App, and without the limitation of App-specific AR content. Moreover, unlike Mobile AR, Mobile-independent AR allows the users themselves to step into the AR scene and physically interact with the computer-generated content within the AR scene itself. These advantages accelerate the penetration of AR technology into the masses. Nevertheless, even the Non-Mobile AR has major shortfalls that make it difficult to create a sustainable product-based business model. It depends on advertising companies creating AR-based advertisements for major advertisers. It's driven by what advertisers create for users, and leaves no room for what users want to create for themselves. For example a user has no option to shoot and save as a memorabilia an exotic video clip that depicts a live out-of-the world experience, such as interacting with a rare exotic animal like big wild cat such as tiger, lion, panther, etc., or an exotic bird like the macaw parrot, falcon, eagle, etc., or an animal species that is already extinct, or a cartoon character, or a science fiction character or object, a fictional terrestrial or extraterrestrial character, or even a past or present celebrity character. All of those special effects are possible either in high budget movies or corporate advertisements. It's certainly beyond the reach or imagination of a common man.
[0014] The present invention, therefore, creates a novel Augmented Reality Kiosk wherein any common man, either for a small fee or free (sponsored by a sponsor), can step into an out-of-the-world AR experience with real life-like computer generated content. And, not just become part of an exotic AR experience, but record and save it for sharing with friends and family and for user's own personal souvenir of lasting memories or memorabilia collection.
[0015] In short, prior art AR systems lack network as well as client components essential to creating real world kiosks, including mobile or virtual kiosks (browser-based) wherein any user can create his or her own recordable AR video in real time. They further lack means to save such user-created AR video in real time and share it with friends, family or social networks via Internet. Therefore, there is a need to design and develop AR Kiosks that bring enhanced AR experience within reach of a common man irrespective of whether he has a special AR-enabled device or not, and whether there are advertisers or sponsors to create and distribute AR content or not.
BRIEF SUMMARY OF THE INVENTION
[0016] The present invention addresses the foregoing need for a mobile-independent augmented reality method that any consumer with or without a smartphone can avail and create an out-of-the-world special effects video experience, and save and share it with family and friends. The present invention is directed to devices, systems, methods, programs, computer products, computer readable media, and modules for controlling one or more operating parameters of a camera-enabled computer apparatus that not only generates one or more virtual layers of content superimposed over the camera view on the display screen, but saves the complete animation effect to a computer readable medium in a media file format, and sends the media file to a user desired destination. Accordingly, there is a need for a versatile invention as summarized herein in some detail.
[0017] It is therefore an object of the present invention to provide an entirely new AR method of interfacing a real world user audience with virtual world computer-generated content, by means of providing public, private, web or mobile kiosks, wherein any individual(s) with or without a smartphone can step into an AR environment and choose a specific computer-generated content to interface, interact with such content and save the experience on the fly in a video or image file format. Such means of creating out-of-the-world special effects experience was, until now, only possible in hi-tech Hollywood movies. This object is achieved by presenting and superimposing in real time one or more layers of computer-generated content over the live captured camera view of a user and displaying the integrated video on a display screen in front of the user. The object is further achieved by providing a means to save the integrated composite video in one or more of the media file formats known to prior art. The object is further achieved by screencasting or sending the composite media file to one or more user specified destination or/and device.
[0018] It is therefore an object of the present invention to provide an AR Kiosk where a user can step in, choose his/her choice of computer-generated virtual content to superimpose on user's real time camera view for the required integrated augmented reality effect, record the AR video, and save or send the AR video to a user preferred Internet destination. As a consequence, it is further object of the invention to provide a public augmented reality kiosk (Public ARK), wherein one or more users, as part of a larger audience, in a public place, participate in an archive-able and sharable interactive and immersive AR experience in front of a large sized screen. It is further object of the invention to provide a private augmented reality kiosk (Private ARK) in a public place or venue, wherein one or more users create a private AR experience that can be saved as a media file and shared with friends and family on the fly and in real time. It is also further object of the invention to provide a web augmented reality kiosk (Web ARK) for extending the exotic AR experience to home-based Internet users with any basic Internet-connected webcam-enabled computer. It is still further object of the invention to provide a mobile augmented reality kiosk (Mobile ARK) for adapting the invention to be implemented in a smart handheld communication device.
[0019] It is yet another object of the present invention to allow user an exotic experience by creating user's AR video footage with one or more animals or plants declared as endangered or extinct under the Endangered Species Act of 1973. It is yet further object of the present invention to allow user an out-of-the-world experience by creating user's AR video footage with one or more terrestrial or extraterrestrial fictional characters or objects. It is also another object of the instant invention to allow user an awesome AR experience by creating user's AR video footage with one or more past or present popular celebrity human characters of user's choice.
[0020] It is also an object of the instant invention to provide a means for visualizing in three-dimensional perspectives and interacting intuitively with rare, extinct or otherwise inaccessible objects, events, artifacts, specimens, architecture, such as historical, cultural, scientific/biological articles showcased in academic institutions, libraries or museums of various types.
[0021] It is also further object of the instant invention to provide a new means for advertisers to engage users by making them protagonists of their own AR video footage. It is also yet another object of the invention to create advertisements on the fly.
[0022] It is also further object of the instant invention to further enhance the camera view of an augmented reality visual by adding another computer generated backdrop layer to replace user's background by means of deploying live chroma keying techniques using monochromatic green or blue screens. As a consequence it is yet another object of the invention to minimize the kiosk space for implementing such three-layered augmented reality composite by means of deploying a two-tiered chroma screening approach.
[0023] It is the eventual object of the invention to create high-end visual effects, which were until now only possible in high-tech movies with select star casts. It is further object of the invention to produce such high-end visual effects media file instantly on-the-fly without any post-production editing and manipulation. It is therefore the final object of the instant invention to make such out-of-world personalized AR visuals, affordable and accessible to a common man and archive-able as a souvenir of lasting memories, and instantly sharable with friends and family.
[0024] These advantages in addition to other 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 the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the software, algorithms, devices, remote servers and combinations thereof particularly pointed out in the appended claims.
[0025] The foregoing discussion summarizes some of the more pertinent objects of the present invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Applying or modifying the disclosed invention in a different manner can attain many other beneficial results or modifying the invention as will be described. Accordingly, referring to the following drawings may have a complete understanding of the invention. Description of the preferred embodiment is as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is an exemplary block diagram illustrating the operating modules of the present invention.
[0027] FIG. 2 is an illustrative flow chart depicting the sequence of steps in the present invention.
[0028] FIG. 3 is an exemplary diagram illustrating the components of an embodiment of the present invention as the Public Augmented Reality Kiosk (Public ARK).
[0029] FIG. 4 is an exemplary diagram illustrating the components of an embodiment of the present invention as the Private Augmented Reality Kiosk (Private ARK).
[0030] FIG. 5 is an exemplary diagram illustrating the components of an embodiment of the present invention as the Web Augmented Reality Kiosk (Web ARK).
[0031] FIG. 6 illustrates exemplary network architecture of an Augmented Reality Kiosk (ARK).
[0032] FIG. 7 is an exemplary diagram illustrating the aerial view of components of an embodiment of the present invention that incorporate two-tiered real time chroma keying technique.
[0033] FIG. 8 is an exemplary diagram illustrating the side view of components of an embodiment of the present invention that incorporate two-tiered real time chroma keying technique.
DETAILED DESCRIPTION OF THE INVENTION
[0034] It is advantageous to define several terms, phrases and acronyms before describing the invention. It should be appreciated that the following terms are used throughout this application. Where the definition of terms departs from the commonly used meaning of the term, applicant intends to utilize the definitions provided below, unless specifically indicated. For the purpose of describing the instant invention following definitions of the technical terms are stipulated:
1. Kiosk—Merriam Webster dictionary defines kiosk as a small structure with one or more open sides that is used to vend merchandise or services. However, within the meaning of this invention a kiosk includes any physical place wherein one or more individuals can interact and participate in a computer-enabled augmented reality experience in front of a digital screen, whether the digital screen is in the private personal space in the privacy of a personal living space such as a home, residence, room; or whether it is in a private enclosure in a public space in shopping mall, public transportation terminal, hotel, trade show, conference, convention center, museum, etc.; or whether it is a digital screen or a digital AR wall, an AR television set, in an open to all (or restricted) public space in shopping mall, public transportation terminal, hotel, trade show, conference, convention center, museum, so on and so forth. 2. ARK—Augmented Reality Kiosk (Public ARK, Private ARK and Web ARK) 3. Public Place—A public space within the meaning of this invention is a social venue or a community center that includes but not limited to shopping mall, public transportation terminal, hotel, trade show, conference, convention center, museum, library, college/university campus, amusement park, social event venue, so on and so forth. 4. Real time image capturing module (RTICM), which is a video camera stationed in a fixed position in front of one or more target objects or human subjects or pets. 5. Real time image display module (RTIDM), which is, either a PDP (plasma display panel), LCD (liquid crystal display), LED (light emitting diode) or OLED (organic light emitting diode) display panel, or a video projector screen, placed in front of the subject(s) preferably in the same vertical plane as the RTICM and capable of displaying high definition video. 6. Augmented Reality Content Module (ARCM), which is a database of computer-generated virtual content in audio, video, animation, 3D image, map or text format or combination thereof in reference to user preferences. 7. Augmented Reality Content Overlay Module (ARCOM), which associates the view captured by the RTICM with specific user preferred content in ARCM database and retrieves the content to display as an overlay that superimposes on the real time view captured by RTICM. 8. Real Time Chroma Keying Module (RTCKM), which comprises of one or more monochromatic chroma key screens whether of green or blue color, deployed to replace the background of the live objects or subjects within the camera's field of view, with a second layer of computer-generated content retrieved from a storage medium in real time serving as altered background of the AR video. Thus RTCKM enables real time production of a multi-layered augmented reality composite video comprising of foreground computer computer-generated virtual content overlay, live camera view layer, and the backdrop computer-generated virtual content overlay, which is created, recorded, personalized, saved locally and delivered to a remote location instantly without any post-production manipulation of the multi-layered composite video. 9. Augmented Reality Video Recording Module (ARVRM), which records on a computer-readable storage medium in real time, the final augmented reality composite scene of the camera view along with the augmented reality overlay audio-video content displayed on the RTIDM as a high definition media (video or image) file in a media format that includes JPG, BMP, PNG, GIF, AVI, FLV, MPEG-4, MP4, SWF, WebM, WMV, MOV, HDMOV, 3GP, MKV, DivX, m4v, f4v, so on and so forth. The ARVRM further personalizes the media file by embedding the name of the user on user's personal copy and names and credentials of user's friends and family on each of the user's shared media file. Thus the ARVRM produces a high definition media file on-the-fly requiring absolutely no post-production editing or manipulation. 10. Communication Module (CM), which instantly delivers the ARVRM recorded video file either to a user defined destination, such as user's communication device, or to user's email account, or to a remote server as a downloadable link, using either wired or wireless telecommunication protocol, or TCP/IP protocol, or WiFi protocol or Bluetooth, or a radiofrequency protocol. 11. Recorded Augmented Reality Content Module (RARCM), which is a database that stores the finally created, recorded, augmented reality media files, personalized with embedded user names and credentials; 12. A central processing unit (CPU), which analyzes and executes the operations of RTICM, RTIDM, ARCM, ARCOM, RTCKM, ARVRM, and CM to complete a user's AR experience.
[0047] The present invention is now described with reference to the drawings. Referring initially to FIG. 1 , the drawing illustrates a system 100 that depicts the operating modules of the ARK. System 100 comprises of RTICM 102 , ARCM 104 , User Interface Module 106 , ARCOM 108 , RTIDM 110 , ARVRM 112 , RARCM 114 , CM 116 . These modules may be hosted on a local or remote server, CPU. Component 102 provides a means for visualization and capture of real time view of one or more target objects or human subjects or pets, by an image-capturing device such as a video camera. Component 104 provides a means for storage of computer generated virtual content in audio, video, animation, 3D image, map or text format. 104 serves as a repository of preselected computer-generated virtual content comprising of media files featuring a singular or plurality of exotic wild animals or plants, whether endangered or extinct. Such exotic wild animals include but not limited to those belonging to the species such as tiger, lion, panther, leopard, jaguar, bear, koala, deer, gorilla, monkey, snake. It may also include singular or plurality of animals that are extinct or in danger of extinction as classified in Endangered Species Act of 1973. Extinct animals include various species of dinosaurs. The computer-generated content may also include extra-terrestrial fictional characters or objects, a singular or plurality of human celebrities from past or present, a singular or plurality of commercial products or services, or a combination thereof.
[0048] The computer-generated content may also include a singular or plurality of exotic birds belonging to the species that include but not limited to eagle, falcon, peacock, seagull, penguin, parrot, so on and so forth. It may also include singular or plurality of cartoon characters, or extraterrestrial alien characters, terrestrial or extraterrestrial vehicles that include popular models of car, motorcycle, or UFO (Unidentified Flying Object). It may also include one or more past or present celebrities. The computer-generated content may also include singular or plurality of body-wearable clothing and accessories, such as headwear, eyewear, makeover items, such as eyelashes, lipsticks, hairbands, hairclips, hairdos, wigs, etc., jewelry items, such as necklace, earrings, nose rings or nose studs, lockets, forehead pendants, etc., bangles and wrist watches, eyewear such as spectacles, sunglasses, contact lenses, makeover items, such as eyelashes, lipsticks, hairbands, hairclips, hairdos, artificial nails, nail polishes, etc. It may also include singular or plurality of advertised products or services.
[0049] Component 106 denotes a means for retrieval of virtual content from 104 based on user preference. The virtual computer-generated Augmented Reality (AR) content is triggered and retrieved either manually when a live target object or subject is positioned within video camera's field of view, or automatically by means of placing an AR marker within video camera's field of view, or markerlessly by means of face or form recognition, or by means of one or more gestures, or by means of an infrared remote controller, or by means of a laser pointing device, or by means of wireless radiofrequency signal. Component 108 provides a means for associating the real time object view captured by 102 and superimposes it with an overlay of computer generated virtual content retrieved from 104 . Component 110 provides a means for display of the finally combined augmented reality content by a device such as a plasma display panel, an LCD (liquid crystal display) panel, an LED (light emitting diode), an OLED (organic light emitting diode) display panel or a video projector. Component 112 provides a means for recording the finally composited AR video content displayed by 110 on a computer-readable storage medium in real time. Component 114 provides a means for storage of the recorded composite AR video content as a personalized digital media file with user's credentials embedded within the AR video. Component 116 provides a means for transmitting the integrated composite AR video file to one or more user specified destinations such as user's communication device or email account.
[0050] FIG. 2 depicts an exemplar methodology illustrating the steps followed in one aspect of the invention. It is to be understood and appreciated that the present invention is not limited by order of steps and that some of the steps may occur in different order and/or concurrently with other steps from that illustrated here. At step 202 , a device such as a video camera captures the real time user or object view. Such camera device is positioned either parallel to or in the same vertical plane as the display screen. At step 204 , the preselected virtual content based on user choice is retrieved from a database of computer-generated content. At step 206 , the computer-generated content is superimposed on the real time user view based on a manual or automatic trigger. In one embodiment of the present invention, this trigger for such computer-generated content overlay may be automatically activated by means of positioning an AR marker or the target object at a predefined point within view of the video camera. It may also be triggered by automatic face or form recognition. In other embodiments of the present invention, the trigger may be activated manually by the user or the operator, by gestures, by means of wireless signaling devices such as a laser pointer, infra red remote controller or a radio frequency enabled device. At step 208 , the integrated superimposed view is displayed in real time on a device such as a plasma display panel, an LCD (liquid crystal display) panel, an LED (light emitting diode), an OLED (organic light emitting diode) display panel or by a video projector. The displayed AR content is captured and recorded in real time at step 210 into a database as a digital media file personalized by embedding the name of the recipient of the composite media file. The composite AR video content file may be stored in one or more of known file formats that include but not limited to JPG, BMP, PNG, GIF, AVI, FLV, MPEG-4, MP4, SWF, WebM, WMV, MOV, HDMOV, 3GP, MKV, DivX, m4v, f4v, so on and so forth. At step 212 , the recorded composite AR video content file is instantly transmitted without any post-production delays usually on account of edits or manipulation of prior art, to one or more user specified destinations by user specified means. User defined destinations include, a handheld communication device, an email account, downloadable URL link of a remote server, so on and so forth. In different embodiments of present invention, the recorded composite AR video content file is transmitted through wired or wireless telecommunication protocol, or TCP/IP protocol, or GPRS protocol or WiFi protocol or Bluetooth or radiofrequency protocol or IMAP, SMTP or a telecommunication protocol.
[0051] With reference to FIG. 3 , which depicts the components of an embodiment of the present invention referred to herein as the Public ARK, 302 represents one or more target users in real time at a public place. 302 may be part of a large audience at a public place. 304 denotes the video camera suitably positioned to capture the real time view of user. In an embodiment of the present invention, 304 is a high definition camera with sensor capability of not less than 1 megapixel sensor. 306 represents a display screen positioned in front of the users. In one embodiment of the invention, the width of 306 is not less than 10 feet and not more than 100 feet, the horizontal field of view of 304 is not less than 80 degrees and not more than 120 degrees, and the distance of 302 from 306 is not less than 20 feet and not more than 50 feet. Preferably, 304 and 306 are positioned in the same vertical plane. 308 represents a means for displaying and recording the superimposed augmented reality content 310 .
[0052] With reference to FIG. 4 , which depicts the components of an embodiment of the present invention referred to herein as the Private ARK, 402 represents one or more target users in real time at a private place, such as a kiosk located in a public place. 404 denotes the video camera suitably positioned to capture the real time view of user. In an embodiment of the present invention, 404 is a high definition camera with sensor capability of not less than 1 megapixel sensor. 406 represents a display screen positioned in front of the users. In one embodiment of the invention, the width of 406 is not less than 40 inches and not more than 100 inches, the horizontal field of view of 404 is not less than 80 degrees and not more than 100 degrees, and the distance of 402 from 406 is not less than 6 feet and not more than 18 feet. Preferably, 404 and 406 are positioned in the same vertical plane. 408 represents a means for displaying and recording the superimposed augmented reality content 410 .
[0053] With reference to FIG. 5 , which depicts the components of an embodiment of the present invention referred to herein as the Web ARK, 502 represents one or more individual internet users in real time at a private place, such as a webcam enabled computer located in a private place. 504 denotes a webcam suitably positioned to capture the real time view of user. In an embodiment of the present invention, 504 is a high definition camera with sensor capability of not less than 1 megapixel sensor. The sensor is either CCD (Charge Coupled Device) type or CMOS (Complementary Metal Oxide Semiconductor) type. 506 represents a display screen, such as a computer monitor positioned in front of the user. In one embodiment of the invention, the width of 506 is not less than 14 inches and not more than 32 inches, the horizontal field of view of 504 is not less than 40 degrees and not more than 90 degrees, and the distance of 502 from 506 is not less than and not more than 12 feet. Preferably, 504 and 506 are positioned in the same or parallel vertical plane. 508 represents a means for displaying and recording the superimposed augmented reality content 510 . Hence, in a preferred embodiment of Web ARK, an AR experience is implemented through an Internet browser of either a desktop computer or a portable computer equipped with a webcam, in which case ARCM database and ARVRM software is hosted on a remote server, and recorded personalized AR media file is saved on the remote server and delivered to the corresponding user either via email, FTP (file transfer protocol) or TCP/IP protocol.
[0054] Referring now to FIG. 6 , there is illustrated the network architecture for implementing the computing environment in accordance with present invention. For the purpose of illustration, the Private ARK embodiment of the invention is shown here, although it may be appreciated that the same architecture can be implemented for any of the other embodiments of the invention. The real time view of user 602 is captured by 604 , displayed on 606 by a processing, integrating and recording means 608 that superimposes augmented reality content 610 on the real time camera view of the user 610 a . The recording means 608 records in one or more of the digital media file formats known to prior art and further personalizes such composite medial file by embedding the credentials of the recipient of the media file. Such AR media file 610 b may be transmitted by wired and/or wireless communications to one or more user specified destinations that include remote computers or other networked computers or devices connected to the internet for the specific users to download. The remote computer(s) may be a server computer 614 , a smart phone device or a hand held computer 616 , workstation 618 , personal or portable computer 620 , a network node 622 . In a networked environment the logical connections depicted include wired/wireless connectivity such as GPRS, TCP/IP, Bluetooth, WiFi.
[0055] In yet another embodiment a backdrop to the AR video may be further augmented by adding an extra layer of computer-generated content that replaces user's background. Such three-layered AR, that includes an extra background layer, in addition to the foreground and camera view layers, is enabled by using novel live chroma key techniques as disclosed herein. In a conventional method of chroma keying, homogenously colored monochromatic screens of a single color such as green or blue are placed behind the subject to make the subject's background transparent. However, in the instant invention chroma keying is implemented in two-tiered approach as explained in the description that follows.
[0056] FIGS. 7 and 8 illustrate the deployment of a novel chroma keying technique in real time to make the user's background transparent and replace it with another layer of computer generated content that serves as the user's backdrop. Although any uniform monchromatic color scheme known to prior art may be used, a preferred chroma keying technique may use either green screens or blue screens. This chroma keying embodiment is more relevant to the Private Kiosks described in the preceding paragraphs, wherein it addressed the following problems:
i) The physical background used to create the AR effect may have the limitations of variety, compatibility with the computer-generated AR content and space constraints in a public place; ii) A camera with wide-angle lens may be more appropriate for creating an AR scene with larger AR objects or characters allowing sufficient mobility within the camera view to create an impactful storyboard for the AR video. However this requires a large area to be covered with chroma keyed backdrop, which is not only very expensive, but bulky enough to be implement in a setting outside of a green screen studio. Thus with the conventional live chroma keying technique it is impossible to create a realistic backdrop.
These problems in creating an effective three-layered live AR experience are overcome by the chroma key embodiments of the present invention as described herein. With reference to FIG. 7 , which depicts the aerial view of the components of an embodiment of the present invention, 702 represents one or more target users or objects or subjects such as humans, props or pets, in real time at an AR kiosk located in a public place. 704 denotes a wide angle video camera suitably positioned to capture the real time view of user. 706 represents a display screen positioned in front of the users. Preferably, 704 and 706 are positioned in the same vertical plane. 708 represents a means for displaying and recording the superimposed AR content 710 , wherein the final AR display comprise of the first computer generated content layer 710 a , the real time camera view 710 b of the subject or object ( 702 ), and the second computer generated layer 710 c created by the Real Time Chroma Keying Module (RTCKM) and retrieved from a storage medium in real time serving as altered background of the AR video. The RTCKM comprises of chroma screens 711 , whether of green or blue color, deployed to replace the background of the live objects or subjects within the camera's field of view, with a second layer of computer-generated content 710 c . To minimize the space, a space-saving segregated scheme of sets of chroma screens are positioned in at least two tiers, such as on sides 711 b , back 711 a and top, synchronized to homogeneously render the entire viewable background within camera's field of view transparent. A chroma key compositing program that runs from the CPU removes color from the chroma screens render them transparent, and replace them in real time with a second layer of computer generated background image or video 710 c , thus considerably expanding the field of view 711 cf within a limited space.
[0059] Likewise, FIG. 8 , which depicts the side view of the tiered components of the chroma keying embodiment of the present invention, 802 represents one or more target users/subjects in real time at an AR kiosk located in a public place. 804 denotes a wide angle video camera suitably positioned to capture the real time view of user. 806 represents a display screen positioned in front of the subject or subjects. Preferably, 804 and 806 are positioned in the same vertical plane. 808 represents a means for displaying and recording the superimposed AR content 810 , wherein the final AR display comprise of the first computer generated content layer 810 a , the real time view 810 b of the subject or object ( 802 ), and the second computer generated layer 810 c created by RTCKM and retrieved from a storage medium in real time serving as altered background of the AR video. The RTCKM comprises of chroma screens 811 laid out in tiers, whether of green or blue color, deployed to replace the background of the live objects or subjects within the camera's field of view, with a second layer of computer-generated content 810 c . To minimize the space, a space-saving segregated scheme of sets of chroma screen are positioned in at least two tiers, on sides, back 811 a and top 811 c , synchronized to homogeneously render the entire viewable background within camera's field of view transparent. A chroma key compositing program that runs from the CPU removes color from the chroma screens render them transparent, and replace them in real time with a second layer of computer generated background image or video 810 c , thus considerably expanding the field of view 811 cf within a limited space. Thus the multi-layered augmented reality composite video comprising of the foreground computer computer-generated virtual content overlay, the live camera view layer and the backdrop computer-generated virtual content overlay is created, recorded, personalized, saved locally and delivered to a remote location instantly without any post-production manipulation of the multi-layered composite video.
[0060] In one further embodiment of the present invention, a handheld communication device, such as a smart mobile phone or a tablet PC can be deployed as a mobile ARK. These smart devices are usually equipped with high-resolution display and video camera on the backside of the display. The back facing camera of such handheld communication devices, which include smartphones and tablet PCs, can be used as RTICM, and the display operates as the RTIDM of the instant invention. The handheld smart communication devices that best suite the implement of the present invention are those that come with high resolution display screen not less than 3 inch and not more than 11 inch in width. The back facing camera integrated within the handheld communication device of the present invention has a horizontal field of view not less than 40 degrees and not more than 90 degrees, and distance of target object from camera is not less than 2 feet and not more than 18 feet.
[0061] In another embodiment of the present invention, sponsored promotional or advertising content may be combined with the integrated AR video file and displayed by the RTIDM. In yet another embodiment of present invention, the real time image display module (RTIDM) is capable of supporting more than one display panels, at least one of which is the customer display facing a user who enters the kiosk for the exotic AR experience, and one or more sponsor displays may be used for displaying interactive advertisements produced by sponsor. In yet another embodiment, the sponsor ad display panels may display sponsored content advertising one or more products or services, either as integrated as stand-alone apparatus, or conjoint with private or public augmented reality kiosk
[0062] Another embodiment of the present invention provides authorized users to securely access online the recorded augmented reality files from the ARCM database. In yet another embodiment of the present invention, the backdrop of the RTICM provides for an environment attuned to the specific content selected from the ARCM database. Such backdrop may be a jungle scene, snow-laden landscape, sea or river, rural or urban landscape, day or night, so on and so forth depending upon the foreground content layer that augments the real time camera view. Such foreground content that suites a jungle scene may include wild exotic animals or birds like tiger, lion, parrot, falcon. Foreground content that suites a snow landscape may suite an overlay that depicts animals or birds like polar bear or penguin.
[0063] In still another embodiment of instant invention, the AR apparatus is architecturally designed and fabricated as an AR Wall or an AR Television set to bring variety of entertaining AR experiences to any human inhabited space, such as a residential space, commercial space, corporate space, or public place such as shopping mall, hotel, conference or tradeshow hall, sports arena, educational institution, library, museum, amusement park, so on and so forth.
[0064] In further embodiment of the present invention, the various components of the disclosed AR system are integrated into a television apparatus to create an Augmented Reality Television (ART) set. Such ART sets can be deployed in public or private spaces that include but not limited to shopping malls, conference venues, trade shows, public transport terminals, sports arenas, hotels, corporate offices, educational institutions, and even in residential homes.
[0065] Although the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims. Therefore, the present embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the written description.
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The invention discloses an apparatus and system for establishing an Augmented Reality (AR) Kiosk (ARK) in public places or social venues such as, shopping mall, public transportation terminal, hotel, trade show, conference, convention center, expo, museum, library, college/university campus, amusement park, etc. Categories of ARKs disclosed include, Public and Private ARK, Web and Mobile Ark and their variants. ARK deploys a camera to capture, in real time, user's physical world environment, augments camera view by overlaying one or more layers of contextual computer-generated virtual content, and allows user/users to interact with the virtual content by positioning at a predefined spot in front of a digital display and the camera. Such interaction is recorded in real time, requiring zero post-production time, as composite media file, personalized with recipient's credentials, and instantly sent via Internet to one or more user specified destinations for future use and sharing with friends and family.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 08/309,043, filed Sep. 20, 1994, now abandoned which is a continuation of Ser. No. 08/060,604, now U.S. Pat. No. 5,348,192.
FIELD OF THE INVENTION
This invention relates to a valve for use in a beverage dispensing device.
BACKGROUND OF THE INVENTION
Concentrated juices, such as orange juice or lemonade, may be shipped frozen in a plastic container which is disposable or refillable. One type of container which is used to ship concentrated juice has a threaded opening onto which an adapter with a ball valve is screwed. The adapter has a threaded portion at one end, and a reduced diameter cylindrical portion with a spring mounted ball valve at the end opposite the threaded portion.
A dispenser concentrate control valve for a bag-in-box type of container is available from Jet Spray Corp. of Norwood, Mass., and is described in U.S. Pat. Nos. 4,856,676 and 5,000,348, each of which are assigned to the same assignee as the present invention, and each of which are expressly incorporated by reference.
To install this general type of valve with a container, a cap is unscrewed and discarded. The valve has a threaded portion or a threaded adapter which can be screwed onto the threaded opening of the container. With the adapter and ball valve arrangement, the adapter would be discarded, and the valve screwed on with its own adapter.
A drawback of this arrangement is that a user, such as an employee in a restaurant or diner, must remove the adapter and add the dispenser valve each time a new container is used. Many restaurants have a fast-paced environment so restaurant managers do not want to expend any extra time and effort replacing food items.
Another arrangement that has been used with a ball valve includes a stationary pin which contacts the ball valve when the container is inserted. With this arrangement, it is cumbersome to rinse the system since the flow of juice cannot be stopped unless the container is removed. This, too, is cumbersome and undesirable in the fast-paced food service environment.
SUMMARY OF THE INVENTION
The invention features a beverage dispenser for use with a container for holding a concentrated beverage. The container has an adapter which is resealably actuatable between an open position for allowing the beverage to flow from the container and a closed position for containing the beverage. The dispenser has a housing with a chamber for holding a container in a fixed position, and a dispenser valve which includes an engaging mechanism for engaging the adapter, and a manually actuatable switch operable between a first position in which the engaging means causes the adapter to be in an open position and a second position in which the adapter is maintained in a closed position. The concentrated beverage is then combined with water.
In preferred embodiments, the adapter has a spring loaded ball valve, and the engaging mechanism includes a pin. In the dispenser, the switch is a rotatable switch for causing the pin to move vertically. The dispenser also comprises a conduit for providing rinse water into the dispenser valve through an opening in the valve. The opening is aligned with the conduit when the adapter is in the closed position, and is out of alignment with the conduit when the adapter is in an open position.
In another aspect, the invention features a beverage dispenser for use with a concentrated juice container which has an adapter with a ball valve at the bottom of the container. The dispenser has a housing with a chamber for holding a container in a stationary position when the container is inserted. A dispenser valve is mounted in the housing and has a pin which is vertically actuatable to a first position in which the pin is spaced from the ball valve so that the juice is contained, and a second position in which the pin engages the ball valve to allow the concentrated juice to flow from the container. A switch is provided for moving the pin between the first and second positions. A conduit provides water from a water supply; and the water and the concentrated juice are combined. A tap provides the combined water and concentrated juice to a user.
In preferred embodiments, the dispenser further comprises a second conduit for providing rinse water to the dispenser valve. The dispenser valve has a movable portion with an opening for receiving water from the second conduit when the opening is aligned with the conduit. This occurs when the pin is in the first position. The dispenser valve has a stationary outer sleeve with grooves and a rotatable inner sleeve with radial pins which mate with the grooves when the inner sleeve is inserted in the outer sleeve. The inner sleeve has a radially extending handle. The chamber in the dispenser can holds a plurality of containers, in which case the dispenser has an equal plurality of dispenser valves.
In another embodiment, the dispenser further comprises a removable cleaning plug to allow cleaning of the dispenser valve. The cleaning plug includes a handle to allow the plug to be easily removed from the dispenser valve.
In yet another embodiment, the pin is cylindrical and is supported by an x-shaped support member. The pin and the support member are integrally formed with the dispenser valve.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages will become apparent from the following description of preferred embodiments and from the claims when read in conjunction with the drawings in which:
FIG. 1 is a perspective view of a beverage dispenser according to the present invention;
FIG. 2 is a perspective view of a container and adapter;
FIG. 3 is a partial cross-sectional view taken through the line 3--3 in FIG. 1;
FIGS. 4 and 5 are partial cross-sectional views of a dispenser valve according to the present invention in rinse and run positions, respectively;
FIG. 6 is an exploded perspective view of the dispenser valve;
FIGS. 7 and 9 are side views of a dispenser valve in rinse and run positions, respectively;
FIGS. 8 and 10 are cross-sectional views through the lines 8 and 10 in FIGS. 7 and 9, respectively; and
FIG. 11 is a cross sectional view of an alternative embodiment of a dispenser valve;
FIG. 12 is a cross sectional view taken along section lines 12--12 of FIG. 11; and
FIG. 13 is a partially broken away perspective view of a dispenser valve according to an alternative embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a beverage dispenser 10 has a refrigerated chamber 12 for holding one or more beverage containers 14. The containers are placed on a horizontal shelf 18 in the chamber through a hinged front door 16. The shelf has slots 19 positioned to correspond to where an adapter 20 extends vertically downward.
Referring to FIG. 2, container 14 has a threaded opening 28 in the bottom surface 30 (the container is shown upside down). Adapter 20 has a threaded portion at one end which screws over opening 28. At the other end 32 is a ball valve which keeps the liquid in the container.
Referring again to FIG. 1, adapter 20 mates with a concentrate control dispenser valve 22 which can be resealably opened or closed to allow a liquid in the container to flow. The concentrate is then mixed with water before being provided to a tap 24. To get juice from the dispenser, a user presses a glass against a switch 26 which causes the tap 24 to dispense combined water and concentrated juice. As an alternative to switch 26, a measured portion can be obtained by pushing a button (not shown).
Referring to FIG. 3, adapter 20 has a threaded portion 34 and a reduced diameter portion 36. At the shoulder between these two portions, a lip 38 extends into the interior of the adapter. Near the bottom of the adapter, a ball 40 is seated in an opening 42. A spring 44 is mounted between the ball and the lip, and keeps the ball pressed against the opening to seal the concentrated juice 46 in the container. An O-ring 47 is provided near the bottom to help seal the adapter when it is inserted in the valve 22.
The adapter is shown positioned over dispenser valve 22. Valve 22 has an engaging pin 48 which is mounted in a rotatable, cup-shaped, inner sleeve 50. The inner sleeve is mounted in a stationary outer sleeve 52, and is sealed by three O-rings 54. The inner sleeve has a radially extending handle 56 which is moved circumferentially to rotate the inner sleeve and the engaging pin relative to the outer sleeve.
Referring to FIGS. 4 and 5, the dispensing valve is shown in rinse position and run position, respectively. When the dispensing valve is in the rinse position (FIG. 4), the adapter extends into the inner sleeve, but the engaging pin and the ball are spaced apart by a small distance. If a user desires to rinse the dispensing valve, rinse water can be provided by a rinse water conduit 72 through a rinse inlet opening 110 in the inner sleeve 50 between the top two O-rings 54 to flow through the dispensing valve, without being combined with juice 46.
Referring to FIG. 5, when the dispensing valve is in the run position, the inner sleeve is rotated by an actuating handle (not shown) which causes the inner sleeve and the engaging pin to rotate upward. As a result, the engaging pin pushes the ball away from the opening and compresses the spring. Pushing the ball allows juice to flow from the container into valve 22. At the same time, the rinse inlet opening 110 in the inner sleeve is moved out of alignment with rinse water conduit 72, so rinse water does not enter the valve. The rinse conduit is now positioned between the bottom two O-rings.
The concentrate is pumped by a pump 100. The pump, as described in U.S. Pat. Nos. 4,856,676 and 4,610,145 preferably has a pump head with an eccentric pump chamber connected to inlet 102. An impeller (not shown) has flexible, rotating names mounted in pump 100. The concentrated liquid is combined with water from a water line 74, through a solenoid valve 76, and is then provided to tap 24.
Referring to FIGS. 3-5, an out-of-juice sensor is provided for detecting when the concentrated juice is low. A sensor, such as that shown in the present application, is described in U.S. Pat. No. 4,856,676 and 4,645,095, each of which are assigned to the assignee of the present invention and are incorporated by reference. Sensor 90 includes a first electrode 92 and a second electrode 94 which is grounded to the shelf 18 through a contact 96. Under normal running operation (FIG. 5), the concentrate contacts both electrodes. Circuitry (not shown) detects a change in impedance when the juice is not in a channel 98 between the electrodes. The circuitry senses the change and provides a visual indication of the change.
Referring to FIG. 6, an exploded view of the adapter and dispenser valve shows more detail. The inner sleeve of the dispenser valve has an inner cylindrical portion 80 and an overhanging portion 82. Two radial pins 84 extend from portion 82 toward portion 80. The outer sleeve has two upwardly slanting circumferential grooves 86, and two vertical grooves 88 extending from the top surface 91 to the middle of grooves 86. When assembled, the inner sleeve is placed over the outer sleeve so that pins 84 are aligned with vertical grooves 88. The inner sleeve is lowered and rotated so that the pins mate with grooves 86. When the handle is rotated, it causes the inner sleeve with the engaging pin to move relative to the outer sleeve as the pins move up or down in the grooves 86. Since the outer sleeve is held in a fixed position, the engaging pin is moved vertically to be in and out of contact with the ball valve without moving either the container or the outer sleeve.
Referring to FIGS. 7 and 8, groove 86 has a ramp portion 90 and a level portion 92. The ramp portion 90 comprises a sector of about 80°, and level portion 89 is about a 10° sector. Accordingly, the handle has a total range of movement of about 90° The level portion at the top of the groove helps to prevent the handle from rotating downward due to gravity or vibrations from the dispenser.
An alternative embodiment is shown in FIGS. 11-13. A dispenser valve 120 has an inner sleeve 122 rotatably disposed in a stationary outer sleeve 126. The sleeves are sealed with a plurality of O-rings 128. A handle 124 is connected to the inner sleeve for rotating it.
The valve 120 receives an adapter 130, which has a ball 132 biased with a coil spring 134. The spring extends downward from a lip 136 and biases the ball against an adapter opening 137 to seal the concentrated juice in the container as shown in FIG. 4. An O-ring 138 is provided near the bottom of the adapter to seal the adapter when it is inserted into the valve 120.
The valve has a cylindrical engaging pin 140, which extends vertically and perpendicular to an x-shaped support member 142 having a hub and four identical spokes 143. The pin and the support member are integrally formed with the inner sleeve 122. The pin is at the hub of the support member while the spokes are formed so that the support is mounted intermediate adjacent O-rings and the spokes are thinner than the distance between the O-rings.
Referring to FIG. 13, an exploded view of the dispenser valve shows more detail. The inner sleeve 122 of the dispenser valve has an inner cylindrical portion 180 and an overhanging portion 182. Two radial pins 184 extend from the overhanging portion toward the inner cylindrical portion. An outer wall 127 of the outer sleeve 126 has raised walls 185 forming two sets of tracks 187. Each set of tracks contains one upwardly slanting track 186, and one vertical track 188 extending from the top surface 191 of the outer sleeve 126 to the middle of track 186. When assembled, the inner sleeve is placed over the outer sleeve so that pins 184 are aligned with vertical tracks 188. The inner sleeve is lowered and rotated so that the pins mate with tracks 186. When the handle is rotated, it causes the inner sleeve with the engaging pins to move relative to the outer sleeve as the pins move up or down in the tracks 186. The tracks, and the radial pins function in a manner similar to that described for the radial pins and the grooves for the embodiment of FIGS. 3-10. In the embodiment shown in FIG. 13 the wall thickness of the outer sleeve 126 can be reduced since the tracks are formed from raised walls extending out from the outer surface 127 rather than from grooves formed within the outer sleeve as shown in FIG. 6.
Valve 120 operates in a manner similar to that described for the embodiment of FIGS. 3-10. When the inner sleeve 122 is rotated in a first direction, engaging pin 140 rotates and moves upward pushing ball 132 away from opening 137 and compressing spring 136, thus allowing juice to flow from the container into valve 120. When the inner sleeve is rotated in the opposite direction, the engaging pin rotates and moves downward so that the engaging pin and the ball are spaced apart by a small distance. In this position, the ball rests against the opening 137 and seals the juice in the container.
The valve includes a removable cleaning plug 144 inserted in an opening 148 of outer sleeve 126. An O-ring 146 seals an interface between the cleaning plug and the outer sleeve. The cleaning plug has a handle portion 150 for grasping the cleaning plug to remove it from the outer sleeve as shown in FIG. 13. With the cleaning plug removed, a brush or some other cleaning instrument may be inserted through opening 148 to clean valve 120. Also, water or a cleaning solution may be injected through the opening to assist in cleaning the valve.
Having described preferred embodiments of the present invention, it will become apparent to those skilled in the art that other modifications can be made without departing from the scope of the appended claims. For example, the chamber can hold one container or many, and have corresponding pumps, sensors, and taps. Also other embodiments of the dispenser can be used, for example, different types of pumps, microproccessor control, and other features.
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A beverage dispenser as provided for use with a container having an adapter with a resealable valve, which is a ball valve, has a valve which includes an engaging mechanism, such as a pin, for mechanically opening the valve in the adapter. The dispenser valve has a handle for rotatable motion, causing the pin to vertically move in contact with the ball valve, thus opening the container so that its contents flow. The valve may also be provided with a rinse water conduit and an opening so that the user can selectively close the adapter valve and rinse the dispenser system. The pin is preferably mounted to an x-shaped support.
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to a monofilament, in particular for use as a component in an industrial textile, such as a papermachine clothing (PMC) fabric.
[0002] Monofilaments formed from polymeric resins are used as yarns in a variety of industrial applications. For example, woven or non-woven fabrics manufactured from polymeric monofilaments are widely used in dryers, conveyors and the like. In particular, endless fabric belts are important constituents of the dryer sections, forming sections and press sections of paper machines. Such fabrics, which are also called paper machine clothings (PMC), are disclosed, for example, in commonly assigned patent application publication US 2012/0214374 A1 and in its counterpart European published patent application EP 2 489 781 A1.
[0003] Monofilaments which are to be used as yarns in an industrial textile are often formed from polyamide (PA). Thermoplastic polyamides generally have a high resiliency, a high abrasion resistance as well as a high toughness. The mechanical properties of monofilaments formed from polyamides are generally sufficient for the above mentioned applications and in particular for the use in the forming sections and press sections of paper machines. In these sections, water based pulp is deposited on a porous forming fabric manufactured from monofilaments. After the deposition of the pulp, water is extracted from the pulp by gravity and suction. During this extraction process, water passes through the pores of the forming fabric. In a further stage of the paper production process, the wet web prepared from the pulp is transported on a press felt. Nip rollers or the like are used to squeeze out water from the web. Finally, the web is dried on a porous dryer fabric by supplying thermal energy.
[0004] The contact between the polyamide yarns and water during a paper production process is problematic, because polyamides tend to absorb a considerable amount of water. This effect is due to the hydrogen bonding capacity of the amide linkages present in the polymer structure. Water absorption affects the mechanical properties of the monofilaments, resulting in dimensional changes of the respective fabric. Therefore, the stability and durability of PMC fabrics made from polyamide yarns is rather poor.
[0005] In order to reduce the water absorption capacity of monofilaments formed from polyamide, chemically modified polyamides and/or additives could be in principle used. However, such approaches are disadvantageous because the tensile and abrasion resistance properties of the monofilaments are reduced and the material costs are increased. On account of these reasons there is a need to enhance the stability of monofilaments for industrial textiles while maintaining the tensile properties.
SUMMARY OF THE INVENTION
[0006] It is accordingly an object of the invention to provide a monofilament, a production method and a fabric which overcome the above-mentioned and other disadvantages of the heretofore-known devices and methods of this general type and which provides a monofilament which is easy to produce and which has a high mechanical stability even when intensely exposed to moisture.
[0007] With the foregoing and other objects in view there is provided, in accordance with the invention, a monofilament formed from a composition including more than 70 weight % to 99 weight % polyamide and from 1 weight % to less than 30 weight % polyphenylene ether.
[0008] Polyphenylene ether (PPE) polymers are amorphous and non-polar. Moreover, they have excellent mechanical and thermal properties as well as being dimensional stable. The inventors have surprisingly recognized that it is advantageous to combine the high resiliency and abrasion resistance of polyamide with the high stability and the low water absorption capacity of polyphenylene ether. The aromatic component of the polyphenylene ether lowers the overall polarity of the composition and thus reduces the water uptake of the formed monofilament.
[0009] In principle, polyamide is poorly mixable with polyphenylene ether. Surprisingly, however, it has been found that the compatibility of polyamide and polyphenylene ether at comparatively low loadings of polyphenylene ether is sufficient to produce stable monofilaments. These monofilaments are easy to produce and have excellent tensile and loop properties as well as high abrasion resistance. Simultaneously reduced water absorption capacity should lead to improved dimensional stability. Therefore, the invention enables longer overall fabric life on a paper machine.
[0010] According to a particularly preferred embodiment of the invention, the polymer part of the monofilament completely consists of or at least essentially consists of the polyamide and the polyphenylene ether as polymer ingredients. Specifically, the sum of weights of the polyamide and the polyphenylene ether based on the total weight of the polymer part of the monofilament may be at least 80 weight %, preferably at least 90 weight %, more preferably at least 95 weight %, even more preferably at least 99 weight % and most preferably 100 weight %. Although it is preferred to use only polyamide and polyphenylene ether as polymeric ingredients, the composition may further comprise non-polymeric additives. For certain applications, it may be advantageous to add further polymers to the mixture of polyamide and polyphenylene ether. However, maximizing of the amount of polymer in the composition increases yarn tenacity.
[0011] Preferably, the composition does not include any compatibilizer.
[0012] According to a preferred embodiment of the invention, the composition does not include any compound belonging to the group consisting of fumaric acid, maleic acid, itaconic acid, dimethylmaleate, maleimide, tetrahydrophthalimide, maleic anhydride, itaconic anhydride, glutaconic anhydride, citraconic anhydride and tetrahydrophthalic anhydride. This maximizes ease of processing and reduces the production costs.
[0013] In accordance with another preferred embodiment of the invention, the composition does not include any functionalized olefinic elastomer.
[0014] Notably good results are achieved when the polymer part of the composition is a binary mixture of polyamide and polyphenylene ether. I. e. it is preferred that the composition doesn't contain any further polymers apart from polyamide and polyphenylene ether. However, as stated above, such a preferred composition may contain additional non-polymeric ingredients.
[0015] In a further development of the present invention, it is proposed that the composition includes a stabilizer, in particular an antioxidant.
[0016] Particularly good results are achieved when the polyphenylene ether has a number average molecular weight of less than 10000 g/mol. In accordance with the present invention, the number average molecular weight is measured by gel permeation chromatography making use of polystyrene standards.
[0017] In accordance with a still further embodiment of the invention, the polyamide is selected from the group consisting of PA6, PA6.6, PA6.T, PA6.10, PA6.12, PA6,6.6, PA4.10, PA5.6, PA5.10, PA5.12 and mixtures thereof. These polyamides have turned out to provide especially good results.
[0018] Notably good results are achieved when the polyamide is PA6 (polycaprolactam) or PA6.6 (nylon).
[0019] According to a further embodiment of the invention, the monofilament has a loop tenacity which is at least 20% greater than the loop tenacity of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide.
[0020] In accordance with the present invention, the loop tenacity is determined by linking two loops of the monofilament or of two respective monofilaments and pulling the loops against each other.
[0021] In accordance with a still further embodiment of the invention, the monofilament has a loop tenacity which is at least approximately 40% greater than the loop tenacity of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide.
[0022] According to yet another embodiment of the present invention, the monofilament has a loop tenacity ranging from 4 gf/den to 10 gf/den, preferably from 5.5 gf/den to 8.5 gf/den, wherein “gf/den” means “grams force per denier” and wherein 1 gf/den×8.83 equals 1 cN/tex.
[0023] In accordance with still another embodiment of the present invention, the monofilament has a water absorption which is at least 15% less than the water absorption of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide, and wherein the water absorption is determined by immersing the respective monofilament in distilled water at 23° C. for 24 h and weighing the respective monofilament before and after the immersion process. Specifically, the water absorption may be determined according to ASTM D570.
[0024] Preferably, the monofilament has a water absorption which is at least approximately 30% less than the water absorption of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide, and wherein the water absorption is determined by immersing the respective monofilament in distilled water at 23° C. for 24 h and weighing the respective monofilament before and after the immersion process.
[0025] According to a further preferred embodiment of the present invention, the monofilament has an abrasion resistance which is at least 50% greater, preferably at least 70% greater, than the abrasion resistance of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide. In accordance with the present invention, the abrasion resistance is measured by the squirrel cage method as disclosed in the above-mentioned US 2012/0214374 A1 and EP 2 489 781 A1.
[0026] Particularly good results are achieved when the monofilament has a tenacity which is greater than 5.0 gf/den. In accordance with the present invention, the tenacity is determined according to ASTM D2256-97.
[0027] According to a further preferred embodiment of the present invention, the monofilament has a thermal stability which is at least 10% greater than the thermal stability of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide, and wherein the thermal stability is determined as percentage of the tenacity retention after exposing the respective monofilament in an oven at 170° C. for 24 h.
[0028] Moreover, it is preferred that the monofilament has an elongation at break ranging from 10% to 50%, preferably from 20% to 35%. In accordance with the present invention, the elongation at break is measured according to ASTM D2256-97.
[0029] In accordance with still another preferred embodiment of the present invention, the monofilament has a maximum diameter ranging from 0.005 mm to 5 mm, preferably from 0.05 mm to 2 mm. According to the present invention, the term “maximum diameter” means the maximum dimension in the cross-section of the monofilament. Monofilaments having a dimension falling in this numeric value range have been found to be specifically suited for PMC applications. Generally, the monofilament according to the invention may have a circular, oval or rectangular cross section. Specifically, the cross-sectional shape of the monofilament may be selected depending on the type of fabric or felt which is to be produced and depending on the application field of the fabric or felt.
[0030] Moreover, the present invention is directed to a fabric, in particular a papermachine clothing (PMC) fabric, comprising a plurality of woven or non-woven monofilaments, wherein at least some of the monofilaments are formed from a composition including more than 70 weight % to 99 weight % polyamide and 1 weight % to less than 30 weight % polyphenylene ether.
[0031] Such a fabric is easy to produce, cost-effective and sufficiently stable to be used in a high moisture environment, such as the forming and press section of a paper machine.
[0032] Notably good results are achieved when the fabric is completely made up from monofilaments which are formed from a composition including more than 70 weight % to 99 weight % polyamide and 1 weight % to less than 30 weight % polyphenylene ether.
[0033] According to a further preferred embodiment of the present invention, the fabric forms an endless belt. Such an endless belt can be used as a conveyor belt or, preferably, as a dryer belt, forming belt or press belt in a paper machine.
[0034] Therefore, according to still another embodiment of the invention, the fabric has a sufficient mechanical and thermal stability to be used as a dryer belt, forming belt or press belt in a paper machine.
[0035] In addition, the present invention relates to a method for forming a monofilament comprising the steps of preparing a resin composition including more than 70 weight % to 99 weight % polyamide and 1 weight % to less than 30 weight % polyphenylene ether, extruding the resin composition through a spinneret to form a monofilament and drawing the monofilament for one or more times.
[0036] Apart from using a mixture of polyamide and polyphenylene ether having a low loading of polyphenylene ether, the drawing of the monofilament may be performed according to the principles that are generally known in the field of monofilament production.
[0037] In accordance with still another preferred embodiment of the present invention, the resin composition is extruded by means of a standard extruder, such as a single screw extruder or a twin screw extruder.
[0038] Particularly good results are achieved when the step of preparing the resin composition includes the step of melt blending a mixture of polyamide and polyphenylene ether.
[0039] Preferably, the melt blending is carried out without adding any compatibilizer. This maximizes ease of processing and keeps the production costs low.
[0040] Moreover, it is preferred that the step of preparing the resin composition does not involve any chemical modification of the polyamide.
[0041] in accordance with a concomitant feature, the invention is also directed to the use of a monofilament as described above for forming a papermachine clothing (PMC) fabric.
[0042] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0043] Although the invention is illustrated and described herein as embodied in a monofilament, a fabric, and a method of producing the same, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0044] 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 SEVERAL VIEWS OF THE DRAWING
[0045] FIG. 1 is a fragmentary perspective view of a portion of a fabric made up from monofilaments; and
[0046] FIG. 2 is a flowchart illustrating an embodiment of the method of making monofilaments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0047] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a portion of a fabric 10 formed from a plurality of woven monofilaments 12 , or monofilament bodies. The fabric 10 may be formed to provide an endless belt. The monofilament bodies 12 have a diameter ranging from 0.005 mm and 5 mm, depending on the application. The specific weave pattern of the fabric 10 may vary from one application to another. Moreover, fabric 10 need not necessarily be a woven fabric, but may include non-woven monofilaments 12 . The monofilaments 12 shown in FIG. 1 have a circular cross section, but this may vary depending on the application. In particular, the monofilaments 12 may have an elliptical cross section or a rectangular cross section with slightly rounded corners.
[0048] At least some of the monofilaments 12 and preferably all monofilaments 12 making up the fabric 10 are formed from a resin composition including more than 70 weight % to 99 weight % polyamide and 1 weight % to less than 30 weight % polyphenylene ether, as it is described above and for an exemplary embodiment below.
Examples
[0049] Different samples of monofilaments were produced on the basis of a polyamide (PA) resin and a polyphenylene ether (PPE) resin. The polyamide resin was PA6 supplied by BASF. The polyphenylene ether was Noryl SA120-100 supplied by SABIC. Of these two polymers, binary mixtures having different PPE loadings were prepared by melt blending as shown at 14 in FIG. 2 . No compatibilitizers were added to the mixtures. Monofilaments 12 or yarns were produced by extruding the mixture through a spinneret in a single screw extruder as shown at 16 in FIG. 2 . The loading of the PPE ranged from 5 weight % to 30 weight % as shown in Table 1 below. A comparative monofilament having a PPE loading of 0 weight % was also prepared. Preblending into pellets was not necessary. The monofilaments 12 were drawn so as to have a diameter of 0.40 mm, as is shown at 18 in FIG. 2 .
[0050] Tensile properties of the monofilaments 12 thus produced were evaluated according to ASTM D2256-97. The results are indicated in Table 1.
[0051] The abrasion resistance of the monofilaments 12 was measured using the squirrel cage method. This method is described in US 2012/0214374 A1 and EP 2 489 781 A1 and involves the use of a rotating drum of metal wires which are aligned perpendicular to the polymer strands. At the beginning of the test, a load is applied to each strand. During the test the strands are continually abraded by the rotation of the drum and the abrasion resistance is quantified by the number of cycles it takes for the strand to fail. The average number of cycles to break for the monofilaments 12 formed from the PA-PPE-mixture was found to range between 16900 and 22700 (Table 1). In contrast, the comparative monofilament having a PPE loading of 0% processed under similar conditions had an average number of cycles to break of 10000. Hence, the abrasion resistance is increased by more than 1.65 times with the addition of PPE. Increasing the PPE loading above 30% resulted in a phase separation of the components and in unacceptable monofilaments.
[0052] To determine the free shrinkage, the samples were kept in an enclosed hot air oven at 177° C. for 3 minutes in an unrestrained condition. After this hot air treatment, the change in the length of each sample was measured and the free shrinkage percentage was calculated therefrom.
[0053] Apart from the abrasion resistance and the free shrinkage, Table 1 shows further tensile properties of the monofilament samples according to the present invention as well as of the comparative monofilament. Thermal stability of the monofilaments was evaluated by exposing the monofilaments to high temperatures and measuring the tensile properties before and after the heat treatment. Specifically, the samples were exposed to 170° C. for 24 hours in an enclosed hot air oven and retained tensile strength of the monofilaments was expressed in percentage after the heat treatment.
[0054] The water absorption of the monofilament samples was measured according to ASTM D570. Specifically, the samples were emerged in distilled water at 23° C. for 24 hours. The samples were then removed, dried using a lint free cloth and weighed.
[0055] It can be deduced from Table 1 that the use of a PA-PPE-composition having a comparatively low PPE loading enables the production of monofilaments having a high stability, excellent tensile and loop properties and a reduced water absorption at the same time.
[0000]
TABLE 1
Monofilament properties
Abrasion
Tenacity
Free
Resistance
Retention
PPE
Elongation
Loop
Shrinkage
(number of
(Thermal
Water
Loading
Tenacity
at Break
Tenacity
(177° C.;
cycles to
Stability
Absorption
(%)
(gf/den)
(%)
(gf/den)
3 min)
break)
Test) (%)
(%)
0
6.42
24.08
5.89
12.9
10000
14.64
6.29
5
6.47
26.12
7.52
13.5
16900
24.57
6.00
10
6.23
25.23
6.86
13.7
19400
35.63
4.55
15
5.79
25.17
7.97
13.7
22700
49.05
5.31
20
5.81
25.59
8.03
13.5
17800
42.51
5.32
30
5.81
31.85
6.56
13.4
20500
55.77
5.00
[0056] While this invention has been described with respect to a preferred embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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A monofilament is particularly suited for use as a component in an industrial textile such as a papermachine clothing (PMC) fabric. The monofilament is formed from a composition including more than 70 weight % to 99 weight % polyamide and from 1 weight % to less than 30 weight % polyphenylene ether.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to ultrasonic bonding machines and more particularly concerns an open center mounting that permits optimum substantially linear motion of a bonder tip.
2. Description of Related Art
In the manufacture of microelectronic circuit packages, certain electrical connections are made with extremely thin gold or aluminum wires. For example, connections between a semiconductor integrated circuit chip and package leads are typically made with such thin wires. As another example, active elements in semiconductor hybrid circuits may be interconnected with extremely thin wire.
Attachment of the interconnecting thin wires is commonly accomplished with an ultrasonic wire bonding machine which supplies wire and makes connections of the wire leads. Such a machine generally includes a wire bonding head which can move vertically, horizontally and rotatably about a vertical axis. An ultrasonic transducer, carrying a bonding tool, is pivotally mounted to the bonding head so that as the tool comes into contact with the workpiece it may be pivotally displaced through a very short distance about a horizontal axis, as may be required to ensure proper contact and pre-load. The transducer includes an arm to which the bonding tool is attached. Linear vertical movement of the bonding head raises or lowers the tool to a position in which the tool tip is close to but spaced from the workpiece. As the tool is finally lowered or initially raised to cause the bonding tip to contact or withdraw from the workpiece, the tool tip must be able to undergo a small vertical motion relative to the machine frame to accomplish or release the small tool preloading. This motion previously has been provided by pivotal motion of the transducer and its tool tip. However, such a pivotal motion introduces a small amount of horizontal motion, commonly termed "tip skid", in the course of the desired vertical preloading motion of the tip. Such horizontal component of motion causes a corresponding horizontal force component to be exerted on the wire which has been or is to be bonded, tending to improperly and undesirably displace the wire.
These undesired horizontal motion components are increased by the location of the tool tip pivot well above the workpiece, as is required to provide clearances required for the usual occupied center mounting. Therefore, if the pivot axis for the preloading motion of the tool tip is positioned above the plane of the workpiece, the adverse tip skid effect of the pivotal motion is increased.
My prior patent, U.S. Pat. No. 4,598,853, for Open Center Flexural Pivot Wire Bonding Head, describes a flexural pivot structure that employs a pair of leaf springs to provide a flexural mounting of the transducer and tool tip. This spring mount defines a vertical motion with minimized tip skid. The arrangement of my prior patent has been found to be efficient and effective, but greater rigidity and stability of the movable mounting for the ultrasonic transducer will provide improved efficiency, repeatability and reliability.
Accordingly,it is an object of the present invention to provide an open center mounting that provides some or all of the above-mentioned improvements.
SUMMARY OF THE INVENTION
In carrying out principles of the present invention, in accordance with a preferred embodiment thereof, an element support is mounted to a frame for motion about a center of motion that is displaced from the support and frame. The mounting arrangement includes mutually spaced guide members on the frame having first and second guide surfaces respectively positioned on one side of the center of motion and first and second guide followers on the element support having a moving contact with the first and second guide surfaces and positioned between the guide surfaces and the center of motion. Means are provided for urging the guide followers against the guide surfaces. The element support is effectively pivoted to the frame for motion about the displaced center, but, for small motions, a tool carried by the support moves with a linear motion that has only negligible transverse components.
In a specific embodiment the guide members are rollers journalled on the frame on transverse axes, and the guide followers are longitudinally extending rods fixed to the transducer carrying support and held against lower mutually facing surfaces of the rollers by tension springs. The springs are inclined to provide a desired preload.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a side view, partly in section, of portions of an ultrasonic bonding machine head embodying principles of the present invention;
FIG. 2 is a cross section taken on lines 2--2 of FIG. 1 of the arrangement of FIG. 1, with parts broken away and parts shown in elevation;
FIG. 3 is a plan view of the bottom of the arrangement of FIG. 1;
FIG. 4 is a plan view of parts of the top of the machine of FIG. 1; and
FIG. 5 is an exploded perspective view of the bonder frame and transducer support of the arrangement of FIGS. 1 through 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An ultrasonic wire bonding machine embodying principles of the present invention incorporates a bonding frame 10 to which is movably mounted, by the open center mounting means of the present invention, a transducer support 12 which carries a bonding tool 13. The bonding frame is formed of a rigid body having a substantially inverted U-shape, including mutually spaced parallel side legs 14,16 and a bight or connecting portion 18. The bight 18 is formed with an arcuate forward facing surface 20 curved about a vertical axis and adapted to be bolted to a bonding head surface 21 (FIG. 4) which is connected to a bonder motion control apparatus (not shown), similar to that shown in my prior U.S. Pat. No. 4,598,853. The motion control apparatus enables the entire bonder head, including frame 10 and transducer support 12, to be moved vertically, horizontally and rotatably about the vertical axis of arcuate surface 20.
Rotatably mounted to inner surfaces of the side leg 14 are first and second ball-bearing rollers 22,24 journaled to the side leg about mutually spaced fixed transverse axes 26,28 (FIG. 3) which extend substantially horizontally and normal to the longitudinal or fore-and-aft axis of frame 10. Similarly, a second pair of ball-bearing rollers 30,32 are journaled to the side leg 16 at the inner side thereof on the same axes 26 and 28 respectively. Roller 32 is a double roller having mutually aligned rollers 32a, and 32b that are slightly spaced axially from one another.
Secured in a hole 40 that is formed in the arcuate surface 20 and extends through bight 18, is an electromagnet 42 (FIG. 1).
Each side leg 14,16 is formed with a vertically extending, downwardly opening recess 44,46 at the upper end of which are fixedly mounted spring holding frame screws 48,50 which are cantilevered to project longitudinally of the frame into the respective recesses but not completely across the recesses.
The transducer support, as pictorially illustrated in FIG. 5, comprises a rigid yoke 52 having side legs 54 and 56 laterally spaced apart to provide a downwardly opening and longitudinally extending arcuate bore 60 (FIG. 2) which receives the cylindrical body 62 of an ultrasonic transducer having a forwardly extending longitudinal arm 64 to which is secured the bonder tip 13, projecting downwardly from the arm 64. Transducer 62 is secured in the arcuate bore 60 of the yoke by means of a pair of screws 66,68 which are employed to forcibly close a pair of inwardly opening slits 70,74 (FIG. 2) formed in the inner surfaces of the bore 60 to thereby clamp the transducer to the yoke.
Extending transversely outwardly from substantially central portions of the lower ends of the yoke legs 54,56, are cantilevered spring holding yoke screws 76,78 having tension springs 80,82 secured at their lower ends to the screws 76,78 and at their upper ends to the frame screws 48,50.
First and second longitudinally extending rigid circular cylindrical follower rods 90,92 are fixedly secured, as by being a press fit for example, in front and back ends of yoke side leg 54 and extend downwardly and outwardly from the yoke leg into contact with surfaces of rollers 22,24 that are below and inwardly of the roller axes. Similarly, a pair of longitudinally extending rigid circular cylindrical follower rods 96,98 are fixed to the forward and rearward ends of yoke leg 56 extending downwardly from the yoke leg and contacting portions of the outer surface of rollers 30,32 that are below and inwardly of the roller axes. As previously mentioned, roller 32 is a double coaxial roller, comprising coaxial roller sections 32a and 32b, which are slightly spaced apart axially to receive the rigid follower pin 96 therebetween. This pin contacts the spaced adjacent edges of the two rollers, thereby providing for relatively fixed lateral positioning of the frame with respect to the yoke.
The upper intermediate section of yoke 52 carries an upstanding post 100 to which is mounted a disc 102 of magnetic material having a face positioned closely adjacent to but slightly spaced from the face of the electromagnet 42 on the frame. Longitudinal position of the disc 102, relative to the magnet 42, is adjustable by means of a screw 104, integral with disc 102 and threaded in post 100 and connected to the disc 102.
An electrical contact 110 carried on an arm 112 that is adjustably threaded in the yoke post 100, cooperates with a second contact 114 carried in a sleeve 116 fixed in a hole 118 of the bight 18 to provide both a physical stop for limiting motion of the upper portion of the yoke toward the frame (toward the right, as viewed in FIG. 1) and an electrical sensor to signal touchdown of the tip 13a on the workpiece by responding to the counterclockwise (as viewed in FIG. 1) motion of the yoke that occurs upon touchdown, which motion separates the normally contacting electrical contact elements 110 and 114.
An optical sensor assembly 119 (FIGS. 2 and 4) carries a light emitting diode (not shown) and a photo detector (not shown) for detecting the forward edge of post 100. The optical center of the sensor assembly is aligned with the forward edge of post 100 so that the sensor provides an output signal that increases as the post 100 moves to its forward limit position.
The apparatus is nominally set up so that a virtual center of motion 120 (FIG. 1) lies in a plane parallel to a line containing the axes 26,28 of the rollers 22,24 and containing the tip 13a of tool 13. The virtual center 120 is equidistant from the axes 26,28 and lies on a vertical line containing the center of gravity of the yoke. The longitudinal axes of follower rods 90,92 are perpendicular to the respective radii of the rollers at the points of tangential contact 122,124 between the follower rods and the respective roller surfaces. The roller radii through the tangential contact points meet at the center of motion 120. The rollers and rod followers are symmetrically disposed on either side of a plane extending parallel to the roller axes and bisecting and perpendicular to the line between the axes. Assuming the axes of springs 80,82 are vertical, as viewed in FIG. 1, (they are actually tilted for preloading as described below) and equidistant from the roller axes 26,28, the yoke will be urged upwardly by the springs so that the points of contact between the follower rods and the rollers are equidistant between the intersections of the roller surfaces with a line joining the axes 26,28 and the intersection of the roller surface with a vertical line extending downwardly from the roller axes. In other words, the tangent points are half way between intersections of horizontal and vertical diameters of the rollers. The structure attains a position of static equilibrium in which the forces on the yoke, exerted by the nominally vertically directed spring axes, are balanced by vertically downward components of force exerted by the rollers on their respective follower pins at the respective tangent points. The rollers, being substantially frictionless, can exert on the follower rods only forces directed radially of the rollers at the tangent points. Horizontal components of these forces are equal and opposite, and thus the springs hold the rollers in a position of fore-and-aft equilibrium from which the yoke may be displaced about the virtual center 120 by a motion that effectively moves each follower rod along the surface of the roller. Stated otherwise, such motion effectively causes the rods to roll along the roller surfaces. Thus, for example, if the yoke is moved about the center of motion so that the upper portion of the yoke moves toward the right, as illustrated in FIG. 1, the forward rod 98 moves along the surface of roller 30 downwardly and toward the right while the rear rod 96 moves along the surface of its rollers 32a and 32b upwardly and toward the right. The net effect of this motion about the virtual center 120 is a substantially linear vertical motion of the tip 13a of the tool 13. There is effectively no horizontal motion of the tool tip within reasonably small ranges of relative motion of the yoke and frame. Thus any tip skid is negligible.
Screws 48,50 are adjustably threaded in the frame sides 14,16 so as to enable adjustable variation of the point to which the upper ends of each of the springs is attached. This provides a downward bias of the tool tip for tool force preload. The upper end of each spring may be moved forwardly or rearwardly by adjustment of the screws 48,50 to thereby achieve a vertical inclination of the spring axes. Thus, as illustrated in FIG. 1, the screws 48,50 are positioned within the frame so that the upper portions of springs 80 and 82 are positioned sufficiently to the right of a vertical line through the virtual center 120 that the spring axes lie along lines indicated at 130. With this inclination of the spring axes, the yoke has a nominal position of equilibrium in which the tool tip 13a is displaced linearly downwardly below the position which it would assume if the spring axes were vertical. However, motion toward this nominal equilibrium position, in which the tool tip 13a is below the position illustrated in FIG. 1, is restrained by abutment of the contact elements 110,114 which serve to limit the clockwise position to that shown in FIG. 1. Thus, the inclination of the spring axes provides a downward bias force, preferably in the order of about 10 grams, which the tool tip will exert upon the workpiece before the contact elements separate.
In operation of the described bonder, during head motion the yoke is locked to the frame by energization of electromagnet 42 to strongly draw the disc 102 toward the fixed frame structure of the magnet. The entire bonder head is moved to a desired position above its bonding location and then moved downwardly, relatively rapidly. When the tool tip 13a is a predetermined distance above the workpiece, downward motion is slowed and the electromagnetic lock is released. Release of the force of the magnet removes the magnetic locking force but does not result in any motion of the yoke which is still biased by the inclined springs to maintain abutment of the contact elements 110,114. Further and slower downward vertical motion of the entire head brings the tip 13a into contact with the workpiece. After initial contact between the tip 13a and the workpiece, continued downward motion increases the reaction force exerted upon the tool tip by the workpiece until it reaches the approximately 10 gram preload caused by the inclination of the spring axes. When the reaction force on the tool tip exceeds the spring load, the upper portion of the yoke moves toward the left (as the tool tip moves vertically upwardly with a linear motion), elements 110,114 separate and a signal is provided to either stop the further downward motion or to enable a predetermined additional amount of downward motion so as to provide some additional increment of preloading.
Although in a presently preferred embodiment the rollers are mounted on the frame and the follower pins are fixed to the movable yoke, it will be readily appreciated that these parts may be reversed with the rollers journaled on the movable yoke and the follower pins fixed to the frame. However for a vibratory device such as the illustrated transducer support it is preferred to place the movable parts, such as the rollers, on the fixed frame.
There has been described an unique mounting for providing limited but substantially entirely linear relative displacement of parts in which frictionless rollers and rod followers are employed to afford a more stable and solid mounting of a movable vibratory part.
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A movable open center mounting for the tool of an ultrasonic wire bonding machine employs ball-bearing rollers (22, 24, 30, 32) to permit limited motion of the wire bonding tip (13a) substantially constrained to a vertical line with a minimum of tip skid. The mounting structure which is all positioned on one side of the tool tip includes a frame (10) of inverted U-shape having a pair of mutually spaced ball-bearing rollers (22, 24, 30, 32) on the end of each frame leg and a transducer support (12) positioned between the frame legs and having fixed roller contacting rods (90, 92, 96, 98) extending fore-and-aft between and partly under each of the respective rollers. A pair of springs (80, 82) urges the transducer support upwardly to press the fixed rods against the roller surfaces, allowing the transducer support to effectively rock about a center of motion (120) that is well below the bonder frame and transducer support, with the rocking motion being so constrained that the bonder tip moves substantially in a straight vertical line for small displacements.
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CROSS REFERENCES TO RELATED APPLICATIONS
This is an improvement of the patents that have been previously issued to the same applicants: Kent U.S. Pat. No. 7,144,052 and Kent U.S. Pat. No. 7,216,903.
BACKGROUND OF THE INVENTION
A. Field of the Invention
It is sometimes important, particularly for apartment dwellers, but also homeowners to prevent entry of an individual into the home. Most doors leading into a house or apartment have both the standard door lock as well as a deadbolt. This device would be inserted in the space between the deadbolt lock and the deadbolt plate from the inside of the door. A series of indentations or channels encircle the deadbolt handle. When the key is inserted into the deadbolt and turned this device would prevent the deadbolt from turning and unlocking the door.
B. Prior Art
Two prior patents have been issued to the inventors in this case. The first of the patents, U.S. Pat. No. 7,144,052 was a device that prevented the entry of a person from the outside of a building through the door.
The second of the patents, U.S. Pat. No. 7,216,093 was an improvement over the initial patent and incorporated a semi-circular ring along the bottom edge of the top half of the device. The purpose of the ring was to insure that the top portion of the device remained over the deadbolt so that the device remained in place.
With this improvement a plurality of teeth has been placed on the ends of the raised surfaces in order to the dead bolt of the door to better grip the raised surface. Another change has been a slight widening of the circular ring in order increase the area of contact of the ring.
BRIEF SUMMARY OF THE INVENTION
This is a device, which will prevent an unnecessary or unwanted intruder from entering a home, business or apartment when it is occupied. Most doors use a deadbolt locking system and this device prevents the deadbolt from turning when the key is being used to attempt to unlock the deadbolt.
This device is particularly helpful in situations such as apartment complexes when various individuals, i.e. maintenance personnel, apartment managers etc. must access the apartment for needed repairs. This could also be used by women or the elderly as an added security measure in their homes or apartments.
Most standard apartments do not have a lock on the door knob and are only equipped with a deadbolt to secure the door. The door allows ingress and egress to the home, business or apartment while the deadbolt is the only means of providing securement of the door and a deadbolt provides more security for the door to the door jamb. The deadbolt is comprised of the lock itself, an entry point for the key, plates for the interior and exterior of the door and a deadbolt handle, which is located in the interior of the building. The deadbolt handle moves when the door is locked and unlocked. The deadbolt handle allows the homeowner to securely lock the door after entry into the apartment or home.
This device will be inserted between the inside deadbolt plate surface and the surface of the deadbolt handle, which is closest to the door. A series of indentations or channels in the device, which are angled would surround the deadbolt when the device is installed.
The device is comprised of a top portion and a bottom portion that are connected together by a pair of parallel connecting members. The device is designed to slip over the door handle when not in use.
A plurality of raised surfaces is positioned along the top portion of the device to form a series of channels or grooves into which the deadbolt handle will be inserted. The raised surfaces are of predetermined dimensions to allow the deadbolt handle to remain in the channel or groove during normal operation. A series of protrusions or teeth are positioned on the ends of the raised surfaces in order to provide a better grip of the device when it is installed.
A retaining ring on the top surface of the perimeter of the raised surfaces is provided for additional security and teeth are added to the end of the raised surfaces so that additional surface are grips the deadbolt as a further means to prevent the device from falling off the deadbolt.
The top portion is connected to the bottom portion of the device with a pair of parallel connecting members. A reinforcing member connects the two connecting members near the bottom of the top portion for additional rigidity and support.
In operation, as someone begins to turn the deadbolt from the exterior with a key the indentation or channel would prevent the deadbolt from turning the necessary number of degrees to allow the door to be unlocked. The device would use the door handle to further insure that the device would not slip off the deadbolt or door handle and prevents the deadbolt from turning.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a front view of the device with the door handle, deadbolt handle and deadbolt faceplate shown with the door not shown.
FIG. 2 is a front view of the device without the deadbolt faceplate or door.
FIG. 3 is a side view of the device.
FIG. 4 is a view of the device installed on a door.
FIG. 5 is an isometric view of the device.
FIG. 6 is a fragmented front view of the device.
FIG. 6A is an exploded fragmented view of the end of the raised surface.
DETAILED DESCRIPTION OF THE EMBODIMENTS
This device is comprised of a top section 8 that surrounds the deadbolt handle 15 of a standard deadbolt and a bottom section 9 that surrounds a door handle 10 such as depicted in FIG. 4 . The top portion 8 and bottom portion 9 are essentially circular and are connected to each other by two parallel connecting members 12 , which join the two circular portions of this device such as depicted in FIG. 1 . The space between the two connecting members is hollow to allow the device to slip over the door handle 10 and dead bolt handle 15 .
The top section 8 is flat and circular with a hole in the center of the top section, which has an outer perimeter and an inner perimeter. Openings 25 are provided along the edges of the inner and outer perimeter through which the deadbolt handle will be inserted. The deadbolt handle 15 fits within a series of channels 25 , which are created by a series of raised surface 30 on the top portion of this device. The raised surfaces are of a predetermined height and extend from the inner to the outer perimeter of the top portion. The channels are wide enough to allow the deadbolt handle 15 to be inserted into the respective channel as needed. Although the device is flat with a series of channels or openings 25 , it allows the deadbolt handle 15 to fit within the channels or openings 25 when it is installed such as depicted in FIGS. 1 and 4 .
The indentations or channels 25 , which are provided, are large enough to allow the deadbolt handle 15 to be inserted within the respective indentation or channel and allow the deadbolt handle 15 to be surrounded by enough of the surface of the raised surfaces 30 to prevent the deadbolt handle 15 from turning the required amount of degrees to open the door when a key in inserted into the key mechanism on the outside.
On one end of the raised surface 30 are a series of teeth 50 that extend outward at the bottom of the raised surface 30 such as depicted in FIGS. 6 and 6A . When the device is installed the teeth 50 serve to add surface area for contact with the dead bolt so that the device will not slip off the dead bolt 15 .
The top portion would be installed such that it would fit between the faceplate 20 of the deadbolt and the back surface of the deadbolt handle 15 . This would allow easy installation of this device and simplicity of use. No modification to the door assembly or to the deadbolt or lock of the door would be required.
A horizontal support member 40 is installed on the bottom portion of the top portion and connects a pair of connecting members 12 . This horizontal member provides additional strength to the top portion. Additionally a retaining ring 45 is inserted around the inner perimeter on the top surface of the raised surfaces to provide additional strength to better insure that the device remains installed as anticipated.
Two connecting members 12 connect the top portion 8 of this device 5 to a bottom section 9 of this device 5 and form one integrated piece. These connecting members 12 are aligned essentially parallel to each other. The bottom portion 9 when the device 5 is installed surrounds the door handle 10 on the bottom. The advantage to completely surrounding the door handle 10 is to ensure that the device stays on the door and also gives an added measure of protection to the deadbolt being turned when a key is placed in the deadbolt key entry access. Additionally when it is not in use the device can simply hang from the door and always be available and easily found.
When the device is installed on the door, the top portion is placed over the deadbolt portion of the door and the bottom portion is placed over the door handle. The dead bolt handle 15 is inserted into one of the channels 25 of the top portion and a portion of the retaining ring would rest above a portion of the deadbolt handle. A portion of the deadbolt handle would extend above the level of the outer perimeter. The device 5 would rest between the deadbolt faceplate 20 and the deadbolt 15 .
This device 5 is designed to be lightweight and the choice of material may include plastic, rubber, or a variety of other materials.
While the embodiments of the invention have been disclosed, certain modifications may be made by those skilled in the art to modify the invention without departing from the spirit of the invention.
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This is a device, which will be inserted over the doorknob and behind a deadbolt. It will prevent a deadbolt from turning in the event that someone with a key tries to enter the home or business while the space is being occupied. This device is not meant to function as a security device but only to insure greater privacy for a homeowner or business owner.
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BACKGROUND OF THE NEW VARIETY
The present invention relates to a new, novel and distinct variety of nectarine tree, Prunus persica var. nucipersica , and which has been denominated varietally as ‘Burnectten’.
ORIGIN
The present variety of nectarine tree resulted from an on-going program of fruit and nut tree breeding. The purpose of this program is to improve the commercial quality of deciduous fruit and nut varieties and rootstocks by creating and releasing promising selections of prunus, malus and regia species. To this end we make both controlled and hybrid cross pollinations each year in order to produce seedling populations from which improved progenies are evaluated and selected.
The seedling ‘Burnectten’ was originated by us from a population of seedlings grown in our experimental orchards located near Fowler, Calif. The seedlings, grown on their own roots, were the result of a controlled cross of the yellow-fleshed, early ripening, open pollinated seedling of the peach tree ‘Rich Lady’ (U.S. Plant Pat. No. 7,290), which was used as the pollen parent, and the low chilling time nectarine tree, ‘SunCoast’, (unpatented) and which was used as the seed parent. One seedling, which is the present variety, exhibited especially desirable characteristics, and was subsequently designated as E45.049. This promising variety was marked for subsequent observation. After the 1999 growing season, the new variety was selected for advanced evaluation and repropagation.
ASEXUAL REPRODUCTION
Asexual reproduction of the new and distinct variety of nectarine tree was accomplished by budding the new variety to ‘Nemaguard’ Rootstock (non-patented). This was performed by us in our experimental orchard which is located near Fowler, Calif. Subsequent evaluations have shown those asexual reproductions run true to the original tree. All characteristics of the original tree, and its fruit, were established and appear to be transmitted through succeeding asexual propagations.
SUMMARY OF THE VARIETY
‘Burnectten’ is a new and distinct variety of nectarine tree, which is of moderately-large size, and which has vigorous growth. The new variety is also a regular and productive bearer of relatively large, firm, yellow fleshed, clingstone fruit which has good flavor and eating quality. This new and novel tree has a relatively low chilling requirement of approximately 350 hours. Still further, this tree also produces relatively uniformly sized fruit throughout the tree with a high degree of red skin coloration, and firm flesh. The fruit of this new tree also appears to have good handling and shipping qualities. Moreover, the ‘Burnectten’ nectarine tree bears fruit that is ripe for commercial harvesting and shipment on approximately May 5 to May 11. In relative comparison with the ‘Sun Coast’ nectarine tree which is the seed parent, the new variety ripens about 20 or more days earlier at the same geographical location.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing, which is provided, is a color photograph of the present variety. It depicts two whole mature fruit and one fruit dissected in substantially the equatorial plane to expose the flesh and the pit. Additionally the photograph displays a characteristic twig bearing typical leaves. Also a pit is displayed with the flesh removed. The external coloration of the fruit as shown is sufficiently matured for harvesting and shipment. The colors are as nearly true as is reasonably possible in a color representation of this type. Due to chemical development, processing and printing, the color of the leaves and fruit depicted in these photographs may or may not be accurate when compared to the actual specimen. For this reason, future color references should be made to the color plates (Royal Horticultural Society) and descriptions provided hereinafter.
DETAILED DESCRIPTION
Referring more specifically to the pomological details of this new and distinct variety of nectarine tree, the following has been observed during the fourth fruiting season under the ecological conditions prevailing at orchards located near the town of Fowler, county of Fresno, state of California. All major color code designations are by reference to The R.H.S. Color Chart (Fourth Edition) provided by The Royal Horticultural Society of Great Britain.
Tree:
Size.— Generally. — Considered medium large when compared to other common commercial nectarine cultivars ripening in the early season of maturity. The tree of the present variety was pruned to a height of approximately 272.0 cm to 290.0 cm at maturity.
Vigor.— Moderately vigorous. The present variety grew from about 118.0 cm to 167.0 cm in height during the first growing season. The variety was pruned to a height of approximately 104.7 cm in the first dormant season and primary scaffolds were then selected for desired tree structure.
Productivity.— Productive. Fruit set varies from at least about three times the desired crop load. Fruit set is spaced by thinning to develop the remaining fruit into the desired market size. The variety typically sets heavy crops. The number of fruit set varies with climatic conditions and prevailing cultural practices during the bloom period and is therefore not distinctive of the variety.
Bearer.— Regular. Fruit set has been heavy and thinning was necessary during the past 4 years.
Form.— Upright, and pruned to a vase shape.
Density.— Medium dense. It has been discovered that pruning the branches from the center of the tree to obtain a resulting vase shape allows for air movement and appropriate amounts of sunlight to enhance fruit color and renewal of fruiting wood throughout the tree.
Hardiness.— The present tree was grown and evaluated in USDA Hardiness Zone 9. Winter chilling requirements are approximately 300 hours below 7.0 degrees C. The variety appears to be hardy under typical central San Joaquin Valley climatic conditions.
Trunk:
Diameter.— Approximately 12.7 cm in diameter when measured at a distance of approximately 15.24 cm above the soil level, at the end of the fourth growing season.
Bark texture.— Considered moderately rough, with numerous folds of papery scarfskin being present.
Lenticels.— Numerous flat, oval lenticels are present. Lenticels are somewhat less prominent than is typically observed in other commercial nectarine varieties. The lenticels range in size from approximately 3.0 to about 4.0 millimeters in width, and from about 1.0 to about 2.0 millimeters in height.
Lenticel color.— Considered an orange brown, (RHS Greyed Orange Group N167 C).
Bark coloration.— Variable, but it is generally considered to be grey-brown, (RHS Grey Brown Group N199 B).
Branches:
Size.— Considered medium for the variety.
Diameter.— Average as compared to other varieties. The branches have a diameter of about 5.9 centimeters when measured during the fourth year after grafting.
Surface texture.— Average, and appearing furrowed on wood which is several years old.
Crotch angles.— Primary branches are considered variable and between about 44 to 52 degrees from the horizontal axis. This characteristic is not considered distinctive of the variety, however.
Current season shoots.— Surface texture — Substantially glabrous.
Internode length.— Approximately 1.9 to about 2.2 cm.
Color of mature branches.— Medium brown, (RHS Grey Brown Group N199 C).
Current seasons shoots.— Color — Light green, (RHS Yellow Green Group 144 B). The color of new shoot tips is considered a bright and shiny green (RHS Yellow Green Group 144 A).
Leaves:
Size.— Considered medium, to medium-small for the species. Leaf measurements have been taken from vigorous, upright, current-season growth at approximately mid-shoot.
Leaf length.— Approximately 132.0 to about 161.0 millimeters.
Leaf width.— Approximately 29.0 to about 37.0 millimeters.
Leaf base shape.— Slightly oblique relative to the leaf longitudinal axis.
Leaf form.— Lancelolate.
Leaf tip form.— Acuminate.
Leaf color.— Dark green, (approximately RHS Green Group 136 B).
Leaf texture.— Glabrous.
Lower surface.— Medium green, (RHS Green Group 139 B).
Leaf venation.— Pinnately veined.
Mid - vein.— Color. — Light yellow green, (RHS Green Group 141 D).
Leaf margins.— Slightly undulating.
Form.— Considered crenate, occasionally doubly crenate.
Uniformity.— Considered generally uniform.
Leaf petioles.— Size — Considered medium-short. Length — About 7.0 to about 10.0 mm. Diameter — About 1.5 to about 2.0 mm. Color — Pale green, (RHS Yellow Green Group 144 C).
Leaf glands.— Size — Considered small for the species; about 1.0 mm in height, and about 1.0 mm in width. Number — Generally one per side, occasionally two per side. Type — Reniform, and considered reasonably unappressed relative to the petiole margin. Color — Orange brown, (RHS Greyed Orange Group163 A).
Leaf stipules.— Size — Medium small for the variety. Number — Typically 2 per leaf bud, and up to 6 per shoot tip. Form — Lanceolate in form and having a serrated margin. Color — Green, (RHS Green Group 141 B) when young, but graduating to a brown color, (RHS Greyed Orange group N172 A) with advancing senescence. The stipules are considered to be early deciduous.
Flowers:
Flower buds.— Generally — The floral buds, depending upon the stage of development are approximately 8.0 millimeters wide; and about 12.0 millimeters long; conic in form; and slightly appressed relative to the bearing shoot.
Flower buds.— Color — The bud scales are reddish-brown, (approximately RHS Greyed Purple Group 183 A). The buds are considered hardy under typical central San Joaquin Valley climatic conditions.
Hardiness.— No winter injury has been noted during the last several years of evaluation in the central San Joaquin Valley. The current variety has not been intentionally subjected to drought or heat stress and therefore this information is not available.
Date of first bloom.— Feb. 18, 2002.
Blooming time.— Considered early season in relative comparison to most commercial nectarine cultivars grown in the central San Joaquin Valley. Date of full bloom was observed on Feb. 21, 2002. The date of bloom varies slightly with climatic conditions and prevailing cultural practices.
Duration of bloom.— Approximately 8 days. This characteristic varies slightly with climatic conditions.
Flower type.— The variety is considered to have a showy type flower.
Flower size.— Flower diameter at full bloom is approximately 41.0 to about 45.0 millimeters.
Bloom quantity.— Considered very abundant.
Flower bud frequency.— Normally 2 or more appear per node.
Petal size.— Generally — Considered medium-large for the species. Length — Approximately 18.0 to about 21.0 millimeters. Width — Approximately 17.0 to about 20.0 millimeters.
Petal form.— Broadly ovate.
Petal count.— Nearly always 5.
Petal texture.— Glabrous.
Petal color.— Light pink when young, (RHS Red Purple Group 73 B) and darkening with advancing senescence and exposure to sunlight to a medium to dark pink, (RHS Red Purple Group N66 C).
Fragrance.— Slight.
Petal claw.— Form — The claw is considered truncate, and has a medium size when compared to other varieties. Length — Approximately 7.0 to about 9.0 millimeters. Width — Aproximately 6.0 to about 8.0 millimeters.
Petal margins.— Generally considered variable, from nearly smooth, to moderately undulate and ruffled, especially apically.
Petal apex.— Generally — The petal apices generally appear entire at the tip.
Flower pedicel.— Length — Considered medium-long, and having an average length of approximately 3.0 to about 4.0 millimeters. Diameter — Considered average, approximately 2.0 millimeters. Color — A medium brown, (RHS Grey Orange Group 177 C).
Floral nectaries.— Color — A Dull orange red, (RHS Red Group 43 B).
Calyx.— Surface Texture — Generally glabrous. Color — A dull red, (approximately RHS Greyed Purple Group 183 B).
Sepals.— Surface Texture — The surface has a short, fine pubescent texture. Size — Average, and ovate in form. Color — A dull red, (approximately RHS Greyed Red Group 183 D).
Anthers.— Generally — Average to above average in length. Color — Red to reddish-orange dorsally, (approximately RHS Greyed Red Group 180 A).
Pollen production.— Pollen is abundant, and has a yellow color, (approximately RHS Yellow Orange Group 17 A).
Filaments.— Size — Variable in length, approximately 13.0 to about 17.0 millimeters in length. Color — Considered a pinkish-white, (RHS Red Purple Group 62 D).
Pistil.— Number — Usually 1, occasionally 2, rarely 3. Generally — Average in size. Length — Approximately 19.0 to about 22.0 millimeters including the ovary. Color — Considered a very pale green, (approximately RHS Yellow Green Group 151 D). Surface Texture — The variety has a long glabrous pistil.
Fruit:
Maturity when described.— Firm ripe condition (shipping ripe). Date of first picking — May 5, 2002. Date of last picking — May 12, 2002. The date of harvest varies slightly with climatic conditions.
Size.— Generally — Considered medium large for early season fruit, and uniform.
Average cheek diameter.— Approximately 69.0 to about 75.0 millimeters.
Average axial diameter.— Approximately 67.0 to about 72.0 millimeters.
Typical weight.— Approximately 248.0 grams. This is highly dependent upon cultural practices and therefore is not distinctive of the variety.
Fruit form.— Generally — Moderately oblate. The fruit is generally uniform in symmetry.
Fruit suture.— Shallow, and extending from the base to apex. No apparent callousing or stitching exists along the suture line.
Suture.— Color — The background color appears to be a yellow to golden yellow (approximately RHS Yellow Orange Group 20 A), and occasionally some red coloration is evident (approximately RHS Red Group 46 A).
Ventral surface.— Form — Slightly indented.
Apex.— Rounded. Usually indented.
Base.— Retuse.
Stem cavity.— Rounded to slightly rounded in the suture plane. Average depth of the stem cavity is about 1.20 cm. Average width is about 2.43 cm.
Fruit skin.— Thickness — Considered medium in thickness, and tenacious to the flesh. Texture — Glabrous. Taste — Non-astringent. Tendency to crack — None observed.
Color.— Blush Color — This red blush color is variable from a reddish orange, (approximately RHS Orange Red Group N34 B) to a dark red, (approximately RHS Red Group 46 B). Blush color ranges from about 75% to about 95% of the fruit surface depending upon sunlight exposure and the prevailing growing conditions. Ground Color — Yellow orange, (approximately RHS Yellow Orange Group 21 C).
Fruit stem.— Medium in length, approximately 7.0 to about 8.5 millimeters. Diameter — Approximately 2.0 to about 3.0 millimeters. Color — Pale yellow-green, (approximately RHS Yellow Green Group 144 D).
Flesh.— Ripens — Evenly. Texture — Firm, and dense. Considered non-melting. Fibers — Few, small, and tender. Aroma — Very slight. Eating Quality — Very good. Flavor — Considered sweet and mildly acidic. The flavor is considered both pleasant and balanced. Juice — Moderate. Brix — About 13.5 degrees. This characteristic varies slightly with the number of fruit per tree; prevailing cultural practices; and the surrounding climatic conditions. Flesh Color — Pale yellow, (approximately RHS Yellow Group 11 B).
Stone:
Type.— Clingstone.
Size.— Considered medium large for the variety.
Length.— Average, about 26.0 to about 28.0 millimeters.
Width.— Average, about 23.0 to about 25.0 millimeters.
Diameter.— Average, about 15.0 to about 19.0 millimeters.
Form.— Obovoid.
Base.— The stone is usually rounded, but may vary from rounded, to straight.
Apex.— Shape — The stone apex is raised, and has an acute, short tip.
Stone surface.— Surface Texture — Irregularly furrowed toward the apex, and pitted toward the base. The stone exhibits substantial pitting laterally. Substantial grooving over the apical shoulders is evident. Surface pitting is prominent generally, and more frequently, it is present basally. Ridges — The surface texture varies from sharp to rounded. Ventral Edge — Width — Considered medium, and having a dimension of approximately 2.0 to about 3.5 millimeters at the mid-suture. The wings are most prominent over the suture line. Dorsal Edge — Shape — Full, heavily grooved, and having jagged edges. The dorsal edge is moderately eroded over the apical shoulder.
Stone color.— The color of the dry stone is an orange-white, (approximately RHS Orange White 159 C).
Tendency to split.— Occasional splitting has been noted.
Kernel.— Form — Kernel is gelatinous and immature when the fruit is fully mature. Texture — Shriveled. Pellicle — Pubescence not developed at fruit senescence. Color — (RHS Greyed Orange Group 164 C).
Use.— The subject variety ‘Burnectten’ is considered to be a Nectarine tree of the early season of maturity, and which produces fruit which are considered firm, attractively colored, and which are useful for both local and long distance shipping.
Keeping quality.— Excellent. Fruit has stored well up to 21 days after harvest at about 1.0 degree Celsius.
Shipping quality.— Good. Fruit showed minimal bruising of the flesh or skin damage after being subjected to normal harvesting and packing procedures.
Resistance to insects and disease.— No particular susceptibilities were noted. The present variety has not been tested to expose or detect any susceptibilities or resistances to any known plant and/or fruit diseases.
Although the new variety of nectarine tree possesses the described characteristics when grown under the ecological conditions prevailing near Fowler, Calif., in the central part of the San Joaquin Valley of California, it should be understood that variations of the usual magnitude and characteristics incident to changes in growing conditions, fertilization, pruning, pest control and horticultural management are to be expected.
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A new and distinct variety of nectarine tree ( Prunus persica, var. nucipersica ) denominated varietally as ‘Burnectten’, and which produces attractively colored yellow-fleshed, clingstone nectarines which are mature for harvesting and shipment approximately May 5 to May 11 under the ecological conditions prevailing in the San Joaquin Valley of central California.
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BACKGROUND OF THE INVENTION
The invention relates to a bonnet type steamer which shortens the duration of preheating and makes the temperature of a resulting steam easily adjustable.
Prior art bonnet type steamer mainly for hair treatment in beauty salons, barbershops and homes is adapted such that feed water from a water reservoir is heated by the use of a heater within a steam generator from which steam is ejected into the interior of a bonnet via an ejection nozzle. The period of time for phase transition from liquid to vapor (i.e., preheating period) is considerably long (say, 10 minutes of preheating or standby as compared to 5 minutes of operation). Since the steam ejected into the bonnet tends to raise the interior temperature of the bonnet due to natural convection, fluctuations in the internal temperature of the bonnet produce difficulty in taking necessary measures and the steam adjacent the nozzle assumes a risky temperature of about 100° C. Another serious disadvantage of the prior art device is incapability of adjusting the vapor temperature because the steam is generated by the heating of water.
An object of the present invention is to provide a bonnet type steamer which is free of the above stated disadvantages in the prior art device.
A further object of the present invention is to provide a bonnet type steamer which shortens the period of preheating for phase transition from liquid to vapor and provides an easy and accurate adjustment of the temperature of a resulting steam.
A still further object of the present invention is to provide a bonnet type steamer which supplies not only steam but also hot air uniformly throughout the hairline area of the head of a customer.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further objects and advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is an elevational cross-sectional view of a bonnet type steamer embodying the present invention;
FIG. 2 is a traversal cross-sectional view of a portion of the steamer as shown in FIG. 1;
FIG. 3 is an elevational cross-sectional view of the portion of the steamer taken in a direction opposite FIG. 1;
FIG. 4 is a schematic diagram of an operational panel of FIG. 1;
FIG. 5 is a block diagram for control circuitry of the bonnet type steamer embodying the present invention;
FIG. 6 is an elevational cross-sectional view of the steamer when the bonnet type steamer is used as a steamer; and
FIG. 7 is an elevational cross-sectional view when the bonnet type steamer is used as a drier.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, there is illustrated one preferred form of a bonnet type steamer constructed in accordance with the present invention, the bonnet type steamer also having the function of a drier. A temperature sensor 3 such as a thermistor, or other conventional sensing element is provided within a bonnet 2 for monitoring the internal temperature of the bonnet 2. A bonnet ring 6 with a cylindrical supply section 5 is affixed to the periphery of the bonnet 2 by means of screws 7. The bonnet ring 6 has an ejection passageway 9 with ejection ports 8 with a spacing therebetween which decreases progressively as it becomes more remote from the supply section 5. A guide member (not shown) is secured adjacent each of the ejection ports for orienting a fluid to be ejected toward the center of the bonnet 2. A partition wall may be provided in the middle of the ejection passageway 9 in order to avoid a conflict in the fluid flow in the ejection passageway 9. A supply passageway 10 is formed directly in the supply section 5 which further carries a first shutter 11 for closing the supply passageway 10 when strongly blown air is fed to the supply section 5 (the steamer serves as a drier in the illustrated embodiment). The supply section 5 is provided with a tube-like heater box 12 which accommodates a heater 13 composed of a predetermined number (say, two) of infrared quartz tube heaters disposed normal to the direction of supply air traversing the heater box 12, with appropriate isolation from each other. There is further provided a second shutter 15 which is open when air is fed into the heater box 12. A blower unit 16 has a housing 17 divided into two segments, each having an air outlet port 18. A blower fan 20 driven by a blower motor 19 is secured within the casing 17 which also has an air inlet port 22. The heater box 12 is provided with a drain opening 23 formed therein and a pivot 24 received in an aperture 26 in a body casing 25 such that the heater box 12 is movable within a limited range and an air intake section is defined around the heater box 12. The blower unit 16 including the casing 17, the blower motor 19 and the fan 20, and the heater box 12 are accommodated within the body casing 25. The pivot 24 on the heater box 12 is movably secured in the body casing 25 such that the inclination of the bonnet 2 is easily adjustable. Over the body casing 25 there is disposed an atomizing fluid reservoir 30 containing a proper fluid (generally, pure water or utility water). On the bottom of the reservoir 30 there are disposed an opening pin 33 for opening a valve 32 to a fluid supply tank 31 from which the fluid 29 is led to the reservoir 30 and a guide pin 36 for guiding a float 35 sensing the level of the fluid 29 in the reservoir 30 and slidably secured by the guide pin 36. An ultrasonic vibrator 38 excited by an ultrasonic oscillator circuit 37 is provided on the bottom of the reservoir 30 for atomizing the fluid 29 in the reservoir 30. A mount 39 on which the supply tank 31 is detachably disposed is provided over the reservoir 30 and an atomizer chamber 40 is defined above the ultrasonic vibrator 38. An air passageway 42 having an inlet port 43 is formed in the body casing 25 for leading mist 41 generated from the atomizer chamber 30 to the exterior of the body casing by the action of an air blown. A fan motor 46 which drives a blower fan 45 for conveying air from the air passageway 42 toward the reservoir 30 is received within the body casing 25 together with a power transformer 44. The air flow created by the blower fan 45 feeds the mist 41 from the reservoir 30 to the heater box 12 through a supply hose 47 of which one end is connected to the atomizer chamber 40 and the other end is connected to the heater box 12. A drain hose 49 has two opposite ends one connected to the reservoir 30 and the other located in a drain tank 50 removably mounted on the body casing 25. A tap 51 is positioned in the drain hose 49 to adjust the amount of the mist to be discharged. A conduit 52 is formed in the drain tank 50 to collect the drain from the ejection ports 23 in the heater box 12. Within the body casing 25 there is disposed a circuit board 75 carrying a control circuit 55 controlling the operating conditions of the heater 13, the blower unit 16 and the ultrasonic atomizer (including the ultrasonic oscillator circuit 37 and the blower motor 46), a series of respective switches 56 to 71 governing the control circuit 55 and a display 73 for visually displaying the operative state of the control circuit 55. The body casing 25 is mounted movable on a slide prop 76 which in turn can be secured slidably anywhere on a second slide prop 77 by means of a fixing knob 78. The second prop 77 is fixed on a basement 80 with casters 79.
An electric cord 81 is connected to the steamer for power supply. There is provided on the rear of the body casing 25 a display panel 82 having a display window 87 to which a time display 73 of FIG. 4 including segmented digital display elements 83, light emitting elements 84, 85 and 86, for example, light emitting diodes each reading "steamer," "drier" and "short water;" a hole 88 through which a power switch 56 passes; holes 90 to 94 for a mode selector of the locked release structure allowing selection of one of a high stream volume switch 57, a low stream volume switch 58, a strong air drier switch 59, a weak air drier switch 60, a breeze drier switch 61; holes 95 to 99 for a temperature selector of the locked release structure allowing selection of one of a room temperature switch 62 useful for the drier or steamer mode (the heater 13 is kept from being supplied with power in order to attain room temperature, a 40° C. switch 63, a 45° C. switch 64, a 50° C. switch 65 and a 55° C. switch 67; holes 100 and 100a for a timer of the momentary structure (the number of actuations are accumulated) allowing one of a 5 minutes switch 67 and a 1 minute switch 68 for determining the period of the steamer or drier mode; a hole 101 for a cancel switch 69 for canceling settings in the timer; a hole 102 for a start switch 70 of the momentary structure; and a hole 103 for a stop switch 71 for discontinuing the mode of operation, all of which are in registry with the respective switches.
FIG. 5 is a schematic block diagram of control circuitry for the above stated bonnet type steamer embodying the present invention, which includes essentially a one-chip microprocessor 105 with a ROM (read only memory) operating as follows.
The microprocessor has the function of comparing an electrical indication of the internal temperature of the bonnet 2 from the temperature sensor 3 with temperature settings in the temperature switches 62 to 66 through a comparator 106 and controlling current conduction through the heater 13 (current is allowed) to conduct when the internal temperature of the bonnet 2 is in excess of the temperature settings and prohibited from conducting therethrough otherwise); the function of controlling a current flow through the ultrasonic atomizer circuit 37 in response to the output from a lever sensor attached to the float 35 (current is prevented from flowing when the level of the fluid in the reservoir 30 is below a given level and allowed when it is above the given level); the function of controlling an exciting current to a loud speaker 108 for releasing alarming sounds (the alarming sounds such as "peep" are liberated when the level of the fluid in the reservoir 30 is higher than the given one); the function of controlling current conduction through the light emitting elements 84 to 86 of the display 73 (the light emitting elements is enabled to blink when the fluid level in the reservoir 30 lowers and approaches the given level and is disabled when the former is higher than the latter); the function of controlling conduction of current to the heater 13, the blower motors 19 and 46, the ultrasonic atomizer circuit 37, a sound circuit 107 and a driver circuit 109 in response to the settings in the time switches 67 and 68 and the mode switches 57 to 61 to excite respective segments of the digital display elements 83 in the display window 73 for a visual indication of time settings and remaining times while blinking indications of the passage of time per second; the function of starting a desired mode of operation upon actuation of the start switch 70; the function of discontinuing a desired mode of operation upon actuation of the time stop switch 71; the function of releasing through the loud speaker 108 sounds representing that the temperature switches 62 to 66, the time switches 67 and 68, the mode switches 57 to 61, etc., have been properly actuated; the function of releasing alarm sounds "peep" from the loud speaker 108 via the sound circuit 107, which sounds indicate malfunction of the temperature sensor 3; the function of releasing alarm sounds "peep" when the temperature switches 62 to 66 or the mode switches 57 to 61 are unlocked during operation for any reason; and the function of releasing interrupted sounds "peep," "peep" from the loud speaker 108 via the sound circuit 107 upon the completion of operation. A power supply circuit 110 stabilizes a power supply voltage from a power plug 111 and supplies such stabilized voltage to the microprocessor 105. Specifically, the microprocessor 105 is supplied with pulses synchronous with the power frequency from the power supply circuit 110, the pulses providing clock pulses, a basis for timekeeping function, for the microprocessor 105. A frequency switch 112 is provided for accommodating for changes in power frequency between geographical zones.
The mode switches 57 to 61, the time switches 67 and 68, the start switch 70 and the stop switch 71 are matrix-wired and led to input terminals of the microprocessor 105. When one of the drier switches 59 to 61 out of the mode switches 57 to 61 is actuated, the microprocessor 105 automatically ignores the output from the level sensor 113 and disables the ultrasonic atomizer circuit 37. At the movement the fan motor 46 is energized for the blower fan 45 so that the air flow drawn by the blower fan 45 prevents the air drawn by the fan 20 from entering into the atomizer reservoir 30 via the supply hose 47 and assists the operation of the blower unit 16. On the other hand, when one of the steamer switches 57 and 58 out of the mode switches 57 to 61 is depressed, the microprocessor 105 renders the ultrasonic atomizer circuit 37 operative and discontinues operation of the blower motor 19 in the blower unit 16 and the output of the ultrasonic atomizer circuit 37 is set at a high level or a low level in response to the operative state of the steamer volume switches. If the reservoir 30 is replenished and the level of the fluid restores its normal level, then alarm sounds as to the level of the fluid 29 are cleared.
The bonnet type steamer apparatus embodying the present invention as discussed above will operate in the following manner.
When the apparatus is desired to operate as a steamer, the supply tank 31 is filled with a measured amount of the fluid to be atomized and the power plug 111 is inserted into a utility power source and the power switch 56 on the operational panel 82 is flipped on. Either the high steam volume switch 57 or the low steam volume switch 58 is selected. Under the circumstances the light emitting element 84 reading "steam" out of the display 73 is energized. Then, upon selection of the temperature switches 62 to 66 the temperature is selected at any one of room temperature, 40° C., 45° C. or 50° C. For example, when 28 minutes of the steamer operation are desirable, the 5 minutes switch 67 is actuated five times and the 1 minute switch 68 is actuated thrice. However, provided that 55° C. (available only during drier mode) is inadvertently selected, alarm sounds "peep" are delivered. The time settings in the time switches 67 and 68 are visually displayed in the display window 87 by the function of the digital display elements 83.
The bonnet 2 is positioned to encircle the hairline area of the customer's head and the start switch 70 on the operational panel 82 is actuated. The microprocessor 105 sets up the steamer mode. In other words, the heater 13, the fan motor 46 and the ultrasonic atomizer circuit 37 are turned on at a time. The digital display elements 83 in the display window 84 provides a visual indication of a remaining period of time minutely while providing a blinking indication of the passage of time per second. By the air drawn by the blower fan 45 the room temperature mist 41 is conveyed from the reservoir 30 to the heater box 12 via the supply hose 47 and thereafter heated up to steam by means of the heater 13 in the heater box 12. The resulting steam is fed into the interior of the bonnet 2 through the ejection ports 8 and the supply passageway 10. When the internal temperature of the bonnet 12 reaches a preset value, the microprocessor 105 stops conducting current to the heater 13 and keeps the internal atmosphere of the bonnet 2 at a constant temperature.
While in the steamer mode, the fan 20 in the blower unit 16 is disabled and the second shutter 15 is in the close position keeping the steam heated within the heater box 12 from entering into the blower unit 16. When this occurs, the first shutter 11 is open so that a portion of the heated steam in the heater box is sent to the interior of the bonnet 2 from the supply passageway 10 which is in face-to-face relationship with a nape region 114 of the hairline area 1 of the customer's head, easing the difficulty in effecting hair treatment at harder hair at the nape region than the other regions. Moving upward from the ejection ports 8 at the periphery of the bonnet 2, the remaining portion of the steam is distributed uniformly over the hairline region 1. The drain (water) from the interior of the heater box 12 is collected at the drain tank 50 via a passageway 115 as depicted by the solid line in FIG. 6.
After the completion of the steam mode, the microprocessor 105 cuts off the control signals. In this case the digital display elements 83 in the window 87 show zero at a moment and shortly after show the original time settings. This offers beautician's convenience in recording entries on customers' cards in or after hair treatment.
When the apparatus behaves as a drier, either the strong wind switch 59, the weak wind switch 60 or the breeze switch 61 is actuated so that the light emitting element 85 reading "drier" is energized to indicate that the apparatus operates in the drier mode. One of the above specified temperatures, room temperature, 40° C., 45° C., 50° C. and 55° C. is selected upon actuation of one of the temperature setting switches 62 to 66 and a desired period of time is set by means of the time switches 67 and 68, this setting being visually displayed on the digital display elements 83 in the window 87.
Thereafter, the hairline area 1 of the customer's head is inserted into the bonnet 2 and the start switch 70 on the operational panel 82 is depressed. The microprocessor 105 initiates the drier mode. Simultaneously, the heater 13 and the blower motor 19 and the fan motor 46 in the blower unit 16 are energized. The digital display elements 83 provide a visual display of the elapsed time minutely while blinking per second. The air drawn by the blower fan 19 in the blower unit 16 is guided to the heater box 12 and heated by the heater 13 in the heater box 12, forming a hot air which is to be fed into the bonnet 2 via the ejection ports 8 in the bonnet ring 6. When the internal temperature of the bonnet 2 reaches a predetermined temperature, the microprocessor 105 ceases supplying conduction current to the heater 13. The heater 13 is thereafter energized in such an interrupted manner as to keep the temperature of the bonnet 2 constant.
During the drier mode the air flow drawn by the blower fan 19 is greatly wilder than that by the blower fan 45 so that the supply passageway 10 is shut off by the first shutter 11 to prevent the hot air from centering on the nape region 114 of the customer's head, generating disagreeable heat and lowering the thermal efficiency of the drier. Since the hot air goes upward from the ejection ports 8 at the periphery of the bonnet 2 and moves out of the bonnet 2 after running through complicated routes along the hair at the hairline area 1 of the customer's head, the length of time where the hot air retains within the bonnet 2 and contacts the hair becomes longer, with an attendant increase in drying efficiency. To this end the same drying efficiency as does the conventional drier is available with a one-half of the amount of air. Due to a decreased amount of air and complicated air flows it is possible to dry the hair without disturbing the hair at the hairline area 1. Because the amount of air may be reduced or because there are the two fans 20 in the blower unit 16, it also becomes possible to eliminate operating noise harsh to the customer being serviced, other customers waiting in beauty salons, even to the beautician.
It should be noted that thermal efficiency is excellent because the air from the inlet port 22 of the blower unit 16 is confined at the periphery of the heater box 12 or adjacent a back lower portion of the bonnet 2 and preheated during the course of drawing the surrounding air thereinto. While the blower fan 45 is operating, the air drawn by the fan 19 is prohibited from entering the atomizer reservoir 30 via the supply hose 47.
The benefits obtained by the bonnet type steamer embodying present invention may be as follows: When in the steamer mode the ultrasonic atomizer and the electric heater start operating and attaining a desired or preset temperature immediately to avoid the need to preheat those devices. The use of the room temperature mist makes it possible to control accurately the temperature of the resulting steam without any overheated or risky condition. An improved steaming effect is assured because of the steam being uniformly distributed from the entire periphery of the bonnet. In addition, during the drier mode the hot air may be supplied from the entire periphery of the bonnet with attendant features: a decreased amount of air, no disturbance of the hair at the hairline area of the customer's head and reduction of noise.
Whereas the present invention has been described with respect to specific embodiments thereof, it will be understood that various changes and modifications will be suggested to one skilled in the art, and it is intended to encompass such changes and modifications as fall within the scope of the appended claims.
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A bonnet type steamer including an ultrasonic atomizer for generating a mist at room temperature and an electric heater for heating the mist for the generation of steam before the mist enters into the interior of a bonnet where the customer's head is inserted for hair treatment. Specifically, the steam is ejected from the entire periphery of the bonnet while running upward within the bonnet. Control circuitry made up of a microprocessor senses and regulates the temperature of the steam with the aid of a temperature sensor. The temperature of the steam and the duration of operation of the steamer are easily selectable and adjustable by the use of manual switches. A hot air generator is provided for generating hot air for drying purposes.
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BACKGROUND OF THE INVENTION
1) Field of the Invention
The field of this invention relates generally to resurfacing methods and more particularly to a new and improved method of recycling an asphalt surface such as a roadway or pavement.
2) Description of the Prior Art
Asphalt is widely used in the construction of highways and parking areas where large areas need to be covered with a relatively hard, flat, weather-resistant surface suitable for vehicular travel. With prolonged usage these asphalt surfaces develop cracks which permit the seepage of water therethrough to undermine the sand and rock subbase. Asphalt pavement includes a light oil that functions as a binder with the aggregate contained within the asphalt. The sun, as well as the amount of vehicular travel, causes this light oil to vaporize thereby causing the asphalt roadway to deteriorate. This deterioration of the asphalt surface necessitates reconditioning of that surface.
In the past it has been a common practice to recondition a worn asphalt surface by a hot application of a new mat of asphaltic material over the existing surface to form a new flat surface. This application of new material raises the general level of the asphalt surface by 1 inch to 11/2 inches. The problem with such an application of new material is that after a few years, and the surface has been reconditioned four or five times, the new surface is 5 inches to 9 inches higher than the old original surface. This raised surface level can be an especially serious problem, especially now where the roadway is at a higher level than the adjoining gutters or sidewalks. Each time a roadway is resurfaced by using overlay procedures reduces overhead room of underpasses. Where overlaying is done across bridges, each overlay applied to the bridge adds to the dead weight that the bridges must carry thereby diminishing the amount of vehicular weight that the bridge is able to carry with safety.
A more recent practice has been to recondition old asphalt surfaces by breaking up of the existing asphalt aggregate material, picking up the material for reconditioning, heating and then reapplying the heated reconditioned material as a new surface. The pavement is heated, scarified to a certain depth by a scarifying tool producing loose aggregate material. This loose aggregate material is then picked up, placed within a mixing vat where it is pulverized, combined with a light oil and then reapplied to the asphalt material.
This past method of recycling of the old asphalt has a disadvantage that it requires picking up of the old asphalt, moving it to a mixing location and then bringing it back and reapplying it to the roadway. It would substantially diminish the cost of resurfacing an asphalt roadway or pavement if this recycling procedure did not require the physical picking up of the loose aggregate material and transporting such to a mixer and then retransporting it back to be applied to the asphalt surface.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to resurface a deteriorated asphalt surface (roadway or pavement) by utilizing the existing material of the surface and accomplishing the resurfacing directly on the surface, eliminating the need for transporting of the material of the surface during the regeneration process.
Another objective of the present invention is to utilize an asphaltic pavement resurfacing process which can be accomplished at a substantially lower cost than previously known for resurfacing processes.
Another objective of the present invention is to provide a surface asphalt recycling process which maintains the established surface configuration such as the common slightly domed configuration for water drainage.
The method of resurfacing an asphalt surface of the present invention utilizes applying sufficient heat to a section of asphalt surface to raise the temperature of the surface to between 220° F. and 375° F. This section of the surface is then scarified to an depth of about 1 inch to 11/2 inches producing a layer of loose aggregate material. A small amount, generally within the range of 10% to 30% by weight of the loose aggregate material, of additional virgin asphalt is applied. To this section of the surface there is now applied a quantity of light oil which has been heated to about 240° F. The amount of light oil that is applied is to be within the range of 0.09 gallons per square yard of surface to 0.12 gallons per square yard. The loose aggregate material, oil and virgin asphalt are thoroughly and evenly mixed, screeded and then rolled achieving compaction and cementing.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 to 9 generally depict the sequence of operations of the method of the present invention that are required to resurface a section of asphalt surface with little or no consideration being given to the actual apparatus that would be employed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to FIG. 1 there is shown a deteriorated section of asphalt surface 10 which includes a plurality of cracks 12. A heater 14 is placed over the section of the pavement 10 with generally the size of the heater 14 being fourteen feet by eighteen feet. Propane gas is to be emitted and ignited within the heater 14 producing an exceedingly high heat environment. This heater 14 is slowly moved across the surface 10 and, after the heater has passed, the section of the surface directly behind the heater 14 will be within the range of 240° F. to 375° F. The now heated surface 10 has a scarifier 16 conducted thereover. The scarifier 16 includes a plurality of sharp rakes 18 each of which is independently mounted on the scarifier 16. This independent mounting will permit the rakes 18 to pass over any kind of solid object such as a manhole. The rakes 18 will dig into the surface 10 to the depth of about 1 to 11/2 inches with this depth being selectable. The result is the upper surface of the surface 10 is formed into a layer of loose aggregate 20.
Referring now to FIG. 3, a hopper 22 is passed over the surface 10 with a quantity of virgin asphalt 24 being contained within the hopper 22. This virgin asphalt 24 is dispensed from the hopper 22 by means of an auger producing a windrow 26 of new virgin asphalt on the surface 10. The virgin asphalt 24 will be heated generally in the range of 220° F. to 240° F.
Referring particularly to FIG. 4 the section of surface 10 which has the loose aggregate 20 and the windrow 26 has conducted thereover a pipe 28 from which extends a plurality of spray nozzles 30. The pipe 28 connects to reservoir 32. Contained within the reservoir 32 is a quantity of an oil 31. This oil 31 is petroleum based and it is what is frequently termed a "light oil". The specification for this light oil 31 is referred to as a RA-5, light grade. This oil 31 is made up of alphaltenes and malthenes. In such an oil the greater the alphaltenes the more viscous the oil and logically the less the alphaltenes, the less viscous or lighter the oil. The oil 31 that is used in conjunction with this invention contains about 1% to 4% of alphaltenes with malthenes being in the range of 96% to 99%. During service of a roadway or pavement, the alphaltenes increase in proportion because the malthenes eventually vaporize. This results in the asphalt pavement becoming progressively harder and more brittle producing the cracks which are referred to as deterioration of the surface. Putting back into the loose aggregate material 20 this light oil causes the asphalt loose aggregate material 20 to be as good as new.
Referring particularly to FIG. 5, a roller 34 is conducted over the surface section 10 of the surface. This roller 34 includes a mass of cutting blades 35. These cutting blades 35 more finely pulverize the loose aggregate material 20 and windrow 26 that contains oil 31 and distribute the virgin material of windrow 26 across the width of the pavement section 10.
Referring particularly to FIG. 6, conducted across the section 10 are a pair of curved blades 36 which pick up the loose aggregate material 20/31/26, mixing such and dispensing of the loose aggregate material 20/31/26 onto a V-shaped section of another pair of curved blades 38. The loose aggregate material 20/31/26 is continuing to be mixed when conducting past the blades 38 and then is deposited in conjunction with a split auger 40. It is the function of the auger 40 to evenly distribute the loose aggregate material 20 that has now been combined with the virgin asphalt material 26 and the oil 31.
Referring now to FIG. 7 a screed 42 is passed over the section 10 producing a smooth level surface of the loose aggregate material 20/31/26. Conducted across this smooth level surface of the section 10 is a compacting roller 44 which is shown in FIG. 8. Actual compaction will occur by generally at least two different types of compaction roller vehicles that are driven across the section 10. After compaction by the roller 44, there is produced the resurfaced asphalt surface within the section 10 shown in FIG. 9.
The equipment used for the heater 14 is designed to comply with the requirements of the local Bureau of Air Pollution Control where the heater 14 is being used. The heater 14 shall have a minimum rating of 15 million BTUs output per hour. The heater 14, although designed to use propane, is also capable of using butane. The combustion chambers shall be insulated and totally enclosed to provide sufficient heat to the pavement 10 in order to sufficiently raise the temperature of the section 10 of the surface. Scarifier 16 may also include a mechanically driven milling drum utilizing carbide cutting bits similar to the roller 34. The width of the scarified pavement shall not be greater than the width of the heater 14. The milling drums that are used, such as roller 34, are normally hydraulically controlled to vary the depth of cut within section 10.
The section 10 shall have a laboratory analysis performed to determine the amount of oil 31 that is to be applied. If the section 10 has only slightly deteriorated, then generally an amount of about 0.09 gallons per square yard of oil will be applied. If the pavement 10 is exceedingly brittle and well deteriorated, approximately 0.12 gallons per square yard of oil will be applied. This is assuming the preselected depth for scarifying of the surface is about one inch. If the preselected depth is increased to about 11/2 inches, an appropriate proportional increase in the amount of oil is to be applied.
Generally for the roller 44 there will be utilized two different roller devices with one being a double drummed steel roller and the other being a pneumatic tire roller. Each of these rollers should be at least twelve tons in weight. The compaction temperature with the rollers 44 shall be at least 220° F.
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The method of resurfacing an asphalt surface which comprisies heating of the surface, scarifying the surface creating a layer of loose aggregate material, adding an amount of additional virgin asphalt in the amount of 10% to 30% by weight of the loose aggregate material, evenly applying a quantity of heated light oil to the loose aggregate material, thoroughly mixing of the loose aggregate material and the oil, screeding the loose aggregate material forming a level surface and then rolling the level surface achieving compaction plus cementing of the loose aggregate material.
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[0001] This application is a divisional application from, and claims the benefit of, U.S. patent application Ser. No. 12/508,462 filed on Jul. 23, 2009 to Wei, also entitled “Method and System For Simulations of Dynamic Motion and Position,” which claims the priority of U.S. Provisional Patent Application Ser. No. 61/135,719 filed on Jul. 23, 2008, which are incorporated herein in their entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to methods and systems for simulations of dynamic motion and position and, more specifically, to methods and simulations for such simulations used in video games.
[0004] 2. Description of the Related Art
[0005] Sports simulation games are a popular component of the video game market. Although much progress has been made, certain games still lack the game play flow of the sports which they purport to simulate. For example, video games that simulate the game of basketball have become very popular. Sports and simulation games, such as flight simulators, have become a major industry unto themselves.
[0006] Sports simulations present particular challenges in terms of game design and execution because garners are familiar with the real-world games. In contrast with other types of games (e.g., fantasy games), where the environment and interactions between game entities are completely at the discretion of the game creators, aspects of sport simulations are dictated by the real-world sport itself. As a result, discrepancies between the virtual and real-world versions of a given sport are readily apparent to garners. This is especially true with sports, such as basketball, that are easily accessible either on television or through physical participation.
[0007] Many would consider the fundamental gamer objective in a video game is to have fun. In sport simulation games part of the fun is realistic competition. In competition of any type, the objective is always the same: to win. Garners will construct strategies within the simulated world in order to achieve this one objective. The greater the error between the simulation and the corresponding real world sport, the greater the discrepancies between these gamer constructed strategies and those of the sport itself. For games which are billed as sport simulations, and for the garners who purchase and play these games, an accurate simulation of dynamic motion and position is critical.
[0008] Certain sports lend themselves to simulation more so than others. For instance American football, with its discrete downs, resets at the line of scrimmage, and highly scripted plays, allows for accurate simulation. On the other hand, in sports such as basketball and soccer, a single instance of continuous play lasts much longer on average. Accordingly, simulation errors have greater time to accumulate and to become more apparent to the game player.
[0009] While scripted plays in American football are designed to create an opening which is instantly exploited, the scripted portion of a basketball play is used to create an opening which is often just the beginning of an offensive sequence. An initial opening is usually not large enough to instantly exploit, but does cause a sequence of rotations and player movements that can be used to create ever larger openings, which may be ultimately exploited. The result of this game play pattern is that continuous play sequences are not as mechanical, relying much more on flow and individual decisions.
[0010] For example one challenge in basketball simulation is the discrete nature of actions and movements. On many systems, a particular action/movement is executed with a directional input from thumb sticks and a combination of buttons. This input set is then mapped to a corresponding animation, which in turn takes a certain amount of time to complete before a subsequent input set may be read. While the number of button combinations allows for a large number of actions/movements, systems do not take full advantage of the available analog inputs. As a consequence, an action/movement is either executed in full or not executed at all. Along with controller input, player collisions can induce player movement. Delegating player movement to the animation system takes this responsibility away from the physics engine. Collisions are a large part of the game, and removing this responsibility from the physics engine introduces simulation error with significant ramifications in game play.
[0011] In addition to the discrete paradigm, the lack of a dynamic player balance measurement affects game play. Performing a number of actions, such as running around multiple screens, making multiple direction changes, getting bumped off course, or executing repeated crossovers and pivots, does not prevent a player from taking a perfectly stable squared up jump shot at the end of such a wild movement sequence. This aspect results in a bias favoring individual one-on-one play, de-emphasizing the importance of team play.
[0012] Finally and most importantly, the inadequate use of artificial intelligence has drastic effects on game play. For example, in real-world basketball a defender is constantly assessing the current threat posed by each offensive player and the ability of his teammates to affect those offensive players. This assessment is used to determine the defender's own optimal position to minimize offensive threats. In the same manner, an offensive player makes the same assessment and attempts to maximize his/her own offensive threat. Using this assessment, players dynamically adjust to the current situation based on their own abilities, the ability of their teammates and opponents, and the relative position of each player on the court. This player behavior is poorly modeled in modern games, resulting in a game flow that does not reflect actual basketball strategies and tactics.
[0013] Game play adjustments have been made in recent years in an attempt to address some of these issues. Computer controlled defensive players are allowed to make hyper-speed movements, making it exceedingly difficult for an offensive player to get by the on-ball defender and allowing off-ball defenders to easily recover to proper defensive positions. While this adjustment does indeed counter exploits of the current simulation model, it in no way results in a more realistic game flow. In fact, an adjustment that allows physics to be violated introduces additional simulation error as in-game openings and advantages fail to correlate with those observed in real-world basketball. This problem is observed in many different sports simulation games.
SUMMARY OF THE INVENTION
[0014] A method for simulating dynamic events in a video game according to one embodiment of the present invention comprises the following actions. Game entity instructions related to at least one game entity are received, the game entity instructions comprising instructions from artificial intelligence inputs. Game constants associated with said at least one game entity are called. A game entity balance measurement is calculated using a balance simulation model, wherein the instructions and the game constants are combined to generate a balance simulation model output. Game entity events are generated based on balance simulation model output.
[0015] A system for calculating game events according to one embodiment of the present invention comprises the following elements. An input module is configured to receive game entity information. A storage module is configured to store constants related to at least one game entity. A physics module is connected to apply game physics rules to information received in the input module and the constants. A balance simulation module is connected to control stability and movement of game entities using values from the physics module. An interaction handler module which combines input module outputs and balance simulation module outputs with game entity interaction rules generates game entity events. An artificial intelligence module determines actions of system controlled entities by combining game entity event information from the modules with game entity threat information. A game entity event output module for outputs game event simulation values.
[0016] A method for simulating game entity balance according to one embodiment of the present invention comprises the following actions. Constants related to at least one game entity are called. Instructions related to at least one game entity are received. The instructions and the constants are applied to a movement model related to the at least one game entity. The instructions and the constants are applied to a stability meter related to the at least one game entity. Outputs from the movement model and the stability meter are combined to generate a game entity balance value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a system-level architecture diagram according to one embodiment of the present invention.
[0018] FIG. 2 is a diagram of a date/execution path of components of a system according to one embodiment of the present invention.
[0019] FIG. 3 is a graph of speed versus time for a sprinting human being.
[0020] FIG. 4 is a perspective view of a damped mass-spring model.
[0021] FIG. 5 is a graph of pixel coordinate versus time sample.
[0022] FIG. 6 is a diagram of an exemplary court configuration according to an embodiment of the present invention.
[0023] FIG. 7 is a diagram modeling a defense mitt according to an embodiment of the present invention.
[0024] FIG. 8 is a graphic representation of a basketball court with a data set overlay modeling a shoot lookup surface according to one embodiment of the present invention.
[0025] FIG. 9 is a diagram of an exemplary court configuration according to an embodiment of the present invention.
[0026] FIG. 10 is a diagram of an exemplary court configuration relative to a basketball goal according to an embodiment of the present invention.
[0027] FIG. 11 is a diagram of a damped mass-spring model according to embodiments of the present invention.
[0028] FIG. 12 is a diagram of a damped mass-spring model used to model game entities relative to a basketball goal according to embodiments of the present invention.
[0029] FIG. 13 is a diagram of an exemplary court configuration according to an embodiment of the present invention.
[0030] FIG. 14 is a diagram of a game entity including associated gradient search data.
[0031] FIG. 15 is a diagram representing a scenario featuring sixteen game entities according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Embodiments of the invention described herein provide a new simulation and analysis model for dynamic games of movement and position. Although embodiments of the present invention are discussed with specific reference to a basketball game, it is understood that the methods and systems described herein may be applied to any sports game, simulation program, or computer software platform that models the motion and position of objects. Overall system architecture and specific algorithms are presented as embodiments of the present invention in the context of a basketball simulation; however, as stated above, the methods and systems are in no way limited to any particular application.
[0033] Although the ordinal terms first, second, etc. may be used herein to describe various elements, components, and/or modules, these elements, components, and/or modules should not be limited by these terms. These terms are only used to distinguish one element, component, and/or module from another. Thus, a first element, component, and/or module discussed below could be termed a second element, component, and/or module without departing from the teachings of the present invention.
[0034] FIG. 1 shows a system-level architecture diagram according to one embodiment of the present invention. The X-Input, MOGRE Newt, and MOGRE blocks represent foundation libraries on which the simulation is built. The Controller Input Handle and the Interaction Handler are event handlers. The Player Artificial Intelligence (AI) block represents an artificial intelligence engine. The Player 1 . . . 10 and Ball blocks represent In-Game Entities. The Top Level block represents a Master Scheduler/Book Keeper. Key elements of the simulation model are discussed below. It is understood that these elements may function as software implementations within a system or as discrete system modules themselves.
[0035] A physical movement model provides a framework for player movement, timing, and animation as well as providing a measure of player balance. This is implemented at the Player block.
[0036] The interaction handler enforces game-play rules, determining the outcome of all interactions between in-game entities. Some the interactions handled in a basketball game are dribbling, deflecting, stripping, shooting, passing, catching, etc. Other interactions may also be processed in the interaction handler.
[0037] A threat assessor determines the offensive threat posed by a given offensive player due to position relative to the goal as well as capability and position relative to other players. This system provides the analysis used by the Player Artificial Intelligence system. It comprises four assessments: a physical movement threat score which represents the static physical capabilities of a given player; a skills threat score which represents the dynamic skills capabilities of a given player; a dive threat score which represents the ability of a player to get to the goal based on current configuration of participating players; and a ball distance threat score which represents a player's threat due to proximity to the ball (e.g., the closer a player is to the ball the higher that player's ball distance threat score will be).
[0038] The Player Artificial Intelligence system determines the positions and actions of computer controlled players. It comprises three elements: defensive positioning which is a sub-system that determines optimal position of a defensive player based on threat assessments and player tendencies; offensive positioning which is a sub-system that determines optimal position of an offensive player based on threat assessments and player tendencies; and an action analyzer, which is a sub-system that determines when computer players perform certain actions.
[0039] FIG. 2 illustrates the data/execution path for the components discussed above according to one embodiment of the present invention. Inputs are received and outputs are sent to supporting components through an interface manager. From FIG. 2 it is possible to ascertain the data dependencies of the proposed system. Errors introduced by the Movement Model will propagate to both the Interaction Handler and Threat Assessor and to other components, following the flow of the data/execution path.
[0040] Of particular note is the feedback nature of player inputs from the Player AI system, with outputs from Defensive Positioning, Offensive Positioning, and Action Analyzer which provide inputs to the Movement Model. Thus, the simulation model is able to constantly react in real-time to changing game state. This feedback system does not, however, present the usual risks of error accumulation and system instability as the current game state is continually refreshed from the rest of the system.
[0041] As stated above, the simulation may be constructed upon a foundation of existing libraries, which provide basic functionality. Some of these libraries include the open source graphics engine OGRE3D which is advantageous for its powerful functionality, ease of use, and extensive documentation. The XInput component of DirectX provides the human/computer interface through a standard XBOX360 controller, for example. Finally, the free Newton Game Dynamics Engine is used to provide accurate and stable Newtonian physics behavior. All foundation components are publicly available, free of charge. The libraries listed herein are only exemplary; the simulation is not bound to these specific libraries. The interfaces between simulation code and foundation libraries are clearly defined, allowing for ease of extraction and implementation with other libraries in a commercial product.
[0042] Movement Model
[0043] Essential to the accurate construction of a sports simulation is an accurate Newtonian physics profile of human motion. FIG. 3 illustrates the acceleration curve for a human being running a 100 m sprint (albeit, a human being with world class speed). This curve is piece-wise approximated by three line segments and used as a foundation of data extrapolation.
[0044] The acceleration curve may be adjusted to typical desired player speeds. For example, in a basketball simulation game three-quarter court sprint times are available to the public on official web sites of professional basketball associations (e.g., the NBA). Thus motion, space, and time within the simulation world are firmly grounded in real world expectations. These constraints are firmly enforced, ensuring that physical realism propagates through the dependency tree shown in FIG. 2 to all simulation components. Likewise, in other kinds of simulations, other game constants can be included. For example, in a flight simulator data related to the acceleration and velocity characteristics of a given airplane may be included.
[0045] The human body is a complex system of bones, joints, muscles, and tendons that work in concert to produce a desired motion. While the motion profile data shown in FIG. 3 produce an accurate macro-model of human movement, it does not aid in modeling the relative motions of human body components. The human body is complex and for the sake of feasible implementation the minimal model displayed in FIG. 4 may be used, although other more complex models are possible.
[0046] Though simple, the model in FIG. 4 produces a significant amount of motion information pertinent to sports game play. It consists of a sphere solid 40 representing the top half of the human body and a rectangular solid 42 representing the bottom half. Total mass is distributed evenly with a spring damper 44 connecting these two solid masses. All external forces are applied to the spherical upper portion 40 only while the spring damper 44 enables movement tracking of the upper portion 40 by the lower portion 42 , modeling the relative motion of the upper and lower body.
[0047] This model provides a framework that can be used to transform scripted animation sequences. More detailed human movement not directly related to game play can be motion captured and mixed with the information provided by the underlying human model. The dynamic state of the player body provided by this simple model can be used to produce more expressive non-discrete animations from a seed set of discrete motion captured animations.
[0048] Beyond animation, this model affects game play by producing realistic movement delays and reaction to external forces. Every lateral acceleration or jump requires a gathering phase which is modeled by a necessary compression of the spring damper proportional to level of acceleration. Thus, realistic movement time delays are enforced affecting overall player movement. The model provides a sense of balance that can be quantified dynamically for each game entity.
[0049] A stability meter measures the sense of balance for each in-game player. The simulation models the human upper body as a sphere of same volume and mass as the upper body portion of the player model. This solid mass is attached to the player upper body solid mass through a spring damper similar to the lower body solid mass except relative movement is constrained to the horizontal plane. As external forces are applied to the upper body solid mass, these forces are transferred indirectly to the stability meter solid mass through the spring damper.
[0050] The stability meter tracks the motion of the upper body with a certain delay and convergence time. The aggregate stability score ε[i] of player i is shown in Equation 1, where:
W Δposition , W Δvelocity , W Δθ , and W Δω are weighting factors for position, velocity, angle, and angular velocity, respectively; P upper [i], V upper [i], θ upper [i], and ω upper [i] are position, velocity, angle, and angular velocity of the player upper body solid mass, respectively; P meter [i], V meter [i], θ meter [i], and ω meter [i] are position, velocity, angle, and angular velocity of the stability meter solid mass, respectively; and ΔP max , ΔV max , Δθ max , and Δω max are the position, velocity, angle, and angular velocity offsets between upper body and stability meter solid masses, respectively.
[0000]
Stability
Measurement
ε
[
i
]
=
1
-
W
Δ
position
*
P
upper
[
i
]
-
P
meter
[
i
]
Δ
P
max
-
W
Δ
velocity
*
V
upper
[
i
]
-
V
meter
[
i
]
Δ
V
max
-
W
Δ
Θ
*
Θ
upper
[
i
]
-
Θ
meter
[
i
]
Δ
Θ
max
-
W
Δ
ω
*
ω
upper
[
i
]
-
ω
meter
[
i
]
Δ
ω
max
Eq
.
1
[0055] From Equation 1, it is observed that when the upper body and stability meter are perfectly matched, the player stability equals one, and as deviation arises along the measurement parameters the stability measurement is degraded. FIG. 5 shows this tracking behavior through experimentally gathered data.
[0056] This measurement of stability is performed for each simulation time step, uninterrupted by player state transitions, and is utilized in both threat assessment and interaction calculations as described below.
[0057] Interaction Handler
[0058] In-game interactions between player entities are handled by the Interaction Handler. This system enforces game rules and determines the outcome of interactions based on the static and dynamic parameters of the participant players. In one embodiment (i.e. a basketball simulation) the interactions handled by this unit are: dribbling, deflecting, stripping, shooting passing, and catching.
[0059] The amount of defensive pressure experienced by an offensive player while performing an action is determined by the relative positions and capabilities of the participant players. In FIG. 6 , an example court configuration is shown, where: node o1 represents the offensive player; nodes d1, d2, and d3 represent the defensive players; and vectors r1, r2, and r3 represent displacement vectors from the offensive player to respective defensive players.
[0060] Capability is defined as a player's ability with respect to a particular aspect of the game and may be measured as a success probability for a given action. Each of the interactions listed above involves an interplay between offensive and defensive player capabilities. The overall score for a particular capability C overall [i] of offensive player i is computed as shown in Equation 2, where:
C offensive [i] is the computed offensive capability of offensive player i; N is the number of defensive players involved in the interaction; C defensive [k] is the computed defensive capability of defensive player k; r ik is the vector magnitude from a reference point of the offensive player i to a reference point of defensive player k (for different interactions, different offensive and defensive reference points may be used); α C is a tunable effect scaling factor for defensive pressure of capability C; β C is a tunable range scaling factor for defensive pressure of capability C; and C offset is a tunable probability offset for particular capability interaction C.
[0000]
Offense
/
Defense
Interaction
C
overall
[
i
]
=
C
offensive
[
i
]
-
α
C
*
∑
k
=
0
N
-
1
C
defensive
[
k
]
1
+
(
β
C
*
r
ik
)
2
+
C
offset
Eq
.
2
[0068] The calculations for the specific offensive and defensive capabilities C offensive [i] and C defensive [i] of player i are discussed in detail below. Equation 2 indicates that the effect exerted by a particular defensive player falls off by a square exponential as the distance from offensive player increases. This behavior mirrors the Coulomb's Law relationship discussed below with regard to determining optimal defensive position.
[0069] For all interactions described in this section, the following terms are defined:
x rand refers to a uniformly distributed random number satisfying inequality 0≦x rand ≦1 (the parameter x rand is used to introduce a random component into interaction calculations); ε[i] refers to player i's stability measurement; B static [i] refers to i's static body control parameter, which determines the magnitude of player i's capability degradation due to instability; ξ scale [k] is the fraction of defensive player k's scale parameter ξ static [k] to maximum value ξ max ; φ static [i] refers to offensive player i's traffic parameter, which determines the magnitude of player i's capability degradation due to traffic.
[0000]
Defensive
Mitt
Scale
Percentage
ξ
scale
[
k
]
=
ξ
static
[
k
]
ξ
max
Eq
.
3
[0075] In some embodiments of the present invention, a static parameter is defined as a player specific parameter which is invariant of time and state. These pre-defined static parameters or game constants together constitute a player profile describing all characteristics and capabilities and are used as inputs to the dynamic system.
[0076] Defensive interactions are initiated by contact between a defensive player's defensive mitt and the ball. The defensive mitt represents a defensive player's hands and is modeled by a circular surface representing a probability density field. Upon contact, the probability percentage value ξ percent is computed as shown in Equation 4, where parameters r contact and r max are illustrated in FIG. 7 .
[0000]
Defensive
Mitt
Contact
Percentage
ξ
percent
=
1
-
r
contact
r
max
Eq
.
4
[0077] In a basketball simulation the Interaction Handler also handles defensive interactions including deflect and strip interactions.
[0078] The deflect interaction is handled for any time step in which the ball is being passed and contacts a defensive player's defensive mitt. Defensive player k's deflect capability D[k] is expressed in Equation 5, where ξ percent is defined in Equation 4.
[0000] D[k]=ξ percent −(1 −ε[k ])*(1− B static [k ]) Eq.5: Deflect Capability
[0079] D offset refers to a tunable probability offset for the deflect interaction and C clean refers to a tunable clean catch probability threshold. If the inequality expressed in Equation 6 is satisfied, defensive player k will be able to perform a clean catch of the ball and obtain possession.
[0000] D[k]−x rand +D offset >C clean Eq.6: Deflect Inequality (Clean Catch)
[0080] Otherwise, if the inequality expressed in Equation 7 is satisfied, defensive player k will deflect the ball from its flight path but not obtain possession.
[0000] D[k]−x rand +D offset >0 Eq.7: Deflect Inequality (Deflect)
[0081] The strip interaction is handled for any time step in which a strip is being attempted and the ball contacts a defensive player's defensive mitt. Defensive player k's strip capability S[k] is expressed in Equation 8, where ξ percent is defined in Equation 4.
[0000] S[k]=S static [k]*ξ percent −(1 −ε[k ])*(1 −B static [k ])
[0082] Depending on whether the ball is being dribbled or held, different conditions must be met for a successful strip attempt. D overall [i] refers to the ball possessor player i's current dribbling score as discussed above. If the inequality expressed in Equation 9 is satisfied and the ball is currently in a dribble state, defensive player k will be able to perform a successful ball strip. Otherwise, if the inequality expressed in Equation 10 is satisfied and the ball is currently in a held state, defensive player k will be able to perform a successful ball strip. The terms σ static [k], D bonus , and S offset refer to defensive player k's strength, the tunable possessor strength bonus to be applied for held state strip attempts, and the tunable strip attempt probability offset parameter, respectively.
[0000] S[k]−D overall [i]−x rand +S offset >0 Eq.9: Strip Outcome Inequality (Dribble)
[0000] S[k ]−(σ static [k]*D bonus +D overall [i ])− x rand +S offset >0 Eq.10: Strip Outcome Inequality (Hold)
[0083] In a basketball simulation, the Interaction Handler also handles offensive interactions such as the dribble, shoot, pass, and catch interactions.
[0084] The dribble interaction is handled for any time step in which the basketball is in a dribbled state. Offensive player i's dribble capability D[i] is expressed in Equation 11, where D static [i] refers to player static dribbling capability parameter.
[0000] D[i]=D static [i ]−(1 −ε[i ])*(1 −B static [i ]) Eq.11: Dribble Capability
[0085] Defensive player k's dribble pressure capability P[k] is expressed in Equation 12, where D static [i] refers to player k's static dribble pressure capability parameter.
[0000] P[k]=P static [k ]−(1 −ε[k ])*(1 −B static [k ]) Eq.12: Dribble Pressure Capability
[0086] Substituting terms D[i] for C offensive [k] and P[k] for C defensive [k] in Equation 2, and substituting associated dribble interaction parameters for tunable parameters α C , β C , and C offset produces the overall dribble interaction value D overall [i]. For the dribble interaction, the reference points producing term r ik are the positions of player i and k. If the resultant inequality expressed in Equation 13 is not satisfied, player i will lose control of the ball as a result of an errant dribble.
[0000] D overall [i]−x rand >0 Eq.13: Dribble Outcome Inequality
[0087] The shoot interaction is handled for any time step in which a shot is released. Offensive player i's shoot capability S[i] is expressed in Equation 14, where S lookup (i, R[i]) refers to player i's static shooting ability from a particular point on the court.
[0000] S[i]=S lookup ( i,R[i ])−(1 −ε[i ])*(1 −B static [i ]) Eq.14: Shoot Capability
[0088] In FIG. 8 , an example shoot lookup surface is shown. A shoot lookup surface is defined as a shot make percentage for a given distance from goal 80 and angle deviation from face-on to the goal 80 . Shot make percentages are defined for a discrete number of distance and angle combinations and intermediate points are linearly interpolated to produce a continuous shot probability surface. This continuous surface is also used in the offensive positioning algorithms discussed below. In FIG. 8 , darker shades represent areas of high shot make percentages and lighter shades represent low shot make percentages.
[0089] Defensive player k's shoot pressure capability D[k] is expressed in Equation 15, where E elevation [k] is an expression of relative elevation advantage, as shown in Equation 16 and to be described below in more detail.
[0000] D[k]=E elevation [k]*( 1−φ static [k ])*(ξ scale [k ]−(1 −ε[k ])*(1 −B static [k ])) Eq.15: Shoot Pressure Capability
[0090] The parameters in Equation 16 for E elevation [k] are defined as:
H defMitt [k] is the current height of defensive player k's defensive mitt; H ball is the current height of the ball at release point; and ΔH max is the maximum elevation deviation range allowed.
[0000]
Elevation
Effect
E
elevation
[
k
]
=
H
defMitt
[
k
]
-
H
hall
+
Δ
H
max
2
*
Δ
H
max
Eq
.
16
[0094] Substituting terms S[i] for C offensive [i] and D[k] for C defensive [k] in Equation 2 and substituting associated shoot interaction parameters for tunable parameters α C , β C , and C offset produces the overall shoot interaction value S overall [i]. For the shoot interaction, the reference points producing term r ik are the positions of the ball and defensive player k's defensive mitt. If the resultant inequality expressed in Equation 17 is not satisfied, player i's shot attempt will be unsuccessful.
[0000] S overall [i]−x rand >0 Eq.17: Shoot Outcome Inequality
[0095] The pass interaction is handled for any time step in which a pass is released. Offensive player i's pass capability P[i] is expressed in Equation 18, where P static [i] refers to player i's static passing capability parameter.
[0000] P[i]=P static [i ]−(1 −ε[i ])*(1 −B static [i ]) Eq.18: Pass Capability
[0096] Defensive player k's pass pressure capability D[k] is expressed in Equation 19.
[0000] D[k ]=(1−φ static [i ])*(ξ scale −(1 −ε[k ])*(1 −B static [k ])) Eq.19: Pass Pressure Capability
[0097] Substituting terms for P[i] for C offensive [i] and D[k] for C defensive [k] in Equation 2 and substituting associated pass interaction parameters for tunable parameters α C , β C , and C offset produces the overall pass interaction value P overall [i]. For the pass interaction, the reference points producing term r ik are the positions of the ball and defensive player k's defensive mitt. Defensive pressure will not prevent the pass to be thrown, but instead produces pass directional error which in turn makes it more difficult or impossible for the pass recipient to catch the ball. The pass error produced is expressed in Equation 20.
[0000] E pass =(1 −P overall [i ])* E max Eq.20: Pass Error Magnitude
[0098] The catch interaction is handled for any time step in which an in-flight pass is within catching range of an offensive player. Offensive player i's catch capability C[i] is expressed in Equation 21, where C static [i] refers to player i's static catching capability parameter.
[0000] C[i]=C static [i ]−(1 −ε[i ])*(1 −B static [i ]) Eq.21: Catch Capability
[0099] Defensive player k's catch pressure capability D[k] is expressed in Equation 22, where Υ static [i] refers to player i's in-traffic catching ability.
[0000] D[k ]=(1−φ static [i ])*(ξ scale −(1 −ε[k ])*(1 −B static [k ])) Eq.22: Catch Pressure Capability
[0100] Substituting terms C[i] for C offensive [i] and D[k] for C defensive [k] in Equation 2 and substituting associated catch interaction parameters for tunable parameters α C , β C , and C offset produces an intermediate catch interaction value C intermediate [i]. For the catch interaction, the reference points producing term r ik are the positions of the ball and defensive player k's defensive mitt. Additional factors affecting catch success must be accounted for to produce C overall [i], as shown in Equation 23 where:
E pass is the distance of the ball from an ideal catch point; C accEffect is the tunable parameter determining effect of accuracy on catch probabilities; V ball and V max are the current and maximum ball velocities; and C velEffect is the tunable parameter determining effect of velocity on catch probabilities.
[0000]
Overall
Catch
Value
C
overall
[
i
]
=
C
intermediate
[
i
]
-
E
pass
*
C
accEffect
-
V
ball
V
max
*
C
velEffect
Eq
.
23
[0105] If the resultant inequality expressed in Equation 24 is not satisfied, player i's catch attempt will be unsuccessful.
[0000] C overall [i]−x rand >0 Eq.24: Catch Outcome Inequality
[0106] Threat Assessor
[0107] The composite threat assessment for a given offensive player comprises four independent assessments:
Physical Movement Threat Score—a measure of the static physical capabilities of a given player; Skills Threat Score—a measure of the dynamic skills capabilities of a given player; Dive Threat Score—a measure of the ability of a player to get to the rim based on current configuration of participating players; and Ball Distance Threat Score—a measure of the player's threat due to proximity to the ball; the closer the player is to the ball the higher the player's ball distance threat score.
[0112] These component threat scores are combined to produce an overall offensive player threat score used to determine the actions of both defensive and offensive players. Offensive players attempt to maximize their own assessment; while defensive players attempt to minimize the assessment of their opponents.
[0113] The physical capability P[i] of player i is computed as a weighted aggregate of the player's various physical characteristics (reflected in game constants), as shown in Equation 25 where:
W height , W jump , W mass , W strength , and W accel are the relative weighting factors for each physical movement score component; H static [i], J static [i], M static [i], S static [i], and A static [i] are the player's static values for height, jump, mass, strength, and lateral acceleration, respectively; H max , J max , M max , S max , and A max are the maximum values for height, jump, mass, strength, and lateral acceleration, respectively; and R[i] and R max are the player's distance and maximum distance from the basket, respectively.
[0000]
Physical
Movement
Capability
Value
P
[
i
]
=
W
height
*
(
H
static
[
i
]
H
max
)
+
W
jump
*
(
J
static
[
i
]
J
max
)
+
W
mass
*
(
M
static
[
i
]
M
max
)
(
1
-
R
[
i
]
R
max
)
+
W
strength
*
(
S
static
[
i
]
S
max
)
(
1
-
R
[
i
]
R
max
)
+
W
accel
*
(
A
static
[
i
]
A
max
)
(
R
[
i
]
R
max
)
Eq
.
25
[0118] The closer the player is to the basket, the higher the player's mass and strength values, and the lower the player's acceleration value. In real-world basketball quicker players have the advantage on the perimeter as there is more room for movement. In contrast, bigger, stronger players have an advantage near the basket where there is less area to move and contact and collisions are a way of life. The dynamic component to a player's physical motion score based on range from the basket emphasizes or de-emphasizes the importance of these characteristics to match real-world physical advantages. The offensive player i's final physical movement score P overall [i] is computed by substituting P[i] for C offensive [i] and P[k] of the defensive players for C defensive [k] into Equation 2.
[0119] Player i's skill capability Ω[i] is computed as a weighted aggregate of the player's various skill characteristics. The skill capability for the offensive ball possessor is shown in Equation 26 where:
W pass , W catch , W shoot and W dribble are the relative weighting factors for pass, catch, shoot and dribble score components, respectively; P overall [i], C overall [i], S overall [i] and D overall [i] are the player's pass, catch, shoot and dribble values, respectively; and R[i] and R max are the player's distance and maximum distance from the basket, respectively.
[0000]
Skill
Capability
Value
(
Ball
Possessor
Offense
)
Ω
[
i
]
=
W
pass
*
P
overall
[
i
]
+
W
catch
*
C
overall
[
i
]
+
W
shoot
*
S
overall
[
i
]
+
W
dribble
*
D
overall
[
i
]
*
(
R
[
i
]
R
max
)
Eq
.
26
[0123] The off-ball offensive player i's skill capability Ω[i] is shown in Equation 27 where:
W pass , W catch , W shoot and W dribble are the relative weighting factors for pass, catch, shoot and dribble score components, respectively; P overall [i], C overall [i], S overall [i] and D overall [i] are the player's pass, catch, shoot and dribble values, respectively; ν(i,j)=P overall [i]*(1−Φ deflect [i,j])*C overall [j], where player i is the ball possessor and Φ deflect [i,j] is the predicted probability that the pass from player i to player j is deflected; and R[i] and R max are the player's distance and maximum distance from the basket, respectively.
[0000]
Skill
Capability
Value
(
Off
-
Ball
Offense
)
Ω
[
i
]
=
ϑ
(
j
,
i
)
*
(
W
catch
+
W
pass
*
P
overall
[
i
]
+
W
shoot
*
S
overall
[
i
]
+
W
dribble
*
D
overall
[
i
]
*
(
R
[
i
]
R
max
)
)
Eq
.
27
[0128] The further player i is from the basket, the less significant the player's dribbling value D overall [i]. Equation 27 includes an additional term ν[i] as player i's ability to pass, shoot, or dribble is dependent on a successful pass from ball possessor k and catch from off-ball player i.
[0129] The predicted deflect value Φ deflect (j,i) is computed by the Threat Scorer and not the Interaction Handler. This is necessary because the Interaction Handler computes a probability of deflection once the ball contacts a defensive mitt surface and does not predict an aggregate probability of ball deflection through the flight path of the ball. The computation for Φ deflect [i,j] is shown in Equation 28 where:
D[k] is defensive player k's ball deflection capability as shown in Equation 5 (the value ξ percent is not determined as no deflection has yet taken place and is estimated by
[0000]
ξ
scale
2
)
;
D offset is the tunable pass deflection probability offset parameter;
N is the number of defensive players in position to affect passing lane;
θ k [i,j] is defensive player k's angle off the vector from passing player i to catching player j of player k as shown in FIG. 9 ;
θ max is the maximum considered value for θ k [i,j];
R[i,k] is the vector from passing player i to defensive player k as shown in FIG. 9 ; and
R[i,j] is the vector from passing player i to catching player j as shown in FIG. 9 .
[0000]
Predicted
Deflect
Value
φ
deflect
[
i
,
j
]
=
(
D
[
k
]
+
D
offset
)
*
∑
k
=
0
N
-
1
θ
k
[
i
,
j
]
*
R
[
i
,
k
]
θ
max
*
R
[
i
,
j
]
Eq
.
28
[0137] The parameters P overall [i], C overall [i] and D overall [i] for pass, catch and dribble are computed through the Interaction Handler as described previously with minimal adjustments. The shoot value S overall [i] is computed slightly differently than in the Interaction Handler, as the relative ball and defense mitt positions at time of ball release on shot must be predicted. A predicted elevation advantage δ static [k,i] is computed from the static parameters of players k and i as shown in Equation 29 where:
W height and W jump are relative weighting factors for height and jumping values; H static [i] and H static [k] are the height values for players i and j; and J static [i] and J static [k] are the jump values for players i and j.
[0000] δ static [k,i]=W height *( H static [k]−H static [i ])+ W jump *( J static [k]−J static [i ]) Eq.29: Predicted Elevation Advantage
[0141] The predicted elevation advantage is used to compute the elevation effect E elevation [k] as shown in Equation 30, where ΔH max is the maximum predicted elevation advantage allowed.
[0000]
Predicted
Elevation
Effect
E
elevation
[
k
,
i
]
=
δ
static
[
k
,
i
]
+
Δ
H
max
2
*
Δ
H
max
Eq
.
30
[0142] The parameter E elevation [k,i] is substituted for E elevation [k] in Equation 15, from which point the Interaction Handler is used to produce term S overall [i].
[0143] A player's dive threat D[i] is a measurement of an offensive player's potential to reach the rim. This parameter is computed as shown in Equation 31 where:
W velocity is the relative importance weighting of velocity to dive threat in relation to open lane threat φ; R[i] is the range vector from offensive player i to the goal; V[i] and V max are offensive player i's velocity vector and maximum velocity magnitude, respectively; φ is an aggregate measure of congestion of a driving lane;
[0148] N is the number of defensive players in position to affect driving lane;
θ k and θ max are the angle off vector to goal of player k and maximum value of θ k , respectively (θ k is shown in FIG. 10 ); R[i,k] and R max are the range from offensive player i to defensive player k and the maximum value of R[i,k], respectively (R[i,k] is shown in FIG. 10 ); and A static [k] and A max are the static acceleration parameter of defensive player k and the maximum acceleration value, respectively.
[0000]
Dive
Threat
Score
D
[
i
]
=
W
velocity
*
R
[
i
]
_
·
V
[
i
]
_
V
max
+
(
1
-
W
velocity
)
*
(
1
-
∑
k
=
0
N
-
1
θ
k
*
R
[
i
,
k
]
*
A
static
[
k
]
θ
max
*
R
max
*
A
max
)
φ
Eq
.
31
[0152] The ball distance threat score B[i] for offensive player i is computed based on distance from ball possessor k. The closer a player is to the ball, the more likely the player will be to receive a pass from the ball possessor. Additionally, the closer the player is to the ball, the less time defenders have to react to the pass. The ball distance score B[i] is shown in Equation 32 where:
β is a tunable range scaling factor; and r ik is the vector from player i to player k.
[0000]
Ball
Distance
Score
B
[
i
]
=
1
1
+
(
β
*
r
ik
_
)
2
Eq
.
32
[0155] The composite threat score T composite [i] for offensive player i accounting for threat scores, is shown in Equation 33 where:
W physicalMovement , W skill , W dive , W ballDistance are the weighting factors for physical movement, skill, dive, and ball distance threat scores, respectively; P[i] is the physical movement score; Ω[i] is the skills capability score computed using Equation 26 or Equation 27, depending on whether offensive player i is the ball possessor; D[i] is the dive threat score; and B[i] is the ball distance threat score;
[0000]
Composite
Threat
Score
T
composite
[
i
]
=
W
physicalMovement
*
P
[
i
]
+
W
skill
*
Ω
[
i
]
*
+
W
dive
*
D
[
i
]
+
W
ballDistance
*
B
[
i
]
Eq
.
33
[0161] Player Artificial Intelligence
[0162] The Player Artificial Intelligence system dictates the movements and actions of computer controlled players. The most common play mode for basketball simulation games is for one game player to control one team composed of five players. Because the game player can only provide direct control of one out of five players at a single time, player artificial intelligence of the other four players is critical in creating the appropriate game flow and simulation accuracy. The Player Artificial Intelligence comprises Defensive Positioning, Offensive Positioning, and an Action Analyzer.
[0163] The term anchor point is used to refer to the default position of a defensive player. This position is defined differently depending on the type of defense being played by each defensive player. Therefore the anchor point system does not preclude an all-zone or all-man defense, and any hybrid defensive scheme (e.g., “box and 1”, “triangle and 2”, “1 man zone”, etc.) can be defined within the framework of this system.
[0164] In FIG. 11 , the relationship between defensive player k and corresponding anchor point P anchor [k] (represented by node with anchor symbol) is shown for a zone defense. The anchor point P anchor [k] is placed at a fixed spot on the court depending on the basketball position (guard, forward, center) and zone defensive scheme (3-2, 2-3, 1-2-2, etc.). In the absence of external forces, defensive player k's position coincides with anchor point P anchor [k]. If an external force acts upon defensive player k and causes a positional displacement, a spring damper 110 applies the necessary force to bring points back into co-location.
[0165] In FIG. 12 , the relationship between and corresponding anchor point (represented by node with anchor symbol) is shown for man defense.
[0166] The relationship between the anchor point and the position of defensive player k remains a spring damper 120 , but now the anchor point is not defined as a static, court-relative position. The anchor point P anchor [k] is defined as an offensive player relative position, linearly interpolated between the direction the hoop 122 and direction of offensive player velocity. The exact relationship is shown in Equation 34, where:
P position [i] is the position of offensive player i; Δg is the tunable desired distance between offensive player i and defensive player k; h i is the vector from offensive player i to the hoop; V i is the velocity vector of offensive player i; and
[0000]
β
=
V
i
V
max
[0000] and is the factor of interpolation between the two input vectors.
[0000]
Anchor
Point
(
Man
Defense
)
P
anchor
[
k
]
=
P
position
[
i
]
+
Δ
g
(
(
1
-
β
)
h
i
_
h
i
_
+
β
*
V
i
_
V
i
_
)
Eq
.
34
[0171] Help defense in an embodiment of the simulation is modeled using Coulomb's Law. Coulomb's Law is a fundamental relationship in the field of electromagnetism expressing electrostatic force F between discrete charges. For the particular case of systems of discrete charges, the relationship is shown in Equation 35, where:
ε 0 is the electric constant of vacuum permittivity; q is the reference test charge; q i is a charge i within the discrete charge system; N is the number of discrete charges in system; r is the position of the reference test charge; and r i is the position of a charge i relative to the reference test charge q.
[0000]
Coulomb
'
s
Law
(
System
of
Discrete
Charges
)
F
=
q
4
*
π
*
ɛ
0
*
∑
i
=
0
N
-
1
q
i
*
(
r
_
-
r
i
_
)
r
_
-
r
i
_
3
Eq
.
35
[0178] The concepts of discrete charges and the game of basketball are related by replacing point charges with player threat assessments, as described above. The resulting equation for adjusted defensive position P adjusted [k]; of defensive player k is shown in Equation 36, where:
P anchor [k] is the default defensive position; ΔP is the offset in position due to network of discrete threats; α and β are tunable scale values for position offset parameter ΔP; γ[k] is the help tendency parameter for defensive player k, which also scales the magnitude of position offset parameter ΔP; T composite [j], applicable only if the defensive player k is in man defense, is a measure of the composite threat assessment of defensive player k's assigned man, denoted here as offensive player j (thus, the higher the threat assessment of offensive player j, the less help defensive player k is able to provide; if defensive player k is playing a zone defense, then T composite [j]=0); T max is the maximum composite threat assessment value possible for an offensive player; T composite [i] is the composite threat assessment for offensive player; N is the number of offensive players (if defensive player k is playing man defense, defensive player k's assigned man j is not included in this set); r ki is the distance from defensive player k's default defensive position P anchor [k] to offensive player i's anchor point; and Ω is a discriminating parameter.
[0000]
Defensive
Position
Due
to
Attractive
Forces
P
adjusted
[
k
]
=
P
anchor
[
k
]
+
1
4
*
π
α
*
γ
[
k
]
*
(
1
-
T
composite
[
j
]
T
max
)
*
∑
i
=
0
N
-
1
(
T
composite
[
i
]
)
Ω
1
+
(
β
*
r
ki
_
)
2
*
r
ki
_
Δ
P
Eq
.
36
[0189] Several modifications are made to Coulomb's original expression, most notably, the interpretation of attractive force as a positional displacement. The relationship between anchor point P anchor [k] and defensive player k's position is represented as a spring damper connection, as described above. Thus, an external force acting on defensive player k ultimately translates into a positional displacement. Directly interpreting the force as a positional offset avoids unnecessary complexity without loss of accuracy. Additionally, a 1 term is added to denominator inside summation to keep the term upper bounded.
[0190] Additional scaling factors α and β are added to provide system level control of help behavior, while the help tendency parameter γ[k] allows control at the player resolution. Also, the test charge from Coulomb's equation is always set to 1, as a defender's capability should be independent of his help tendency which is already quantified by the parameter γ[k]. Other differences include adding a discriminating factor Ω to help spread out and magnify differences in threat assessments, ignoring the attraction force to the assigned defensive player for man defense, and position offset trimming which is described in detail above.
[0191] An offensive player i's threat assessment represents player i's local advantage. Assuming that offensive players are stationary, as defensive players are drawn closer by the attractive force created by this advantage the cumulative defensive effect increases until an equilibrium state is reached. At this equilibrium state each defensive player feels an equal pull from each offensive player. Stated in terms of Equation 36, P adjusted [k] is computed continuously for each time step yielding different values until converging to a single value, at which point P adjusted [k]=P equilibrium [k].
[0192] Position offset trimming ensures that the position offset ΔP computed from Equation 36 does not make the defensive player travel directly through an offensive player. In the context of the game of basketball, this would likely constitute a foul and, thus, an undesirable behavior. The process of position offset trimming is shown in FIG. 13 , where:
v 2 is the computed displacement ΔP; v 1 is vector from defender to an offensive player; θ 1 is the angle between v 2 and v 1 ; and v 3 is the resulting trimmed position offset.
[0197] Position offset ΔP is only magnitude limited to ∥ v 1 ∥ if θ 1 <θ threshold , where θ threshold is a tunable parameter.
[0198] Using the threat assessments, a system is constructed to control the positioning of offensive players. From FIG. 8 , it can be seen that an offensive player's static shoot capability produces a continuous surface of more or less decreasing capability with increasing range from goal. Taking into account the current capabilities and positions of defensive players produces the dynamic assessment for the shoot capability which can also be viewed as a continuous surface across position parameter δ. In the context of other kinds of simulations, such a surface may have any number of dimensions.
[0199] A player's shoot capability is one input to composite threat assessment T composite [i] held and each capability across position parameter δ produces a similar surface. The combination of all capability surfaces across position parameter δ in the manner shown in Equation 32 produces a continuous composite threat assessment surface T composite (i,δ). One optimizing criteria for the position of an offensive player i is to maximize this threat assessment parameter T composite (i,δ).
[0200] Besides optimization for maximum threat, an offensive player in the game of basketball attempts to “space the floor.” While moving to position δ may result in higher T composite (i,δ) value for offensive player i, having multiple players occupy the same space is an undesirable result. To spread out the court, a spacing score S spacing (i,δ) is assessed for each position δ. The computation of S spacing (i,δ) is similar to the calculation of positional offset ΔP of a defensive player presented in Equation 34. Key modifications to Equation 34 are:
computing a repulsive instead of attractive force; considering players on the same team and not the opposite team as the system of discrete threat assessments; and converting the resultant force to a percentage of maximum allowable force.
[0204] By using a modified version of Equation 34, the relative threat assessments of offensive players is considered as a spacing criterion. The result of this algorithm is that offensive players with greater current threat are given more space to operate, mirroring the behavior and considerations of real-world basketball players. Along with T composite (i,δ) the parameter S spacing (i,δ) is used as an optimizing criterion for the position of offensive player i.
[0205] Gradient search algorithms work by iteratively moving in the direction of highest optimality along a given surface and finding a local optimum. The computation of a gradient at a given time step is shown in FIG. 14 , where:
+Δx, −Δx, +Δz and −Δz are equal magnitude offsets along orthogonal horizontal axes x and z from offensive player o 1 ; G composite (i,δ) is the composite gradient search value for player i at position δ and is the term to be maximized by the gradient search (G composite (i,δ) is computed for positions δ=P[0], P[0]+Δx, P[0]−Δx, P[0]+Δz and P[0]−Δz, where P[0] is the current position of player i; and V max is the direction of movement vector of a tunable magnitude (if none of the G composite (i,δ) values for the delta positions exceed that of the current position, no movement takes place as the offensive player i is already at a local optimal point; otherwise, the direction of V max is linearly interpolated between maximum directions along each axis with G composite (i,δ) as the interpolating factor).
[0209] The composite gradient search value G composite (i,δ) for player i at position δ is computed as shown in Equation 37 where:
T composite [i,δ] is the composite threat assessment; S spacing (i,δ) is the spacing score; and W spacing is a tunable weighting factor determining relative importance of parameters T composite [i,δ] and S spacing (i,δ).
[0000] G composite ( i ,δ)=(1 −W spacing )* T composite ( i ,δ)+ W spacing *S spacing ( i ,δ) Eq.37: Composite Gradient Search Value
[0213] System-tuning parameters as well as player aggressiveness static parameters are used to control player movement tendencies. An offensive player i will only move if the gradient value G composite (i,δ) satisfies the inequality shown in Equation 38 where:
α is the tunable scaling factor for offensive movement tendency; and A staticOff [i] is the static parameter of offensive aggressiveness;
[0000] G composite ( i ,δ)>α* A staticOff [i] Eq.38: Offensive Movement Tendency
[0216] Based on the static and dynamic parameters of the participating players, the Interaction Handler determines a probability of success for a given initiating action. This probability value, along with player static parameters, is used by the Action Analyzer to determine if a given action is initiated. Offensive and defensive aggressiveness parameters A staticOff [i] and A staticDef [k], respectively, provide probability of success threshold which must be satisfied for player i to initiate a given action. For instance, the strip outcome inequality from Equation 9 would become Equation 39:
[0000] S[k]−D overall [i]−x rand >(1 −A staticDef [k ]) Eq.39: Example Action Analyzer Threshold (Strip)
[0217] The previous detailed example represents one or more embodiments of the present invention. The game of basketball was chosen as a representative game of movement and position, with a specific set of rules and limitations. The proposed simulation model is in no way limited to the game of basketball. More complex dynamic games and simulations of motion and position with larger number of participants, more interactions, less restrictions, increased uncertainty, and different environmental factors can be constructed using the fundamental concepts discussed herein without departing from the intended scope of the invention.
[0218] For example, the size and complexity of the dynamic game or simulation of motion and position can theoretically be increased to an arbitrarily large value number N of offensive, defensive, and goal entities. In practice, because computational load increases exponentially with number of entities a finite limit may exist. However, optimizations and localization of effect can significantly reduce computational load. An exemplary abstract game is shown in FIG. 15 where:
Nodes o 1 . . . 8 represent 8 offensive entities; Nodes d 1 . . . 8 represent 8 defensive entities; and Nodes g 1 . . . 3 represent 3 goal entities.
[0222] One of reasonable skill in the art would be able to apply the concepts outlined herein to many different simulation scenarios in many different applications. For example, the present invention may be applied to many different sports simulation video games as well as simulator programs and systems, such as flight simulators, for example. Thus, although the present invention has been described in detail with reference to certain embodiments thereof, other versions are possible. Therefore, the spirit and scope of the invention should not be limited to the versions described above.
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Methods and systems for simulating dynamic motion and position. The methods and systems are particularly well-suited for use in sports simulation video games (e.g., a basketball simulation) and gaming systems. Using a simplified model of mass and structure and a physics engine, realistic movement can be mimicked by simulation/game entities. For each entity a sense of balance may be measured that affects the entities ability to achieve objectives. The entities are projected onto an n-dimensional space, the properties of which affect the probability that an entity will succeed with respect to a given objective. The methods and systems may be used to generate a visual representation of simulation, such as in a video game.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to resin compositions adapted for weather, heat and light resistance, and which are also resistant to discoloration.
2. Prior Art
Resin compositions are useful for coating and protecting items subject to weathering, and which are otherwise in some way sensitive to the environment in which they are used. Such coatings may be transparent, but are more often colored, although such coloration is frequently white.
However, the resins themselves, although more resistant than their substrates, are also subject to decomposition by factors such as heat and light. Commonly used resins are based on styrene polymers, especially polystyrene, acrylonitrile-styrene copolymer and acrylonitrile-butadiene-styrene copolymer (ABS type resin).
Research into the problems of decomposition and discoloration has established that copolymers with a maleimide sub-unit have an improved resistance to weathering, and that the maleimide monomer may be used in excess over its comonomers. However, maleimide-containing resin compositions generally need to be molded under at high temperatures, and this can frequently lead to discoloration occurring during the molding process. Furthermore, although improved, maleimide-containing resin compositions still tend to suffer from the drawback of being unstable to light and from being susceptible to discoloration.
Other research has yielded a number of stabilizers, both general and specific to the various adverse factors. Some may prevent discoloration, while others help circumvent the effects of heat. For example, Japanese Unexamined Patent Publication No. 252458/1987 provides hindered amine-type stabilizers, while other publications provide thermal stabilizers and light stabilizers, including phenol, phosphorus and amine compounds.
Other prior art which relates to relevant compounds is, for example, GB-A-1266035 which discloses hindered amine-type stabilizers, wherein one, two or three 2,2,6,6-tetraalkyl-piperidyl groups are linked to a corresponding mono-, di- or tri- acyl group.
EP-A-13 443 discloses a specific range of compounds comprising a 2,2,6,6-tetramethylpiperidine group substituted by hindered phenol groups containing acyls in both the N and the 4-positions.
GB-A-1516780 discloses bis-(2,2,6,6-tetraalkyl-piperidyl) diacyl ester derivatives, particularly where the diacyl group is a malonic group substituted by a hindered phenol residue.
All of the above references and any others referred to herein are incorporated herein by reference.
However, the stabilizers of the prior art do not provide satisfactory protection against discoloration, and there is still a demand for stabilizers having good discoloration preventing properties.
SUMMARY OF THE INVENTION
Accordingly it is an object of the invention to provide resin compositions resistant to weathering.
It is a further object of the invention to provide resin compositions resistant to heat and light.
The present invention provides a resin composition comprising discoloration effective amounts of: (i) a hindered amine stabilizer [Component (A)]; (ii) a hindered-phenol-hindered amine stabilizer [Component (B)]; and (iii) a UV absorber [Component (C)].
DETAILED DESCRIPTION OF THE INVENTION
The resin compositions of the present invention preferably comprise maleimide-type copolymers. By "maleimide-type" is meant a copolymer containing sub-units of the formula (IV) ##STR1## wherein X represents a single bond or a methylene group, R 4 and R 5 are the same or different, and each represents hydrogen or methyl, R 6 represents hydrogen, unsubstituted or substituted C 1-18 alkyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 6-10 aryl, unsubstituted or substituted aralkyl wherein the aryl portion contains 6-10 carbons and the alkyl portion contains 1-6 carbon atoms, substituted groups having one or more substituents selected from the group consisting of C 1-4 alkyl groups, halogen atoms, hydroxy groups, C 1-4 alkoxy groups, carboxy groups, nitro groups, C 6-10 aryl groups, cyano groups, C 6-10 aryloxy groups and C 6-10 -aryl-C 1-4 -alkyl groups. Suitable examples of R 6 include the N-substituents of the maleimide type monomers described hereinafter.
In the sub-units of formula (IV), when X is a single bond, R 4 and R 5 are preferably both hydrogen and, when X is a methylene group, R 4 and R 5 are preferably the same. It is preferred that X is a single bond.
R 6 preferably represents hydrogen, C 1-18 alkyl, C 3-6 cycloalkyl, phenyl or phenyl substituted with C 1-4 alkyl, halogen, hydroxy, C 1-4 alkoxy, carboxy, nitro, phenyl, naphthyl, cyano, phenoxy, naphthyloxy or C 1-4 alkylphenyl groups. More preferably, R 6 represents hydrogen, C 1-6 alkyl, cyclohexyl, phenyl or tolyl, particularly hydrogen, cyclohexyl or phenyl, and especially hydrogen or phenyl.
The present invention preferably provides resin compositions comprising:
(A) 0.005 to 6 parts by weight of a hindered amine stabilizer of general formula (I), ##STR2## [wherein, R 1 represents a hydrogen atom or a methyl group, R 2 represents a mono- to tetra-valent hydrocarbon group having 1 to 20 carbon atoms which may also be interrupted with a nitrogen atom, and n represents an interger of 1 to 4],
(B) 0.005 to 6 parts by weight of a hindered-phenol-hindered amine stabilizer of the general formula (II) and/or (III), ##STR3## [wherein, R represents a methyl group or a t-butyl group], and
(C) 0.01 to 5 parts by weight of a UV absorber, per 100 parts of the composition, the composition comprising a copolymer having 5 to 90% by weight of a sub-unit of formula (IV) as defined above.
The resin compositions of the invention overcome the above problems, and are discolored little, or not at all, under conditions of high temperature molding and intense light. What is particularly marked, is that the compositions of the invention are vastly superior to those possessing only two of the components (A)-(C).
Suitable preparations of compounds (I), (II) and (III) are generally commercially available, and may also be prepared in accordance with the disclosures of, for example, GB-A-1266035, EP-A-13 443 and GB-A-1516780, respectively.
UV absorbers are also well known in the art, and any may be used as appropriate, although the benzotriazole type is preferred.
Suitable maleimide type monomers for copolymers containing the sub-unit of formula (IV) wherein X represents a single bond include: maleimide; α-methylmaleimide; α,β-dimethylmaleimide; N-C 1-18 alkylmaleimides (such as N-methylmaleimide, N-ethylmaleimide, N-propylmaleimide, N-isopropylmaleimide, N-butylmaleimide, N-hexylmaleimide, N-octylmaleimide, N-laurylmaleimide and N-octadecylmaleimide); N-C 3-6 cycloalkylmaleimides (such as N-cyclopropylmaleimide, N-cyclopentylmaleimide and N-cyclohexylmaleimide); α-methyl-N-cyclohexylmaleimide; α,β-dimethyl-N-cyclohexylmaleimide; N-phenylmaleimide; α-methyl-N-phenylmaleimide; α,β-dimethyl-N-phenylmaleimide; and N-substituted phenylmaleimides wherein the phenyl ring is substituted with one or more substituents selected from C 1-4 alkyl (for example, methyl, ethyl, propyl or butyl), halogen (for example, fluoro, chloro and bromo), hydroxy, C 1-4 alkoxy (such as methoxy, ethoxy, propoxy or butoxy), carboxy, nitro, aryl (such as phenyl or naphthyl), cyano, aryloxy (such as phenoxy or naphthyloxy), and phenyl-C 1-4 -alkyl groups (such as benzyl and phenethyl). These may be used either singly or in combination (two or more).
Specific examples of suitable N-(substituted phenyl) maleimide monomers include; N-tolylmaleimide, N-ethylphenylmaleimide, N-butylphenylmaleimide, N-dimethylphenylmaleimide, N-chlorophenylmaleimide, N-bromophenylmaleimide, N-dichlorophenylmaleimide, N-dibromophenylmaleimide, N-trichloromaleimide, N-tribromomaleimide, N-hydroxyphenylmaleimide, N-methoxyphenylmaleimide, N-carboxyphenylmaleimide, N-nitrophenylmaleimide, N-biphenylmaleimide, N-naphthylphenylmaleimide, N-cyanophenylmaleimide, N-phenoxyphenylmaleimide, N-benzylphenylmaleimide, N-(methyl-chlorophenyl) maleimide, N-(methoxychlorophenyl)maleimide.
Particularly preferred monomers for copolymers having a sub-unit of formula (IV) wherein X is a single bond are monomers in which both of R 4 and R 5 are hydrogen, more preferably, maleimide, N-C 1-6 alkylmaleimide, N-cyclohexylmaleimide, N-phenylmaleimide, N-tolylmaleimide, especially maleimide, N-cyclohexylmaleimide, N-phenylmaleimide and N-tolylmaleimide.
Comonomers do not form an essential feature of the present invention, but are preferably selected from aromatic vinyl type monomers, unsaturated nitrile type monomers, unsaturated carboxylic acids (including their ester type monomers) and olefinic monomers. Again, these may be used singly or in combination (two or more).
Suitable examples of aromatic vinyl type comonomers include; styrene, α-methylstyrene, α-chlorostyrene, p-t-butylstyrene, p-methylstyrene, o-chlorostyrene, p-chlorostyrene, 2,5-dichlorostyrene, 3,4-dichlorostyrene, p-bromostyrene, o-bromostyrene, 2,5-dibromostyrene and 3,4-dibromostyrene, preferably styrene and α-methylstyrene. These can be used either singly or in combination of two or more compounds.
Examples of unsaturated nitrile type comonomers include acrylonitrile, methacrylonitrile, maleonitrile and fumaronitrile, preferably acrylonitrile. Again, these may be used singly, or in combination.
Suitable examples of carboxylic acids and their esters as comonomers include: acrylic acid, methacrylic acid and their esters (such as methyl, ethyl, propyl, butyl, octyl, lauryl, cyclohexyl, 2-hydroxyethyl, glycidyl and dimethylaminoethyl esters); dicarboxylic acids (such as maleic acid, itaconic acid, citraconic acid and hymic acid) and their monoalkyl or dialkyl esters (such as monomethyl, dimethyl, monoethyl, methylethyl, monopropyl, dipropyl, monobutyl and dibutyl esters); and acid anhydrides (such as maleic anhydride, itaconic anhydride, citraconic anhydride and hymic anhydride); preferably methacrylic acid, methyl methacrylate and maleic anhydride. These may be used either singly or in combination of two or more compounds.
Suitable examples of olefinic comonomers include ethylene, propylene, but-1-ene, isoprene, pent-1-ene and 4-methylpent-1-ene.
As used herein, the term "maleimide type" includes reference to graft copolymers having 5 to 90% by weight of a sub-unit of formula (IV), based on the total amount of the polymer components.
Suitable rubbery polymers to form a graft copolymer include: polybutadiene, styrene-butadiene random or block copolymers, hydrogenated styrene-butadiene random or block copolymers, acrylonitrile-butadiene copolymers, Neoprene rubber, chloroprene rubber, isobutylene rubber, natural rubber, ethylene-propylene rubbers, ethylene-propylene-nonconjugated diene rubbers, chlorinated polyethylenes, chlorinated ethylene-propylene-nonconjugated diene rubbers, acrylic rubbers, ethylene-vinyl acetate copolymers, ethylene-acrylic acid or methacrylic acid ester (such as methyl, ethyl, butyl, glycidyl and dimethylamino ethyl esters) copolymers, ethylene-vinyl acetate-glycidyl methacrylate copolymers, ethylene-methyl acrylate-glycidyl methacrylate copolymers, polyvinyl butyral, polyester elastomers and polyamide elastomers. These may be used crosslinked or uncrosslinked, as may be mixtures of two or more.
Of the above-mentioned copolymers, the most preferred are polybutadiene, styrene-butadiene random or block copolymers, ethylene-propylene rubbers, ethylene-propylene-nonconjugated diene rubber, acrylic rubbers, particularly polybutadiene and styrene-butadiene random or block copolymers.
The ratio of sub-units of formula (IV) to other units in the copolymer is preferably from about 5% to about 90% by weight for heat resistance and workability, more preferably about 10% to about 80%, particularly about 20% to about 70%.
A copolymer containing the sub-units of formula (IV) may be prepared by any suitable method known in the art. In general, when X represents a single bond, the imide monomer may be polymerized directly, or the free acid or anhydride used, followed by treatment with a suitable imidating agent, such as a compound of formula
NH.sub.2 R.sup.6 (V)
(wherein R 6 is as defined). Other suitable imidating agents include isocyanic esters.
Where the copolymer to be prepared contains sub-units of formula (IV) wherein X represents methylene, then such a polymer may be prepared by the polymerization of a corresponding acid or anhydride, followed by imidation as above. However, the most economic technique is to polymerize methacrylic acid, acrylic acid, or a mixture thereof, according to whether R 4 and R 5 are both methyl, both hydrogen, or a hydrogen and methyl, respectively. The resulting polymer may then be imidated.
Copolymers may be directly copolymerized in the presence or absence of a rubbery polymer. Suitable polymerization techniques include: bulk polymerization; suspension polymerization; bulk-suspension polymerization; emulsion polymerization; and solution polymerization.
Suitable polymers for blending with the polymers containing sub-unit (IV) of the present invention include: polystyrene, impact-resistant polystyrene, acrylonitrile-styrene copolymer and acrylonitrile-butadiene-styrene copolymer (ABS type resin). The ABS copolymer may comprise 5 to 90 parts by weight (preferably 10 to 80 parts by weight, especially 25 to 75 parts by weight) of a rubber elastomer, 5 to 90 parts by weight (preferably 10 to 80 parts by weight, especially 10 to 70 parts by weight) of an aromatic vinyl monomer, 0 to 90 parts by weight (preferably 5 to 70 parts by weight, especially 5 to 50 parts by weight) of an α,β-unsaturated nitrile type monomer, and generally 0 to 85 parts by weight of other, suitable comonomers copolymerizable therewith.
A suitable proportion of the blending polymer is anywhere from about 0% to about 90%, preferably from about 20% to about 80%, and any proportion may be used according to requirements.
Suitable rubbery elastomers include: polybutadiene, styrene-butadiene copolymers, hydrogenated styrene-butadiene copolymers, acrylonitrile-butadiene copolymers, Neoprene rubber, chloroprene rubber, isobutylene rubber, ethylene-propylene rubber, ethylene-propylene-unconjugated diene rubber, chlorinated polyethylene, chlorinated ethylene-propylene unconjugated diene rubber, acrylic rubber and ethylene-vinyl acetate copolymers. Preferable elastomers include: polybutadiene, styrene-butadiene copolymers, acrylic rubber, chlorinated polyethylene, ethylene-propylene rubber and ethylene-propylene-unconjugated diene rubber, especially polybutadiene rubber and styrene-butadiene copolymers.
Suitable aromatic vinyl type monomers include those mentioned above, especially styrene and α-methyl-styrene. These may be used singly or in combination, as before.
Suitable examples of α,β-unsaturated nitrile type monomers include acrylonitrile, methacrylonitrile, maleonitrile and fumaronitrile, especially acrylonitrile. These may be used either singly or in combination, as above.
Suitable comonomers copolymerizable with the above monomers include: unsaturated carboxylic acids, including their esters (such as acrylic acid, methacrylic acid and their esters, including methyl, ethyl, propyl, butyl, octyl, lauryl, cyclohexyl, 2-hydroxyethyl, glycidyl and dimethylaminoethyl esters); dicarboxylic acids (such as maleic acid, itaconic acid, citraconic acid and hymic acid) and their monoalkyl or dialkyl esters (such as monomethyl, dimethyl, monoethyl, diethyl, monobutyl and dibutyl esters); and acid anhydrides (such as maleic anhydride, itaconic anhydride, citraconic anhydride and hymic anhydride). The most preferable of these are methacrylic acid, methyl methacrylate and maleic anhydride. These may be used either singly or in combination, as above.
Other suitable comonomers include olefinic monomers such as ethylene, propylene, but-1-ene, isoprene, pent-1-ene, 4-methylpent-1-ene and butadiene.
The most preferable polymers for blending in the resins of the present invention are ABS copolymers, copolymers having acrylonitrile and styrene graft-polymerized onto acrylic rubber and copolymers of chlorinated polyethylene copolymerized with acrylonitrile and styrene. Particularly preferred are ABS copolymers, particularly when prepared by the graft method.
Suitable compounds useful as the hindered amine type stabilizer of formula (I) are as follows.
When n is 1, R 2 may represent, for example: an alkyl group having 1 to 18 carbon atoms (such as methyl, ethyl, propyl, isopropyl, butyl, s-butyl, pentyl, hexyl, heptyl, octyl, 2-ethylhexyl, nonyl, decyl, undecyl, dodecyl, tetradecyl, heptadecyl and octadecyl); or a phenyl group optionally substituted with one or more substituents selected from alkyl groups having 1 to 4 carbon atoms (such as methyl, ethyl, propyl or butyl), alkoxy groups having 1 to 4 carbon atoms (such as methoxy, ethoxy, propoxy, butoxy) and halogen atoms (such as fluorine, chlorine, bromine). R 2 is preferably an alkyl group having 11 to 17 carbon atoms or a phenyl group.
When n is 2, R 2 may represent, for example, an alkylene group having 2 to 20 carbon atoms, such as ethylene, propylene, butylene, pentamethylene, hexamethylene, heptamethylene, octamethylene, nonamethylene, decamethylene, dodecamethylene, hexadecamethylene, octadecamethylene, nonadecamethylene or eicosamethylene. Preferred is an alkylene group having 2 to 10 carbon atoms.
When n is 3, R 2 may represent, for example, an alkanetriyl group having 3 to 8 carbon atoms, such as one of the following: ##STR4## and, when n is 4, R 2 may represent an alkanetetrayl group having 4 to 5 carbon atoms, such as: ##STR5##
Those compounds wherein n is 2 and R 2 is an alkylene group having 2 to 10 carbon atoms and those compounds wherein n is 4 and R 2 is: ##STR6## are preferred, especially those compounds wherein n is 2 and R 2 is an alkylene group having 2 to 10 carbon atoms.
Compounds of formula (I') are also suitable for use as the hindered amine type stabilizer: ##STR7## wherein R 1 is as defined above, R 3 represents an alkyl group having 1 to 18 carbon atoms (such as the examples given hereinbefore), BTCA represents a butanetetracarboxylic acid residue, and m is a number between 1 and 2. Particularly preferred are those compounds wherein R 1 is hydrogen or methyl, R 3 is an alkyl group having 8 to 15 carbon atoms, and m is 1.7.
Component (B) may comprise one or both of the compounds of formulae (II) and (III) in which preferably R represents a t-butyl group. It is preferred that component (B) comprises the compound of formula (II) alone.
Examples of suitable UV absorbers for use in accordance with the present invention include: 2-(2'-hydroxyphenyl)-benzotriazole derivatives (wherein the substituents may be selected from, for example, such as 5'-methyl-, 5'-t-butyl, 3',5'-di-t-butyl-, 5'-(1,1,3,3-tetramethylbutyl)-, 5-chloro-3',5'-di-t-butyl-, 5-chloro-3'-t-butyl-5'-methyl-, 3'-s-butyl-5'-t-butyl, 4'-octoxy-, 3',5'-di-t-amyl- and 3',5'-bis(α,α-dimethylbenzyl)-groups); 2-hydroxybenzophenone derivatives (wherein the substituents may be selected from, for example, 4-hydroxy, 4-methoxy-, 4-octoxy-, 4-decyloxy-, 4-dodecyloxy-, 4-benzyloxy-, 4,2',4'-trihydroxy- and 2'-hydroxy-4,4'-dimethoxy- groups); and benzoic acid ester derivatives (such as 4-t-butyl-phenyl salicylate, phenyl salicylate, octylphenyl salicylate, dibenzoylresorcinol, bis(4-t-butylbenzoyl)resorcinol, benzoyl resorcinol, 3,5-di-t-butyl-4-hydroxybenzoic acid, 2,4-di-t-butylphenyl ester and hexadecyl 3,5-di-t-butyl-4-hydroxybenzoate).
Preferred UV absorbers are the 2-(2'-hydroxyphenyl)benzotriazole derivatives and benzophenone derivatives, especially the 2-(2'-hydroxyphenyl)-benzotriazole derivatives, and particularly preferred are 2-(2'-hydroxy-5'-methylphenyl)-benzotriazole, and 2-(2'-hydroxy-3',5'-bis(α,α-dimethylbenzylphenyl)-benzotriazole.
The amounts of the amine stabilizers necessary (components (A) and (B)), will vary according to the application for which the resin is intended and also with other factors, such as the other constituents of the composition, especially other stabilizers. Suitable quantities will be readily apparent to those skilled in the art. However, generally, based on the weight of the copolymer, suitable amounts of components (A) and (B) are about 0.005 to about 6% by weight, preferably about 0.01 to about 5% by weight, more preferably about 0.05 to about 3% by weight, and especially about 0.1 to about 1% by weight.
A suitable amount of the UV absorber (component (C)) will generally be in the region of about 0.01 to about 5% by weight based on the weight of the copolymer, preferably about 0.02 to about 3% by weight, especially about 0.1 to about 1% by weight.
The resin compositions of the present invention may also contain various other suitable additives known in the art of polymer technology. Some non-limiting examples are as follows:
1. PHENOL TYPE ANTIOXIDANTS
(1) 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionic acid esters
The methanol, octadecanol, 1,6-hexanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol, tris(hydroxyethyl)-isocyanurate and N,N'-bis(hydroxyethyl)oxalic acid diamide esters.
(2) 3-(3-t-butyl-4-hydroxy-5-methylphenyl)propionic acid esters
The methanol, diethylene glycol, octadecanol, triethylene glycol, 1,6-hexanediol, pentaerythritol, neopentyl glycol, tris(hydroxyethyl)isocyanurate, thiodiethylene glycol and N,N'-bis(hydroxyethyl)oxalic acid diamide esters.
(3) 3-(3,5-dicyclohexyl-4-hydroxyphenyl)propionic acid esters
The methanol, octadecanol, 1,6-hexanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol, tris(hydroxyethyl)isocyanurate and N,N'-bis(hydroxyethyl)-oxalic acid diamide esters.
(4) 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionic acid amide
N,N'-bis(3,5-di-t-butyl-4-hydroxyphenylpropionyl)-hexamethylenediamine, N,N'-bis(3,5-di-t-butyl-4-hydroxyphenylpropionyl)trimethylenediamine, and N,N'-bis(3,5-di-t-butyl-4-hydroxyphenylpropionyl)-hydrazine.
(5) Others
2,6-di-t-butyl-p-cresol; distearyl (4-hydroxy-3-methyl-5-t-butyl)benzylmalonate; 2,2'-methylenebis(4-methyl-6-t-butylphenol); 4,4'-methylenebis(2,6-di-t-butylphenol); 2,2'-methylenebis[6-(1-methylcyclohexyl)p-cresol]; bis[3,3-bis(4-hydroxy-3-t-butylphenyl)butyric acid]glycol ester; 4,4'-butylidenebis(6-t-butyl-m-cresol); 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)butane; 1,3,5-tris(3,5-di-t-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene; 3,9-bis[1,1-dimethyl-2-(3,5-di-t-butyl-4-hydroxyphenyl)ethyl]-2,4,8,10-tetraoxaspiro-[5.5]undecane; 1,3,5-tris(3,5-di-t-butyl-4-hydroxybenzyl)isocyanurate and bis[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionyl]oxamide.
2. PHOSPHITE AND PHOSPHONITE TYPE STABILIZERS
tris(2,4-di-t-butylphenyl)phosphite, triphenylphosphite; tris(nonylphenyl)phosphite; distearylpentaerythritol diphosphite; 4,4-butylidenebis(3-methyl-6-t-butylphenyl-di-tridecyl)-phosphite; bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite; tetrakis(2,4-di-t-butylphenyl)-4,4-biphenylene phosphonite and bis(2,6-di-t-butyl-4-methyl-phenyl)pentaerythritol diphosphite.
3. NICKEL TYPE STABILIZERS
Ni-monoethyl-3,5-di-t-butyl-4-hydroxybenzyl phosphonate; butylamine-Ni-2,2'-thiobis(4-t-octylphenolate) complex; Ni-dibutyl-dithiocarbamate; and Ni-3,5-di-t-butyl-4-hydroxybenzoate.
4. METAL SALTS OF HIGHER FATTY ACIDS
Calcium, magnesium, barium, zinc, cadmium and nickel stearates, and calcium, magnesium, cadmium, barium and zinc laurates.
Otherwise, if necessary, metal deactivating agents, organic tin compounds, epoxy compounds and thioether type peroxide decomposing agents may all be used as required, in any combination.
Other suitable additives include colorants, and useful pigments include: inorganic pigments such as titanium dioxide, ultramarine blue, red iron oxide, carbon black, cadmium yellow; organic pigments such as azo type (Chromophthal [trade mark] Yellow GR, Chromophthal [trade mark] Red BR), isoindolinone type (Irgazine [trade mark] Yellow-2 GLT), anthrone type (Chromophthal [trade mark] Yellow 6GL, Chromophthal [trade mark] Red A3B), phthalocyanine type (Phthalocyanine Blue B, Phthalocyanine Green 2YL), dioxazine type (PV Fast Violet BL, Chromophthal [trade mark] Violet B), perylene type (Heliogenmaloon G, Indanthrene Scarlet R), perinone type (Indanthrene Bordeau HRR, Perinon Red), quinophthalone type (Dialite Yellow GYGR) and dyes.
Other additives may include: reinforcing materials (such as glass fiber), fillers (such as talc, silica and calcium carbonate), inorganic/organic flame retardants, plasticizers, nucleation agents, antistatic agents, lubricants, foaming agents, pigment dispersing agents and antifungal agents in any suitable combination.
The present invention will now be further illustrated by reference to the following Examples which are not limiting of the invention. In the Examples and Preparation examples, unless otherwise noted, parts and percents are by weight.
PREPARATION EXAMPLE 1
Rubber-Reinforced Styrene Type Copolymer Resin (a)
A monomeric mixture (I) comprising 70 parts of styrene, 30 parts of acrylonitrile and 1.1 part of t-dodecylmercaptan (a molecular weight controller) was prepared.
Into a glass flask equipped with a stirring device, a reflux condenser, a thermometer and an aid addition device, 270 parts (including water) of a styrene-butadiene rubber latex (styrene content 10% by weight, rubber solid concentration 37% by weight and average rubber particle size 0.30 μm) and 100 parts of deionized water were charged, and the inner temperature brought to 70° C. with stirring under a stream of nitrogen. Ferrous sulfate (0.01 part--dissolved in a small amount of deionized water), 0.8 part of dextrose and 1 part of sodium pyrophosphate were added into the polymerization system.
Subsequently, into the flask, 25 parts of an aqueous dispersion of cumene hydroperoxide (CHPO) containing 0.5 part of CHPO were added, with stirring, over 180 minutes, the total amount of the monomeric mixture (I) being added continuously over 140 minutes, and the polymerization reaction initiated at the same temperature. After 120 minutes from the initiation of the polymerization reaction, 0.2 part of sodium dodecylbenzenesulfonate was added into the polymerization system. After initiation, the graft-polymerization reaction was continued at the same temperature for 210 minutes.
The latex obtained after completion of the graft-polymerization reaction was added dropwise into a 4% aqueous magnesium sulfate solution heated to 95° C. for salting-out, dehydrated and dried to give a powdery styrene type graft copolymer (a) (graft gel content 70% by weight).
PREPARATION EXAMPLE 2
Maleimide Type Copolymer Resin (b)
Into a pressure polymerization tank equipped with a condenser, a stirring device and a starting material aid feeding device were charged 690 parts of styrene and 19 parts of maleic anhydride, and the tank atmosphere was replaced with nitrogen. Under stirring, the inner temperature of the polymerization tank was brought to 95° C. to initiate the bulk polymerization reaction. One hundred parts of molten maleic anhydride liquid heated to 70° C. were added continuously at a constant rate into the polymerization system at 95° C. for 460 minutes after the initiation of polymerization. After this time, a viscous liquid with a polymerization degree of 44% by weight was obtained.
The viscous liquid was poured into a large excess of methanol to remove unreacted monomers, followed by drying, to give a styrene-maleic anhydride copolymer. Three hundred parts of the styrene-maleic anhydride copolymer obtained and 600 parts of xylene were charged, with stirring, into an autoclave equipped with a stirring device and a starting material aid feeding device, under a nitrogen atmosphere. The reaction system, which had become a uniform solution, was brought to 155° C., and 93 parts of aniline and 0.9 part of triethylamine were added into the autoclave to initiate the imidation reaction. For 240 minutes from the initiation of the reaction, the polymer imidation reaction was continued at the same temperature. The polymer solution obtained was poured into methanol to be precipitated, washed, filtered and dried to give a maleimide type copolymer resin (b).
The composition of the maleimide polymer resin (b) was analyzed by NMR and was found to comprise 57.6% by weight of the styrene component, 41.6% by weight of the N-phenylmaleimide component and 0.8% by weight of the maleic anhydride component.
EXAMPLES 1-3, COMPARATIVE EXAMPLES 1-5
To 50 parts by weight of the copolymer (a) obtained in Preparation Example 1 and 50 parts by weight of copolymer (b) obtained in Preparation Example 2 were added 0.3 part by weight of triethylene glycol bis[3-(3-t-butyl-5-methyl-4-hydroxyphenyl)propionate], 0.3 part by weight of ultramarine blue and various stabilizers (components (A)-(C), amounts shown below), and the mixture was melted and mixed through an extruder and formed into pellets, which were then injection-molded at 270° C. to prepare test plates having a thickness of 1 mm. The test plates were subjected to photoirradiation in a UV-ray fadometer (FAL-AU Model, Suga Shikenki K. K.) at a black panel temperature of 83° C. for 600 hours, followed by determination of Hunter color difference ΔE according to JIS Z8722. The results obtained are shown in Table 1.
TABLE 1______________________________________ Stabilizer (parts by weight)No. (a) (b) (c) ΔE______________________________________Example1 0.25 0.25 0.2 3.42 0.5 0.25 0.2 2.83 0.25 0.5 0.2 3.1ComparativeExample1 0.5 -- 0.2 8.22 0.75 -- 0.2 7.03 -- 0.5 0.2 6.94 -- 0.75 0.2 6.55 -- -- -- 13.5______________________________________ (a) bis(2,2,6,6tetramethyl-4-piperidyl)sebacate (b) 1[2[3(3,5-di-t-butyl-4-hydroxyphenyl)-propionyloxyethyl4-[3(3,5-di-t-buty-4-hydroxyphenyl)propionyloxy2,2,6,6-tetramethylpiperidine (c) 2(2hydroxy-5methylphenyl)benzotriazole
EXAMPLES 4-6, COMPARATIVE EXAMPLES 6-10
Test plates were prepared in the same manner as in Example 1, except that 0.3 part by weight of Anthraquinone Blue was used in place of Ultramarine Blue in Example 1, and subjected to photo-irradiation to determine ΔE. The results are shown in Table 2.
TABLE 2______________________________________ Stabilizer (parts by weight)No. (a) (b) (c) ΔE______________________________________Example4 0.25 0.25 0.2 8.25 0.5 0.25 0.2 7.36 0.25 0.5 0.2 7.6ComparativeExample6 0.5 -- 0.2 20.17 0.75 -- 0.2 18.88 -- 0.5 0.2 18.39 -- 0.75 0.2 16.710 -- -- -- 26.4______________________________________
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The present invention relates to weather resistant resin compositions consisting essentially of at least one polymeric substance and comprising discoloration effective amounts of:
(i) a hindered amine stabilizer;
(ii) a hindered-phenol-hindered amine stabilizer; and
(iii) a UV absorber.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/552,109 filed on Oct. 4, 2005, now U.S. Pat. No. 7,472,749, which is a 371 of PCT/GB2004/001472 filed Apr. 2, 2004, which claims priority to GB 0307766.6 filed Apr. 4, 2003, and GB 0316427.4 filed Jul. 14, 2003.
FIELD OF THE INVENTION
This invention relates to drifting tubing; that is, the process of determining whether the bore of a length of tubing is restricted or obstructed.
BACKGROUND OF THE INVENTION
In the oil and gas exploration and production industry long strings of jointed tubing or pipe are utilised to carry fluids between the surface and downhole locations within drilled bores, which strings and bores may be several kilometers long. In all downhole operations there is a small possibility of the pipe bore becoming restricted by, for example, cement residue or foreign objects such as a piece of wood or a metal bolt. In most cases this does not have any detrimental effect on operations. However, there are numerous tools and procedures that require a ball, dart or plug to travel through the pipe to perform a specific function downhole. Accordingly, prior to such operations it is necessary to inspect the pipe for the presence of any restrictions which would hold up the ball, dart or plug. Such inspections are normally achieved by checking the pipe string in stages as the string is pulled out of the bore and the pipe sections are separated at surface, before being reassembled in preparation for the operation involving the passage of the ball, dart or plug. Pipe strings are normally formed of large numbers of pipe sections that are typically around 10 meters long and have threaded ends. The pipe sections are often made up and stored as “stands”, each formed of three pipe sections, and thus around 30 meters long. Accordingly, when a pipe string is being pulled out of a bore, the string is lifted in 30 meter stages, to allow the uppermost stand to be removed.
One other commonly used method of checking the pipe bore for restrictions is to drop a hollow sleeve, of a slightly larger diameter than the ball, sleeve or plug, on a 40 m length of wire into the upper end of the pipe string. The pipe string is then pulled out of the bore to allow removal of the top pipe stand. If the wire is visible when the stand is separated from the string the operator knows that the sleeve is in the next stand and that the stand that has been separated from the string is unobstructed. This operation may be carried out relatively rapidly, but on many occasions the sleeve will not drop through the pipe, and the wire may become tangled or drop down such that it is not visible when the stand is separated. Thus, the drift and the obstruction point may go unnoticed.
In another method, an operator working at an elevated level simply drops an object, or drift, of a slightly larger diameter than the ball, sleeve or plug, through each pipe stand as it is being racked. The drift is retrieved at the bottom of the stand and then returned to the operator by means of the elevators used to lift the pipe out of the bore. This process is relatively slow, and it is not unknown for the drift to be dropped or otherwise fall, at significant risk to operators working below.
Bjørnstad U.S. Pat. No. 6,581,453 teaches a method of drifting pipe where the drift includes a radio transmitter or radioactive source. The drift is used in conjunction with a detection device positioned at surface to locate the position of the drift inside the drillpipe as the pipe is pulled from the hole. Such electronic detection of a drift has the drawback of being somewhat complicated, and the equipment would require to be physically robust. The equipment would also have to be intrinsically safe so as not to provide an ignition source. If the drift incorporated a radioactive source, regulations would require the drift to be handled and stored with great care. Bjørnstad also teaches a 30 m long drift in the form of a pipe that will be detected by default as the pipe is pulled from the hole. However, it is believed that the considerable weight of the drift and other issues would pose significant practical difficulties for an operator.
Polley U.S. Pat. No. 4,452,306 describes apparatus for detecting ruptures in drill pipe above and below the drill collar. The apparatus is deployed in response to surface loss in drilling pressure, indicative of washout in the drill pipe. The apparatus comprises a tool that may be pumped down through a drill pipe string to seat in a sub in the drill string above the drill collars. The drill pipe string is then pressurised above the tool to a predetermined pressure and the pressure held for a predetermined time. The pressure is monitored and, if the pressure holds, any rupture in the drill pipe is below the tool. If the pressure holds, the pressure in the string above the tool is increased to shear pins in the tool, allowing an actuator within the tool body to move and expose by-pass apertures. This allows fluid to drain from string as the string is retrieved to permit drill pipe repair below the drill collars. If, on the other hand, the drill pipe does not hold pressure above the tool, the drill pipe is pulled one section at a time. The stands are checked until the drill pipe washout is located. The damaged pipe is replaced and the drill string is tested again. If the pressure holds, the pressure is increased until the pins shear, to allow circulation through the tool. The tool may then be retrieved on wireline.
Morrill U.S. Pat. No. 5,343,946 describes a drop-in check valve used to re-establish control of a well in circumstances where there may be a gas build-up downhole. The valve is pumped from surface to lock into a landing sub provided in the string close to the bottom of the hole. The valve includes a ball that is pushed against a seat when the downhole pressure exceeds the pressure above the valve.
It is among the objectives of embodiments of the present invention to provide an efficient, technically simple and safe method for drifting tubing.
BRIEF SUMMARY OF THE INVENTION
According to the present invention there is provided a method of checking for restrictions in a string of tubing comprising a plurality of tubing sections, the method comprising:
providing a profile in the tubing string;
providing a drift member adapted to engage with said profile;
passing the drift member through the tubing string; and
determining whether the drift member has engaged with said profile prior to separating the tubing sections.
The invention also relates to apparatus for identifying the presence of a bore restriction in a tubing string, the apparatus comprising a drift member adapted to pass through tubing and to engage a profile in the tubing bore, the engagement of the drift member with the profile being operator detectable.
The tubing may be located in a hole or bore, and will typically take the form of a tubing or pipe string. If the tubing profile is located towards the distal end of the tubing, the passage of the drift member through the tubing to engage the profile identifies to the operator that the tubing does not contain any restrictions which would prevent passage of the member, such that the tubing string may then be retrieved without having to carry out any further checks for the presence of restrictions. In other embodiments it may be desired to run a ball, dart or plug through the tubing without first retrieving the tubing string, and the passage of the drift member through the tubing to engage the profile identifies to the operator that the ball, dart or plug will be free to pass through the tubing to its intended location. In this case, the drift member is preferably retrievable, and to this end may be provided with a fishing neck of the like. Of course if the drift member fails to engage the profile this indicates to the operator that the ball, dart or plug would be unable to pass through the tubing and the tubing must then be cleared or retrieved for inspection.
The method may further include the step of identifying the diameter of a ball, dart, plug or other device to be passed through the tubing and selecting a drift member of similar diameter; typically, a drift member will be selected which defines a diameter or dimension only slightly larger than the device. Thus, in some cases, the drift member will not identify minor restrictions in a length of tubing, which would not affect the passage of the device. This avoids unnecessary inspection of tubing for restrictions, which would not impact on the passage of the device.
Preferably, the drift member is adapted to be pumped through the tubing. The member may thus travel relatively quickly and positively through the tubing, and will not be reliant solely on gravity to pass through the tubing, reducing the likelihood of the member stopping in the tubing other than when the member encounters a substantial restriction. The drift member may incorporate fins, which may be flexible, to facilitate in translating the member through the tubing, or the member may be otherwise configured to assist in moving the member reliably through the tubing.
Preferably, the drift member is adapted to permit fluid flow therethrough, for example the member may be in the form of a sleeve. Thus, even with the drift member engaged with the profile, or engaged with a restriction, fluid may pass through the member. This permits fluid to drain from the tubing through the member and, if necessary, for fluid to be passed through the tubing. In certain embodiments, the drift member may have a configuration adapted to prevent or significantly restrict fluid flow: the member may incorporate a burst disc or the like which initially serves to occlude the tubing, but which may be removed or otherwise opened. One advantage offered by such an arrangement is that, if the drift member encounters a restriction, the location of the restriction may be determined by identifying the volume of fluid that has been pumped into the tubing behind the drift member when the member encounters the restriction. Thus, when the tubing string is being retrieved, it will not be necessary to check for restrictions until reaching the anticipated location of the drift member in the string.
In one embodiment of the invention, a first drift member adapted to permit fluid flow therethrough may be passed through the tubing. Such a drift member may be pumped through the tubing relatively quickly. If no restriction is encountered, the tubing may then be retrieved. However, if the presence of a restriction is identified, a second drift member adapted to prevent or significantly restrict fluid flow is then passed through the tubing, typically at a slower rate than the first drift member. Of course the second drift member will encounter and be stopped in the tubing by the first drift member. The location of the restriction may then be identified, by reference to the volume of fluid pumped into the tubing behind the second drift member, such that only a limited length of the tubing string need be checked for the presence of restrictions.
Preferably, engagement of the drift member with the profile restricts fluid flow through the tubing, which restriction is remotely detectable. Where the tubing extends downhole, engagement of the member with the profile may be identified as a rise in pump pressure at surface.
Preferably, the drift member comprises a sleeve or the like incorporating a flow restriction, such as a nozzle or orifice, adapted to create a fluid pressure differential in fluid passing therethrough. The flow restriction may comprise a hardened or otherwise erosion-resistant material.
It should be noted that any hollow sleeve would produce a restriction upon landing on a restriction or profile. However, in order to be useful in the preferred environment of the present invention the sleeve must create a noticeable pressure increase, and so the restriction must be significant. This may be illustrated by way of example: although pipe size can vary greatly, the most common drill pipe size is 5 inch diameter, which normally comprises sections of pipe each with an internal diameter of 4.25 inch over most of its length and 2.9 inch at the pipe connection. This corresponds to a flow area of 14.2 sq-in and 6.6 sq-in respectively. A typical mud pump has a maximum working pressure of 5000 psi and the pumps normally work at about 4000 psi. The maximum typical flowrate for a drifting situation would be 500 gallons per minute (1900 LPM). At this rate an operator at surface would typically see a 750 psi increase in pressure from a 0.75 in choke (0.44 sq-in), a 235 psi increase from a 1.0 in choke (0.79 sq-in), or a 45 psi increase with a 1.5 in choke (1.76 sq-in). If the operator were only able to pump at half this rate the corresponding pressures increases would be only one quarter, that is 188 psi, 59 psi & 12 psi respectively. It will be clear from this example that if a clear and unambiguous pressure increase is required on a 5000 psi scale pressure gauge to confirm a good drift, the choke must be of a known and significantly smaller internal diameter than the pipe minimum diameter. Thus, a simple hollow sleeve is unlikely to create a pressure increase at surface of sufficient magnitude to be easily and reliably identified.
Preferably, the drift member is adapted to be retrievable from the tubing. The member may incorporate a profile, more particularly a fishing profile, to facilitate withdrawal of the member from the tubing.
The tubing profile may be formed integrally with a portion of the tubing, for example the tubing may incorporate a section or sub that defines the profile. Most preferably, the profile may be defined by a member, such as a ring or sleeve, adapted to be located within a section of tubing, which section of tubing may be adapted to receive the member. Such a profile member may thus be removed and replaced when worn or damaged, or when it is desired to employ a different form of drift member, more particularly a drift member of different dimensions. Alternatively, the profile may be defined by a member adapted for location in conventional tubing, the member preferably adapted for location at a connection between tubing sections, particularly in a female or box connection. The profile member will thus be readily accessible when the tubing is disassembled, and may be located in a tubing string at an appropriate location while the string is being made up. Conveniently, the profile member may be located in a stress relief profiled section of a box connection.
When the drift member engages the profile member, the velocity of the drift member and the momentum of the fluid following behind the drift member are likely to be such that profile member will be struck with considerable force. Indeed, in one embodiment of the invention it has been estimated that a five tone force is exerted on the profile member when the drift member lands on the profile. In such circumstances the profile member may be forced into tight engagement with the tubing and thus subsequent removal of the profile member from the tubing may be difficult. To this end, the profile member may include a profile or the like adapted to engage a tool or device to facilitate removal of the profile member from the tubing.
The profile member may be adapted to form a seal with the tubing.
The drift member may define a profile adapted to engage with the tubing profile. Preferably, the drift member comprises a body and the profile is removably mounted thereon. Thus, a drift member may be readily modified to define a different diameter by replacing the drift profile. Also, a worn or damaged drift profile may be readily replaced.
The drift member may be adapted to form a seal with the profile, such that any fluid flowing through the tubing when the drift member is engaged in the profile must flow through the drift member. This will ensure the presence of a predictable or predetermined pressure drop when the drift member is correctly located in the profile, facilitating differentiation from occasions when the drift member encounters and is restrained by a restriction in the tubing before reaching the profile.
In one embodiment, the drift member may define one or more flow ports spaced from the leading end of the member. For example, where the drift member comprises a sleeve, the one or more ports may be provided in the sleeve wall. Thus, if the leading end of the sleeve encounters and engages a restriction fluid may flow through the annulus between the trailing end of the sleeve and the tubing, through the flow ports and into the interior of the sleeve, and then through the leading end of the sleeve. This minimises the likelihood of the drift member engaging with an obstruction being mistaken for the drift member engaging the profile. In a preferred embodiment, the drift member comprises a sleeve having an external profile and defining an internal flow restriction. In such an apparatus, the flow ports may be located in the sleeve wall forwardly of the internal flow restriction and the profile.
According to another aspect of the present invention there is provided a method of checking for restrictions in a length of tubing, the method comprising:
passing a drift member through the tubing; and
identifying the location of the drift member in the tubing.
The location of the drift member may be identified remotely, as described above; that is, by utilising a drift member adapted to prevent or significantly reduce fluid flow through the tubing. If the drift member encounters a restriction, the location of the restriction may be identified by determining the volume of fluid that has been pumped into the tubing behind the drift member. Preferably, this drift would have a rupture disc, or other means to allow the fluid to drain while pulling the pipe after the position of the obstruction has been located.
Alternatively, the drift member may be simply and practically adapted to be readily detectable to an operator as the tubing is retrieved, or alternatively by an appropriate sensor. Thus, the tubing may be retrieved without the requirement to check for restrictions or obstructions until the presence of the drift member is detected, at which point the obstruction can be removed or the section of pipe with the obstruction can be removed from the string. In one embodiment this may be achieved by attaching a tail to the drift member, preferably a stiff tail, the tail most preferably being made up of shorter, smaller diameter interconnected sections of flexible rod or pipe that can be easily handled. Preferably, the tail would be of relatively lightweight material to facilitate handling of the assembled apparatus and to avoid or minimise damage as the apparatus member travels through the tubing. Alternatively, the drift member could be fitted with an audible signalling device, such as a bell provided with a hydrostatic control switch. The signalling device could be battery powered or most preferably clockwork, such that when the drift member came to surface, where there is no hydrostatic pressure, the bell sounds, alerting personnel to the presence of the drift member in the pipe.
In certain embodiments the drift member may comprise a radioactive source, detectable by means of a Geiger counter or the like. Alternatively, the drift member may comprise a radio transmitter, the signals from the transmitter being detected by an appropriate receiver. In other embodiments, the drift member may include means for producing an electromagnetic or electrical output, or simply a magnetic member, or indeed any form of output or signal that is detectable externally of the tubing. However, as these embodiments require the provision of dedicated detection apparatus, with the associated cost and potential inconvenience, it is anticipated that operators will prefer solutions such as the bell described above.
In other embodiments, the location of the drift member may be identified from surface immediately following landing of the drift member on an obstruction. For example, the tubing or surrounding bore-lining casing may incorporate sensors capable of identifying the drift member location and transmitting the appropriate information to surface.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a sectional view of apparatus for identifying bore restrictions in tubing, in accordance with an embodiment of the present invention and showing a drift member located externally of a profiled sub;
FIG. 2 is an enlarged sectional view of the drift member of FIG. 1 ;
FIG. 3 is a sectional view of apparatus for identifying bore restrictions in tubing, in accordance with a further embodiment of the invention;
FIG. 4 is a sectional view of apparatus for identifying bore restrictions in tubing in accordance with a still further embodiment of the present invention;
FIG. 5 is an enlarged sectional view of the drift member of FIG. 4 ; and
FIGS. 6 a and 6 b are sectional views of apparatus for identifying bore restrictions in accordance with a yet further embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is first made to FIG. 1 of the drawings, which illustrates apparatus for use in identifying bore restrictions in tubing, in accordance with an embodiment of the present invention. The apparatus 10 comprises a sub 12 and a drift member in the form of a drift sleeve 14 adapted to engage within the sub 12 , as will be described.
The sub 12 is intended for incorporation in the lower end of a string of conventional drill pipe, and thus incorporates conventional pin and box connections 16 , 17 , and defines a central through bore 18 . However, the bore 18 defines a profile in the form of a shoulder 20 arranged to receive and engage the drift sleeve 14 , which is illustrated externally of the sub 12 in FIG. 1 .
The drift 14 is illustrated in greater detail in FIG. 2 of the drawings, and comprises a generally cylindrical body 22 with a slightly tapered leading end 24 , whereas the trailing end 26 defines an external profile 28 for co-operation with the sub shoulder 20 and an internal fishing profile 30 . An internal ledge 32 within the sleeve body 22 supports a hardened nozzle ring 34 that is in sealing engagement with the inner wall of the sleeve body 22 .
Radial flow ports 36 are provided in the body 22 , between the leading end 24 and the nozzle ring 34 .
In use, as a pipe string is made up and lowered into a drilled bore, the sub 12 is incorporated in the string, at or towards the leading or distal end of the string. Once the operation requiring use of the string have been completed, and before the string is pulled out of the bore and disassembled, the drift sleeve 14 is inserted into the string bore at surface and pumped down through the string. If the string bore is substantially free from obstruction or restriction, the sleeve 14 will pass down through the string until it encounters the drift sub 12 , where the sleeve profile 28 will engage the sub shoulder 20 and prevent further travel of the sleeve 14 . The sub bore 18 and the sleeve external configuration are such that the sleeve 14 is substantially a sealing fit within the sub 12 , such that any fluid passing through the string from surface must then pass through the nozzle 34 , and will therefore experience a pressure drop. The restriction introduced into the string bore by the nozzle 34 is reflected at surface by a readily identifiable increase in pump pressure, which indicates to the operators on surface that the sleeve 14 has engaged within the sub 12 , and that the pipe string is substantially free of obstruction and restriction.
However, where the pipe string has been restricted or obstructed by, for example, cement residue, the sleeve 14 will not be able to pass the restriction to reach and engage with the sub 12 . In such circumstances, the sleeve 14 will of course still create a flow restriction in the pipe string bore, however the leading end 24 will land on the restriction in the pipe but the sleeve 14 will not sealingly engage with the pipe such that fluid will flow around as well as through the sleeve 14 . If the leading end 24 should encounter an annular pipe restriction, preventing flow between the exterior of the leading end 24 and the pipe wall, fluid may still pass through the flow ports 36 . Thus, while the engagement of the sleeve 14 with a restriction may be reflected in an increase in pump pressure at surface, this increase will be noticeably less than the pressure increase that would be expected if the sleeve 14 were to engage and locate within the drift sub 12 . Accordingly, the operators are then alerted to the fact that the string bore is restricted or obstructed. In this case, which it is expected will occur in perhaps one in ten runs of a drift sleeve 14 , the pipe string can be checked for obstructions on a stand-by-stand basis, in a conventional manner, as described above. Alternatively, the sleeve 14 may be used in conjunction with a further drift sub as will be described subsequently, with reference to FIGS. 4 and 5 .
Of course, in the perhaps nine out of ten cases in which the drift sleeve 14 passes through the string to engage within the drift sub 12 , it is not necessary for the operator to check the string bore as the string is disassembled on surface, providing a significant saving in time and thus expense.
Reference is now made to FIG. 3 of the drawings, which illustrates apparatus 40 for use in identifying bore restrictions in tubing, in accordance with a further embodiment of the invention. The apparatus 40 is substantially similar to the apparatus 10 described above, however, rather that incorporating an integral profile or shoulder 20 , as in the drift sub 12 , the drift sub 42 of this embodiment is provided with an insert 44 that defines an internal profile 46 adapted to engage a corresponding profile 48 on the drift sleeve 50 . The insert 44 sits on a ledge 52 defined within the sleeve bore and also carries external seals 54 to ensure that no fluid passes between the sleeve 44 and the sub bore wall.
The provision of an insert 44 allows the profile 46 to be modified to suit different drift sleeve configurations, and of course the insert 44 may be replaced in case of erosion or damage.
Furthermore, the drift sleeve 50 of this embodiment includes an audible signalling device, in particular a clockwork bell 56 provided with a hydrostatic control switch, such that when the drift sleeve 50 comes to surface, where there is no hydrostatic pressure, the bell sounds, alerting personnel to the presence of the drift sleeve 50 in the pipe.
The ringing of the bell 56 will alert the operators to the presence of the sleeve 50 in a stand of pipe, such that the stand may then be checked for the presence of an obstruction. Of course, it will not have been necessary to check any of the preceding stands for the presence of the sleeve 50 and a corresponding string bore restriction or obstruction.
Reference is now made to FIGS. 4 and 5 of the drawings, which illustrate apparatus for identifying bore restrictions in tubing in accordance with a still further embodiment of the present invention. In this embodiment, there is no requirement to provide a specially adapted drift sub, as the profile 60 for engaging with the drift member, in this example in the form of a cylindrical drift dart 62 , is adapted to be located within a conventional pipe section, and in particular within the “bore back” box connection 64 of a pipe section 66 . This particular form of box is a common feature on pipe sections, intended to reduce fatigue at the connection.
The profile 60 is defined by a nozzle ring 68 which may be located within the box connection 64 during the make-up of the pipe string, the ring 68 forming a sealing fit with the inner wall of the connection 64 .
The drift dart 62 comprises a generally cylindrical body 70 having a tapering leading end 72 and defining an external profile 74 adjacent the leading end 72 , for engaging with the profile 60 . The trailing end 76 incorporates a burst disc 78 and features external flexible fins 80 that assist in stabilising the dart 62 as it is pumped through the tubing string.
In use, the dart 62 is inserted into the tubing string bore at surface and is then pumped down through the string. If there are no significant bore restrictions or obstructions the dart 62 will pass through the string until it engages with the profile 60 . This will be reflected by a sharp increase in pump pressure at the surface, which will be readily detectable by the operators. By identifying the volume of fluid that has been pumped into the string bore behind the dart 62 , it is possible to confirm that the dart has reached the profile 60 , as the location of the profile 60 is known. By increasing the pump pressure further the operators may burst the disc 78 , such that fluid may drain from the tubing string as it is withdrawn and dismantled.
If, on the other hand, the dart 62 encounters a restriction or obstruction before reaching the profile 60 , there will be a similar increase in pump pressure at surface. However, as the dart 62 has not traveled as far as it would in the absence of the restriction or obstruction, the volume of fluid pumped into the string bore will be less than that which would be expected were the dart 62 to pass all the way through the pipe string and engage with the profile 60 . Accordingly, the operators will be alerted to the fact that there is a restriction or an obstruction in the string bore. Furthermore, the volume of fluid pumped into the bore will provide an indication of the location of the obstruction in the string such that the bore need not be checked as the string is pulled out of the bore until approaching the anticipated location of the dart 62 in the string.
This embodiment thus offers the advantage, over the embodiment of FIGS. 1 and 2 , of providing an indication of the location of the obstruction and thus reducing the number of pipe stands that need to be checked for obstructions at surface. However, to prevent bursting the disc 78 immediately on encountering a restriction, or the profile 60 , the dart 62 must be pumped into the string relatively slowly, and thus may take significantly longer to travel through the string. Accordingly, in some situations, operators may choose to check for restrictions in a pipe string by first pumping down a drift sleeve 14 , as illustrated in FIG. 2 , which operation may be carried out relatively rapidly. If the sleeve 14 passes all the way through the string to engage with a drift sub 12 , no further action is necessary, and the string may be retrieved and dismantled. However, if an obstruction is identified (which is the case in perhaps 5-10% of cases), the drift dart 62 is then pumped into the pipe string. The drift dart 62 will pass down through the string until it encounters the drift sleeve 14 , and by noting the volume of fluid pumped down behind the dart 62 , the location of the dart in the string, and thus the location of the restriction, may be determined.
Running the drift sleeve 14 is a relatively rapid means for determining the presence of a string bore restriction or obstruction, and in those cases where an obstruction is identified, running the drift dart 62 allows the location of the obstruction to be determined. The additional time involved in running the drift dart 62 is more than compensated for by the saving in time made when retrieving and disassembling the string: the pipe stands need not be checked for the presence of obstructions until the section of the string in which the drift members 14 , 62 are located is brought to surface.
Reference is now made to FIGS. 6 a and 6 b of the drawings, which are sectional views of apparatus 110 for identifying bore restrictions in accordance with a yet further embodiment of the present invention. The apparatus 110 comprises a drift member in the form of an elongate drift rod 111 having a stabilising sleeve 114 b at its leading end and a drift sleeve 114 a at its trailing end.
The drift sleeve 114 a comprises a generally cylindrical two-part body 122 a carrying a replaceable drift profile 124 a . The upper free end of the drift sleeve 114 a defines a fishing neck 130 , to facilitate retrieval of the apparatus 110 , if required. The sleeve leading end defines a threaded male profile 128 a for co-operation with the upper end of the drift rod 111 . The body 122 a has an open upper end leading into a bore 123 a which permits the flow of fluid through the body 122 a , the fluid entering or exiting the lower end of the bore 123 a via two radial flow ports 125 a.
The drift rod is formed of a number of composite rod sections. The rod sections are of a length and weight selected to facilitate handling and are joined together to provide a rod 111 approximately 100 feet long. The rod sections may be formed of any appropriate material, such as a polymeric material, a composite or a lightweight metal alloy, and define a smaller diameter than the drift and stabilising sleeves 114 a,b . The rod sections are sufficiently stiff such that the sections are self-supporting but do permit a degree of flex, thus facilitating handling and passage of the apparatus through a string.
The leading, stabilising sleeve 114 b is of generally similar construction to the drift sleeve 114 a and comprises a generally cylindrical two-part body 122 b carrying a replaceable tapered centralising/stabilising profile 124 b , defining a slightly smaller diameter than the drift profile 124 a , the sleeve trailing end defining a threaded male profile 128 b for co-operation with the lower end of the drift rod 111 . The body 122 b has an open leading end and a bore 123 b communicating with two radial flow entry ports 125 b.
In other embodiments, different forms of stabilising or centralising arrangement may be utilised, for example a bow-spring type centraliser.
In use, the diameter to which the string should be drifted will have previously been identified; this may be the diameter of a ball, dart or plug it is intended to pass through the string after the string has been retrieved and then run into the bore once more. The diameters of the profiles 124 a , 124 b are selected to match this diameter, the trailing drift profile 124 a typically being selected to be slightly larger than the ball, dart or plug diameter, and the leading stabilising profile 124 b being slightly smaller (although in some embodiments the diameter of the leading profile may be the greater). The pipe string will also incorporate an appropriately dimensioned a sub 12 , 42 or profile 60 . The sleeves 114 a , 114 b are then assembled and made up to the ends of the drift rod 111 , which has been formed by joining the rod sections together. The assembled drift member is inserted into the string bore at surface and pumped down through the string, typically just before retrieval of the string commences.
If the string bore is substantially free from obstruction or restriction, the member will pass down through the string until the drift sleeve 114 a engages a sub 12 , 42 or profile 60 , as described above. The landing of the sleeve 114 a on the sub or profile is identified from the rise in pump pressure at surface. However, where the pipe string has been restricted or obstructed by, for example, cement residue, the sleeve 114 a will not be able to pass the restriction. As noted above, this may result in a rise in pump pressure at surface, but the rise will be significantly less than that produced by the sleeve 114 a landing on a sub 12 , 42 or profile 60 . If necessary, the apparatus 110 may be retrieved from the pipe string by running an appropriate tool into the string to engage with the fishing neck 130 , the sleeve 114 a ensuring that the neck 130 is centralised in the pipe.
As noted above, where the pipe string has been restricted or obstructed the location of the obstruction can be identified without difficulty as the string is retrieved and disassembled on a stand-by-stand basis; the drift rod 111 is longer than a stand of pipe and thus will extend from the end of the stand in which the drift sleeve 114 a has landed.
The apparatus 110 may be withdrawn from the obstructed stand of pipe and the stand put to one side for inspection. The apparatus 110 is then dropped into the remainder of the string still to be retrieved, to check for the presence of any further restrictions or obstructions.
The apparatus may also be used in circumstances where a sub 12 , 42 or profile 60 has not been provided in the pipe string. In these circumstances the apparatus 110 , provided with profiles of appropriate diameter 124 a , 124 b , may simply be dropped into the string, rather than pumped through the string. If the string bore is substantially free from obstruction or restriction, the member will pass down through the string until the stabilising sleeve 114 b encounters the upper end of the bottom hole assembly (BHA) or some other pre-existing restriction. The relatively light weight of the apparatus 110 is such that the apparatus will not cause any damage to the string as it passes therethrough, and will not damage the BHA when the member lands on an upper part of the BHA.
However, where the pipe string has been restricted or obstructed by, for example, cement residue, the sleeve 114 a will not be able to pass the restriction. The operator will not be aware whether the apparatus 110 has passed through the length of the string or has landed on a restriction, however the apparatus 110 will be immediately visible as the string is retrieved and disassembled on a stand-by-stand basis, allowing the presence and location of any restriction to be readily identified.
It will be apparent to those of skill in the art that the above-described embodiments of the present invention provide a relatively rapid means for determining whether there is any significant restriction or obstruction present in a tubing string. The operation may be carried out easily and safely while the tubing string remains in the bore, and the form of the various drift members is such that in the presence of a drift member within a string will not interfere or complicate the subsequent pulling out and disassembly of the string. As noted above, in the great majority of cases where no significant restriction or obstruction is likely to be identified, the operator may then disassemble the string with the knowledge that no restrictions or obstructions are present, and the normal checks for restrictions need not be carried out. Furthermore, a number of embodiments of the present invention allow the location of any restriction or obstruction to be determined, such that only selected portions of the string need be checked for the presence of obstructions.
It will also be apparent to those of skill in the art that the above-described embodiments are merely exemplary of the present invention, and that various modifications and improvements may be made thereto without departing from the scope of the invention.
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A method of checking for restrictions in a string of tubing formed of a plurality of tubing sections. The method involves providing a profile in the tubing string, providing a drift member adapted to engage with the profile, passing the drift member through the tubing string, and determining whether the drift member has engaged with the profile prior to separating the tubing sections.
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BACKGROUND OF THE INVENTION
The invention relates generally to an improved stereoscopic viewing device. It is particularly directed to the provision of a stereoscopic viewer adapted for using a film strip containing spaced stereograms thereon in cooperation with an attached booklet.
Stereoscopic viewers are known which enable stereograms to be viewed. Typically, the viewer requires either the use of a pair of stereoscopic picture frames mounted or recorded on a film to have a fixed center-to-center spacing equal to a selected interocular distance such as in U.S. Pat. Nos. 2,807,191 issued Sept. 24, 1957 to Rolla T. Flora and 2,889,744 issued June 9, 1959 to Joseph L. Bonanno, or the use of mirror devices for reflecting juxtaposed paired stereoscopic picture frames to the viewing lenses such as in U.S. Pat. No. 4,026,636 issued May 31, 1977 to Giuliano Cecchini. A major disadvantage of these type devices is the associated cost of the film recording technique and/or the (mirror) image reflecting devices.
The following patents represent some of the prior art pertinent to the field of the present invention: U.S. Pat. Nos. 2,590,260 issued Mar. 25, 1952 to G. M. Mast et al; 2,643,577 issued June 30, 1953 to J. N. Williams; 2,573,543 issued Oct. 30, 1951 to J. C. Childs; 2,326,718 issued Aug. 10, 1943 to G. M. Mast; 2,122,649 issued July 5, 1938 to M. Kahn; and 2,667,810 issued Feb. 2, 1954 to J. F. Jaros. These prior art patents are merely typical of the art showing stereoscopic viewers and are not in any way intended to be an all inclusive list of the pertinent patents.
In contrast to the prior art, the present invention provides a stereoscopic viewer which enables the use of a film strip having a pair(s) of stereoscopically recorded spaced picture frames which are brought together to have a center-to-center interocular separation for alignment with the viewing lenses by means of a new and improved film drive and film take-up mechanism, is adapted for ease of use by the operator and involves a minimum of associated parts. A booklet can readily be attached to the viewer which, in written form, provides supplementary information relevant to the stereogram(s).
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the invention, a stereoscopic viewer is provided which utilizes a film strip having at least one pair of stereoscopically recorded (spaced) picture frames which are effectively displaced to have a center-to-center interocular disposition by means of a film take-up device whereby said stereogram can be brought into registration with the viewing lenses of the viewer.
According to the preferred embodiment of the invention, a portable stereoscopic viewer is provided which utilizes a split 35 mm film strip. The film drive mechanism is adapted for ease of use by either a left or right handed operator with actuation of a centrally disposed manually operated actuator. The viewer is adapted for carriage of a booklet for being used in cooperation with the stereograms.
Accordingly, it is an object of the present invention to provide a stereoscopic viewer adapted for utilizing a film strip with spaced stereograms.
Another object of the invention is to provide a stereoscopic viewer having a curved or arcuate film guide channel which functions as a film takeup mechanism.
Another object of the invention is to provide a stereoscopic viewer having a new and improved film drive mechanism.
Another object of the invention is to provide a new and improved film drive and film take-up mechanism for a portable stereoscopic viewer to enable multiple sprocket teeth engagement with sprocket holes formed along an edge of a split 35 mm film.
Another object of the invention is to provide a new and improved stereoscopic viewer which substantially eliminates any design prejudice impedimental to its use by either left or right handed persons.
It is a further object of the invention to provide a new and improved portable educational and/or entertainment device which incorporates and integrates the presentation of information in two complimenting media, i.e., stereoscopic pictures with attached written information relative thereto.
Another object of the invention is to provide a leisure product, e.g., a tour guide or travelogue device, which incorporates stereoscopic pictures and relevant information in a small, lightweight and easy-to-use device adapted for being readily carried, e.g., in the pocket of an operator of the viewer.
Further advantages and objectives of the present invention will be apparent from the following detailed description of the preferred embodiment of the invention. Like reference numerals refer to like devices/functions throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a stereoscopic viewer and attached booklet according to the present invention;
FIG. 2 is a top plan view, partly cutaway, of a stereoscopic viewer having an arcuate film guide channel and booklet nest according to an embodiment of the present invention;
FIG. 3 is a front view of a stereoscopic viewer having a centrally disposed and protruding thumbwheel according to an embodiment of the present invention;
FIG. 4 is a cross sectional view taken through an assembled viewer of this type shown in FIG. 2 along the line A--A; and
FIG. 5 is a plan view of a strip of photographic film illustrating an arrangement of stereograms on a split 35 mm film in accordance with the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The film 1, FIG. 5, is preferably a strip of split 35 mm film, with standard perforations or sprocket holes 2 along its bottom edge 3. Techniques for longitudinally splitting standard 35 mm photographic film are well known in the field such as is described in U.S. Pat. No. 4,026,636 issued May 31, 1977 to Guiliano Cecchini and, therefore, will not be described in detail herein to avoid prolixity.
Each pair 1L-1R, 2L-2R, 3L-3R . . . of the stereoscopic picture frames are recorded on the film 1 with a longitudinal center-to-center separation greater than the selected interocular distance.
It should be recognized, however, that other film sizes such as 16 mm could also be depicted as alternative embodiments. And, in accordance with the invention, the term "stereoscopically recorded pictures or image" as used throughout the specification and claims refers to two corresponding-paired pictures or images for use in a stereoscope to give a three-dimensional effect and which are recorded on a film strip having a center-to-center picture or image frame separation greater than the interocular distance selected for the placement of the lenses of the viewer.
Referring now to FIGS. 1 and 2, a stereoscopic viewer 4 is shown which basically comprises a box-like case 5, two eyepiece lenses 6a, 6b, a film guide channel 7, lens tubes 8a, 8b, a film drive mechanism 15 and a nest or alcove 10 dimensioned to accommodate a booklet 11 therein. The viewer 4 is lightweight and dimensioned to be easily carried in a pocket or handbag of the operator. The constituent parts of the viewer 4 can be constructed of any suitable materials such as plastic, glass, metal, cardboard or from various resins including acrylic or vinyl resins.
The back wall 12 of the viewer 4 has a window 13 formed by a translucent or opaque shield, and through which diffused light can enter to illuminate the film frames.
A film guide channel 7 is provided between front 8 and rear 9 guide walls to enable the photographic film 1 to be interposed therein. The film 1 can be inserted edgeways into the guide channel 7 either during assembly or threaded through the device after assembly. The ends of the film 1 may have an abutment means 14 to prevent the film 1 from being disengaged from the film drive mechanism 15.
Each guide wall 8, 9 contains viewing windows 16, 17, 16a, 17a, respectively, which are dimensioned to accommodate registration with the picture frames 18 and have a center-to-center planar separation approximately equal to a preselected interocular distance of an average operator of the viewer 4.
As previously noted, a film guide channel 7 is provided between the guide walls, 8, 9. Each guide wall 8, 9 contains an intermediate arch 19 which combine to form an arcuate film take-up passageway 20. The arcuate passageway 20 is predetermined, either empirically or by calculation, to have a radius of curvature to effect a longitudinal shortening of the film 1 in the plane of the windows 16, 17 and 16a, 17a. Thus, the length of the guide channel 7 between the windows, 16, 16a, to 17, 17a, is selected to substantially equal the separation or spacing between the paired stereoscopic picture frames. In this manner, each pair of stereoscopically recorded frames 2L-2R, 3L-3R . . . , which are recorded at a center-to-center separation greater than the selected interocular distance, are brought into registration with the windows 16, 16a and 17, 17a. Film storage cavities 21 are affixed to each end of the film guide walls 8, 9.
Sprocket wheel openings 22, 23 are provided at the base of each film guide wall 8, 9, respectively, to accommodate insertion of the sprocket wheel 24 therein.
The film drive mechanism 15 comprises a thumbwheel 25, a sprocket wheel 24, a detent 26 and the film archway or arcuate passageway 20.
The thumbwheel 25 includes a crown like portion on the outside of the case 5 and a shaft or axle 28 which extends through the bottom wall 27. The thumbwheel 25 is rotatably mounted within a recess portion 29 of the bottom wall 27. The shaft 28 includes: intermediate flat sections 30 on the inside of the case 5 which cooperate with a cantilevered spring blade 31 to provide a multiple position rotary detent 26 to hold the film 1 in a stationary viewing position; a key-way (sprocket wheel) drive portion 32; and a retaining ledge 33. The shaft 28 may also include an enlarged base or washer like portion 28a to enable superjacent positioning of the sprocket wheel 24 therewith.
The sprocket wheel 24 is predetermined to have a circumference whose radius of curvature is approximately equal to that of the archway 20. The sprocket wheel 24 contains a plurality of teeth 34, which partially extend into the opening 23 in the rear guide wall 9 beyond the film guide channel 7 to insure engagement with the sprocket holes 2 of the film 1. The sprocket wheel 24 and the archway 20 are configured to cooperatively form an arcuate film drive track to provide simultaneous meshing or engagement of a plurality of sprocket teeth 34 each with a film sprocket hole 2, along the archway 20. The sprocket teeth 34 are contoured to enhance smooth engagement with the sprocket holes 2. It can be appreciated that this feature of the preferred embodiment of the invention is provided to protect or guard against possible damage to the sprocket holes 2 and/or to virtually eliminate film 1 binding or slippage in the guide channel 7. The sprocket wheel 24 is rotatably driven, either clockwise or counterclockwise, to advance or rewind the film 1 through the guide channel 7, by actuation of a manually rotatable thumbwheel 25.
The detent function is obtained by the cantilevered spring blade 31 being biased into engagement with the flat portions 30 of the shaft 28. The cantilevered spring blade 31 can be mounted 35 to a structural member, e.g., a lens tube 8a, of the viewer in any conventional manner such as by use of a clamp, adhesive or rivet, and projects therefrom to exert not only a radial contact pressure against the flat portions 30 of the shaft 28, but also cooperates with the retaining ledge 33 to restrict or substantially eliminate axial travel of the sprocket wheel 24 and thumbwheel 25. The flat portions 30 may be configured to provide several tactile detent positions to facilitate film frame 1L-1R . . . registration with the lenses 6a, 6b.
With the shaft 28 inserted into the case 5 and through a key-way hub opening 36 in the sprocket wheel 24, an edge 37 of the cantilevered spring blade 31 abuts against the retaining ledge 33 to hold the sprocket wheel 24 and thumbwheel 25 in an interlocked relationship. In this manner, a dual function detent and mounting assembly device is provided.
The nest 10 contains a retaining ridge 38 having an opening 39 therein and a peripheral mounting ledge 40. The opening 39 is provided to enable easy access to and selection of the pages of the booklet 11 by the operator of the viewer 4. The ledge 40 functions as a support platform for the booklet 11. The height of the retaining ridge 38 is predetermined to provide a nest depth which is at least equal to the thickness of the booklet 11.
The two eyepiece lenses 6a, 6b are mounted on the forward wall 41 of the viewer 4 and have a center-to-center separation approximately equal to the interocular or inter-pupil distance.
Two substantially parallel hollow lens tubes 8a, 8b, optically couple or permit, in a conduit like manner, the light entering through the translucent window 13 to strike the two eyepiece lenses 6a, 6b respectively. The length of the lens tubes 8a, 8b and, therefore, the placement of the constituent parts of the viewer 4, for example, the guide walls 8 and 9, are determined by the focal length of the lenses 6a, 6b.
The forward wall 41 of the case 5 may define a recessed nose portion 42, such as a V or concave configuration, between the two lenses 6a, 6b to accommodate the nose of the operator. The walls 43 of the nose portion 42 extend smoothly downwardly and outwardly to enhance comfortable viewing.
With the booklet 11 inserted into the nest 10, the viewer-booklet combination form a flat-shaped and pocket-sized portable device for easy handling and protection of the booklet 11.
The booklet 11 contains information relative to the stereoscopic pictures. The back (cardboard or paper) cover 44 of the booklet 11 can be adhesively affixed to the platform to form a top cover member of the viewer 4 and to also function as a film retainer-guard over the film guide channel 7.
The film strip 1 winds and unwinds, under the influence of the driving mechanism 15, into and out of the tubular film cavities 21. The cavities 21 are configured and affixed to the guide walls 8, 9 without the viewing area, to facilitate and urge the film 1 to wind therein and unwind therefrom with sprocket wheel 24 rotation.
As may be seen from FIGS. 3 and 4, the crown portion of the thumbwheel 25 is centrally disposed and rotatably mounted within an indentation or recess 29 of the bottom wall 27. The crown portion is dimensioned to enable rotation thereof by the thumbs of an average operator of the viewer 4 while holding said viewer 4 with either or both hands. The bottom surface 46 of the thumbwheel 25 is, for example, embossed to provide improved frictional engagement with the thumb(s).
In the operation of the device as illustrated in FIG. 3, the operator of the stereoscopic viewer-booklet device manually rotates the thumbwheel 25 against the spring bias of the cantilevered spring blade 31 to align the desired stereoscopic pictures with the lenses 6a, 6b. The viewer 4 can be held in proximity to the face of the operator to enable viewing of a selected stereogram. The attached booklet 11 can be referenced to obtain information relevant to each stereoscopic picture-scene. In this manner, the stereoscopic viewer-booklet device can be utilized as a picture-booklet travelogue and/or as an educational device. For example, the stereoscopic pictures can depict suggested sightseeing items/places such as the Eiffel Tower while the booklet provides relevant and interesting information pertaining thereto. The viewer-booklet device can also be used as an educational device, for example, to teach or present subjects which require conceptualizing of spatial and/or intermingled relationships such as mechanical engineering and automotive repair. In this manner, the interrelationships of objects or parts can be depicted to give a three-dimensional and spatial effect when viewed through the stereoscope while detailed tolerances, etc., can be provided in the attached booklet.
While the invention has been described with respect to a preferred embodiment, it should be apparent to those skilled in the art that numerous modifications may be made thereto without departing from the spirit and scope of the invention. For example, a gear train drive may be interposed between the thumbwheel and the sprocket wheel to effect multiple sprocket wheel revolution with each revolution of the thumbwheel. Another alternative would be to utilize a thumbwheel dimensioned and/or positioned to enable easy actuation from the periphery or side(s) of the viewer.
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A stereoscopic viewer and booklet device for presenting information in two complimenting media, i.e., stereograms accompanied by a booklet containing relevant and interesting information pertaining thereto. The viewer utilizes a split 35mm film having pairs of stereoscopic spaced (corresponding picture) frames. Sprocket holes are provided at regular intervals along the film. The viewer includes a film guide channel having a film take-up archway, adapted to accommodate the film spacing between paired frames to thereby effect alignment of the paired frames with respective lenses of the stereoscope. A centrally disposed thumbwheel is manually actuated to rotate a sprocket wheel for advancing and rewinding the film laterally through the stereoscopic viewer. The sprocket wheel cooperates with the film take-up archway to provide multiple sprocket teeth engagement with the sprocket holes.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an adjusting member for adjusting seat back slope, especially to a two-stage adjusting member for adjusting seat back slope that the user can operate a first stage adjusting member to make the seat back recline a certain angle. Then by a second stage adjusting member, the seat back further reclines such as 10 degrees more and becomes more close to a horizontal position. Thus the adjustment of the seat back is more safer.
[0002] There are various designs of adjustment mechanisms on office chairs such as height adjustment mechanism for armrests, height adjusting member for seats, seat slope adjusting member, seat back slope adjusting member, height adjusting member for seat backs, or waist support adjusting member, as prior arts disclosed in Taiwanese patent M321261, M326807, M308687, M3281531, M272463, M270739, M244008, M244006, M244008, 1227118, Taiwanese publication No. 00480961, 00312709, 00219466, 00148174, 00051473, 0578518, 00444555, 306219, 296582, Chinese patent No. ZL99235672.5 and U.S. Pat. No. 6,994,400 etc. The seat height adjustment mechanism and/or seat back slope adjustment mechanism are/is disposed in a main frame (first frame) of a base on bottom surface of the seat. Then by a control rod extending from the base to the edge of the bottom surface of the seat and on the left/right sides of the seat, the user can operates the mechanisms by left or right hand according to their needs.
[0003] Now the reclining function of the office chair is getting more important for users, especially for persons who sit on the seat for long period of time such as computer users. The office chair is not only a task chair but also for multiple purposes such as lounge chairs and recliner chairs. Thus the seat back of the office chair requires at least two kinds of slopes for users to choose. Generally, most of the seat back slope adjusting member available now is one-stage adjustment. That means the user adjusts the slope of the seat back only once. While adjusting the chair, the users recline and decide which slope of the seat back they require. However, the base of the office chair is disposed with rolling wheels. Thus the user may recline suddenly a large angle or to an almost flat position, fall backward and get hurts.
SUMMARY OF THE INVENTION
[0004] Therefore it is a primary object of the present invention to provide a two-stage adjusting member for adjusting seat back slope that includes a first frame whose top surface is fastened on the bottom surface of the seat, a second frame, a first stage adjusting member and a second stage adjusting member. A bottom surface of the first frame connects with a supporting mount. The rear end of the first frame is pivoted and connected with the second frame. The first stage adjusting member in the two-stage adjusting member for adjusting seat back slope is used to adjust the slope of the seat back to a first stage slope. The front end of the second frame is pivoted and connected with the first frame while the rear end of the second frame is fastened and connected with the seat back. The second stage adjusting member is disposed between the first frame and the second frame. The user operates the first stage adjusting member so as to make the seat back recline an angle for users to lie face up. Furthermore, the user operates the second stage adjusting member so that the seat back reclines from the first stage slope to the second stage slope. Thus the two-stage adjustment of the seat back is much more safer for users.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is an embodiment of the present invention assembled on an office chair;
[0006] FIG. 2 is a perspective view of an embodiment according to the present invention;
[0007] FIG. 3 is a partial enlarged view of the embodiment in FIG. 2 ;
[0008] FIG. 4 is an explosive view of an embodiment according to the present invention;
[0009] FIG. 5 is an explosive view of a seat back depth adjusting member of an embodiment according to the present invention;
[0010] FIG. 6 is a schematic drawing showing a usage of an embodiment according to present invention;
[0011] FIG. 7 shows an embodiment of the present invention recline to a first stage slope;
[0012] FIG. 8 shows an embodiment of the present invention recline to a second stage slope;
[0013] FIG. 9 shows a user lying face up in the embodiment in FIG. 8 ;
[0014] FIG. 10 shows a status before adjustment of an embodiment according to the present invention;
[0015] FIG. 11 shows a status after adjustment of the embodiment in FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Refer from FIG. 1 to FIG. 4 , a two-stage adjusting member for adjusting seat back slope 1 according to the present invention includes a first frame 20 , a second frame 30 and a second stage adjusting member 40 . The two-stage adjusting member for adjusting seat back slope 1 is disposed on a bottom surface 11 of a seat 10 and a rear end thereof extends to and fastened with a seat back 13 so that a certain angle formed between the seat 10 and the seat back 13 , as shown in FIG. 6 .
[0017] A top surface of the first frame 20 is fastened on the bottom surface 11 of the seat 10 while a bottom surface of the first frame 20 connects with a supporting mount 12 standing on the ground. By a pivot 50 , the first frame 20 is pivoted with the second frame 30 . A first stage adjusting member 21 is disposed on the first frame 20 and the second frame 30 is pivoted backward to a certain angle (about 20 degrees) around the pivot 50 by operation of a first adjustment rod 211 . Thus the seat back 13 on top of the second frame 30 also reclines an angle A, as shown in FIG. 7 . This is the first stage adjustment.
[0018] A front end of the second frame 30 is pivoted and connected with the first frame 20 by the pivot 50 while a rear end of the second frame 30 is fastened with the seat back 13 . Refer from FIG. 6 to FIG. 10 , an elastic device 14 is formed by a spring and is used to adjust supporting strength of the seat back 13 while the seat back reclining. That's elastic returning strength of the seat back 13 that enables the seat back 13 to turn back. Moreover, a seat back depth adjusting member 60 is disposed on the second frame 30 . The seat back depth adjusting member 60 makes the seat back 13 move from an anterior position, as shown in FIG. 10 , to a rearward position, as shown in FIG. 11 . In this embodiment, the seat back depth adjusting member 60 is formed by an upper housing and a lower housing ( 60 ). A top surface 61 thereof is disposed with two vertical serrated slots 62 and stopping surfaces 63 , as shown in FIG. 4 & FIG. 5 . The seat back depth adjusting member 60 corresponds to a stage control device 64 . The stage control device 64 includes an adjusting rod 65 that inserts through and locates between two holes 33 of the second frame 30 . Two sets of positioning rings 66 and cams 67 are arranged on the adjusting rod 65 , respectively and symmetrically on the right and left sides. That means each one side of the adjusting rod 65 is disposed with one positioning ring 66 and one cam 67 . Through an insertion hole 34 on the second frame 30 , the positioning ring 66 and one cam 67 correspond to and work with the serrated slots 62 and the stopping surface 63 . When the positioning ring 66 and one cam 67 are respectively released from the serrated slot 62 and the stopping surface 63 , the seat back 13 is able to be adjusted forward or backward for changing depth. After moving to a certain depth, rotate the adjusting rod 65 so that the two sets of positioning rings 66 and cams 67 rotate synchronously and the positioning ring 66 locks into one of the serrated slots 62 while the cam 67 presses against on the stopping surface 63 so as to finish operation of the seat back depth adjusting member 60 . Thus the space for seating or reclining of the seat is adjusted for improving comfort of the chair. Furthermore, a fixing member 68 is further disposed between the upper and the lower housing ( 60 ), as shown in FIG. 5 . Thus the fastening strength of the seat back depth adjusting member 60 with the seat back 13 is improved.
[0019] Refer to FIG. 4 , the second stage adjusting member 40 is arranged between the first frame 20 and the second frame 30 . As shown in FIG. 7 , when the seat back 13 reclines a certain angle A by the adjustment of the first stage adjusting member 21 , the seat back 13 can recline a further angle B such as 10 degrees, as shown in FIG. 8 . Thus the user can lie face up and take a good rest, as shown in FIG. 9 . The second stage adjusting member 40 includes a pin 41 formed by an inner end 411 and an outer end 412 and being disposed between left and right holes 23 of the first frame 20 . The second frame 30 includes left and right holes 31 a - 31 b corresponding to the left and right holes 23 of the first frame 20 .
[0020] Moreover, the inner end 411 of the pin 41 connects to a handle 42 while the handle 42 is connected with a guide pin 46 which is disposed in a guiding hole 32 of the second frame 30 moveably. The pin 41 is arranged with an elastic member 43 such as spring and is restricted by a stopping block 44 so that the pin 41 can turn back automatically by elasticity of the elastic member 43 after movement. Furthermore, a projective rod 45 on the pin 41 moves freely inside the hole 31 a of the second frame 30 . Thereby, when the handle 42 is pulled outward horizontally by guiding of the guide pin 46 , the outer end 412 of the pin 41 and the projective rod 45 synchronously move outward and release from the hole 31 b and the hole 31 a of the second frame 30 respectively. Now the second frame 30 further reclines an angle such as ten degrees from the slope of the first stage so that the slope of the second stage is achieved. In comparison, the conventional adjusting member only has one stage adjustment and the chair may recline from a vertical position to almost a flat position suddenly. This may cause danger or harm to users. Instead, the present invention adjusts the slope of the seat back 13 in two stages. By two-stage adjustment, the chair becomes much more safer. In addition, the second-stage slope can automatically turn back by elasticity of the spring of the elastic member 14 , as shown from FIG. 6 to FIG. 10 . Thus it's convenient for users to adjust the slope of the chair from the second stage back to the first stage. And the pin 41 also turns back to the original position-into the holes 31 b , 31 a automatically by the elasticity of the elastic member 43 .
[0021] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A two-stage adjusting member for adjusting slope of a seat back formed by a first stage adjusting member and a second stage adjusting member is disclosed. A user operates the first stage adjusting member so that the seat back reclines from 90 degrees to 70 degrees to the horizontal. Then the users operates the second stage adjusting member so as to make the seat back further incline backward such as 10 degrees more to another slope. Thus the seat back slope is adjusted in two stages and such design is much more safer for users and can prevent danger or harm caused by suddenly reclining.
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FIELD OF THE INVENTION
The invention relates to a radial piston engine.
BACKGROUND AND PRIOR ART
A radial piston engine of this type, as is known for example in French Published Patent Application 2,296,778, and therein only a partial compensation of the hydraulic forces acting on the guide body of the piston is possible in as much as the pressure-medium acting on the guide body from outside to inside always acts in the same direction on the guide body, whereas the pressure acting in the opposite direction from inside to outside, by which the guide body is kept in place against the bearing shell, follows in its alignment the swivelling motion of the guide body, that is to say continually changes the alignment, so that the counteracting compressive forces over the swivelling range cannot be compensated.
This is explained in greater detail with reference to FIG. 1, which diagrammatically shows the known design according to the abovementioned French Published Patent Application. The pressure p B of the pressure medium, fed in for example via passages in the cylinder cover, which prevails in the pressure space 1 above the guide body 2 over the diameter de of this pressure space exerts a force F H which remains constant during the swivelling motion of the guide body 2, which engages in a hollow piston 3. In the swivelling position of the piston and guide body represented in FIG. 1, there acts on the underside of the guide body 2, which is provided with clearances for the pressure medium to pass through, the same pressure p B with the resulting force F K , which keeps the guide body 2 in place with its spherical-annular bearing face 4 against a spherical-annular bearing face 5 of the housing or cylinder cover. Resolving this resultant, a force F KY opposes the bearing relieving force F H acting on the upper side. The component F KY of the force pressing the guide body against the bearing acts transversely with respect to the longitudinal axis of the guide body 2 and consequently acts transversely on the piston 3.
The equilibrium of the forces in this swivelling position gives a dependence between the permissible degree of bearing relief m and the geometry of the engine as
m.sub.por =F.sub.H /F.sub.K =cos α-sin αtg φ.
For example, for a swivelling angle α of 10° and φ=35°, a permissible degree of relief of m por =0.863 is obtained, without taking frictional forces into account.
If at α=0 the working piston is not swivelled, the guide body could theoretically be relieved completely with a hydraulic counterforce F H , which is equal to F K . In this case, the excess of the forces is 1-0.863=0.137, that is to say virtually 14%, producing an adverse effect on the contact pressure on the spherical-annular face between the guide body and the housing, entailing a corresponding frictional moment. An increased frictional moment on the spherical bearing of the guide body causes the shoe of the piston, not shown in FIG. 1, to lift off from the circumference of the eccentric on one side, producing increased frictional and leakage losses in this area, because pressure medium is passed via restricting bores onto the underside of the piston shoe for relief of the hollow piston.
If the frictional forces N. μ occurring are also taken into account, the permissible degree of relief is less by a few percent. In order to be able to keep the oscillating guide body reliably in place against the ball seat, a few percent therefore have to be added to this with regard to dimensional and geometrical errors of the ball, so that with the engine data (α, φ) specified above an effective degree of relief of about 70 to 75% is obtained.
SUMMARY OF THE INVENTION
The invention is based on the object of designing a radial piston engine of the type described in which the effective degree of relief can be maximized.
This object is achieved according to the invention by the features described hereinbelow. Due to the fact that the spherical-annular bearing face on the housing is dimensioned in relation to the spherical-annular bearing face on the guide body in such a way that, upon the swivelling motion of the guide body, the bearing face on the housing, and not the bearing face on the guide body (as is the case with the above prior art), is partially freed from pressure medium impingement, the relief diameter de on the guide body upon which the relieving force F H acts follows the oscillating motion of the guide body, so that in each swivelling position a constantly high relief can be obtained which, on account of the constant alignment of the counteracting forces, can also be exactly designed.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWING
The invention is described in more detail by way of example with reference to the drawing, in which:
FIG. 1 shows the forces acting on the guide body of a piston in a diagrammatic representation in the case of the known design,
FIG. 1a is a diagrammatically simplified representation of this known design,
FIG. 2 shows the distribution of forces in the case of the design according to the invention in the same representation as FIG. 1,
FIG. 2a illustrates the design according to the invention in the representation according to FIG. 1a, and
FIG. 3 shows a further embodiment of the design according to the invention.
DETAILED DESCRIPTION
In the embodiment according to FIG. 2, the spherical-annular bearing face 4 on the guide body 2 is designed to be approximately the same width as the corresponding spherical-annular bearing face 5 on the housing or cylinder cover 6, so that in the maximum swivelling position shown of the guide body 2, the bearing face 4 of the latter on one side covers the bearing face 5 on the housing 6, whereas on the opposite side the bearing face 5 on the housing 6 is partially freed i.e. exposed to the pressure P B . The width of the spherical-annular bearing face 4, i.e. the dimensions along the longitudinal axis of the guide body 2, can be designed in any way desired. Theoretically, it can reach the extreme value zero, as FIG. 2a shows. Consequently, there is no interrelationship between width of the spherical-annular bearing face 4 and the spherical bearing face 5 on the cylinder cover. The spherical bearing face in the cylinder cover must have a certain minimum width, since the spherical-annular bearing face 4 has to transfer only the resulting residual force, unless the degree of relief is 100%.
As a result, the end face 8 of the guide body 2 forming the relief diameter de, i.e. the hydraulically effective plane on which pressure P B is applied, is constantly acted on by the pressure medium introduced through the pressure space 1, so that the relieving force F H as the resultant of the compressive pressure p B follows the swivelling motion and always acts along the axis of the guide body 2.
In the central position at α=0, an outer part of the bearing face 5 on the housing 6 is exposed over the entire circumference, so that the relief face on the upper end face 8 of the guide body 2 is subjected to the pressure p B in the same way as in the maximum swivelling position according to FIG. 2.
In contrast to the known design according to FIG. 1, in the case of the design according to the invention as shown in FIG. 2, the relief face on the end face of the guide body 2 is not formed by a portion of the bearing face 4 on the guide body but only by the straight end face 8, the edges of which brush over the bearing face 5 on the housing 6 during the swivelling motion. In the case of the known design, a sub-area of the bearing face 4 on the guide body 2 is always acted on by the pressure of the pressure medium, so that the relieving force F H cannot follow the swivelling motion of the guide body 2.
In the case of the known design, the relief face de is fixed by the approximately cylindrical pressure space 1 in the housing 6, whereas in the case of the design according to the invention the relief face de is fixed on the guide body 2. This is illustrated by the diagrammatic representations in FIGS. 1a and 2a. In the case of the known design according to FIG. 1a, the bearing face on the housing is reduced to a circular sealing edge 5', against which the spherical-annular bearing face 4 of the guide body 2 bears. The pressure space 1 above the guide body is essentially formed by a cylindrical bore or opening having the fixed diameter de. The sealing edge 5' determines the size of the pressure area p B and consequently also its steady-state position, because the sealing edge 5' does not change during the swivelling motion of the guide body 2.
In contrast to this, in the case of the design according to the invention as shown in FIG. 2a, the pressure space 1 above the guide body 2 is formed by an approximately spherical-cup-shaped recess, the bearing face 4 of the guide body 2, reduced to a peripheral edge 4', bearing as sealing edge in this spherical-cup-shaped recess. The diameter de of this circular sealing edge 4' determines the size and position of the pressure area p B acting on the guide body 2, so that the alignment of the pressure area inevitably follows the alignment of the sealing edge 4', which in the case of this representation is formed by the upper end face 8 of the guide body 2. As a result of the fact that, according to the invention, the cylindrical element 2 in FIG. 2a is movable in relation to the fixed element 5 with the concave spherical bearing face, the sealing line 4' between these two elements, together with the associated pressure area, is also movable.
In other words, in the case of the design according to the invention the plane of the relief face de or its projection in the axial direction intersects the spherical-annular bearing face 5 on the housing 6. The width of the bearing face 5 on the housing 6 is essentially determined by the swivelling range of the relief face de running perpendicularly to the longitudinal axis of the guide body 2. This applies for fixing the minimum height of the upper edge of the bearing face 5. The lower edge of the bearing face 5 is designed such that an adequate bearing face for the guide body 2 still remains at the bottom right even in the maximum swivelling position according to FIG. 2.
FIG. 2 shows in the maximum swivelling position of the guide body 2 the minimum height of the upper edge of the bearing face 5 on the housing. As FIG. 2a shows, this upper edge may also be higher. In the case of the exemplary embodiment according to FIG. 2, the width of the bearing face 4 on the guide body corresponds to the width of the bearing face 5 on the housing, so that in the maximum swivelling position the two bearing faces overlap completely on one side. However, as explained above, this width of the bearing face 4 is not a requirement.
It is achieved by this configuration of the bearing area between guide body and housing or cylinder cover that the hydraulic relief area and the resulting relieving force F H is associated with the swivelling guide body. The hydraulic relieving force acts in the same plane or alignment against the reaction force on the radially inner side of the guide body, so that there is no critical position in which lifting-off of the piston has to be feared, because the same frictional moment is applied in each swivelling position. F H must not be greater than F K , so that the degree of relief is no longer limited by the geometry of the radial piston engine but only by the size of the pressure areas. Theoretically F H =F K is possible, so that theoretically the degree of relief would be 100%.
With a high degree of relief, the frictional forces are minimized. This has very positive effects on the frictional moment of the guide body.
FIG. 3 shows a design according to the invention, in which the guide body 2' extends over the piston 3'. In the case of this design, the same condition applies, that the plane of the relief face de can be swivelled only in the area of the bearing shell 5 on the housing 6 and not beyond it. The frictional moment on the guide body 2' can be reduced to a minimal value by the fact that only low frictional forces N.μ occur due to a high degree of relief. Although, for constructional reasons, this design is provided with a relatively large sphere radius R K , which is greater than the piston diameter because the piston enters into the guide body, in this way the frictional moment can nevertheless be kept very small.
In the case of the design according to FIG. 3, the upper part of the guide body 2' is spherical, a supporting ring 10, supported by springs 9, being provided in the lower region of the sphere, the said ring being supported in the housing or in the cylinder cover. The eccentric on the circumference of which the pistons 3' or 3 bear in a sliding manner is indicated in FIG. 3 at 11.
In FIG. 3, an annular groove formed on the bearing face 4 is denoted by 12, which groove is formed close to the end face of the guide body 2' on the circumference of the latter and is constantly connected to the leakage oil space of the radial piston engine via an oblique bore 13. As in the case of the embodiment according to FIG. 2, in the case of the design according to FIG. 3 as well, only a relatively narrow sealing face is necessary between the bearing faces 4 and 5 in order to obtain a high degree of relief and to transfer the remaining forces from F K -F H , as can also be deduced from FIG. 2a. The annular groove 12 is therefore formed near the end face of the guide body 2' in its spherical-annular bearing face 4. As a result, the pressure face is precisely defined on the end face 8 of the guide body 2', since the annular groove 12 reduces the oil pressure in the remaining area of the spherical-annular bearing face 4 via the oblique bore 13. Without this annular groove 12 with relief bore 13, the pressure reduction in the bearing area, and consequently the pressure-relief area, would not be precisely defined. The convex spherical-annular bearing face 4 lying below the annular groove 12 in FIG. 3 serves only for reducing the contact pressure and for better bore guidance in the cylinder cover.
By the design according to the invention, on the one hand the effective degree of relief can be maximized and on the other hand the degree of relief can be predetermined clearly and exactly, because the compressive force acts on the guide body in the direction of the axis of the latter in every swivelling position.
Whereas in the case of the design according to FIG. 2 the piston 3 is designed as a hollow piston and the guide body 2 is designed to correspond to a solid-cylindrical component which enters in the hollow piston, in the case of the design according to FIG. 3 the guide body 2' is provided with a cylindrical recess, in which the piston 3', represented solid-cylindrically, is displaceably guided, so that in the case of this design the guide body 2' extends over the piston 3'.
On the end face 8 of the guide body 2 or 2', elevations or the like may also be formed in the central area. The essential requirement is the presence of the hydraulically effective relief face, determined by the diameter de, which face intersects the bearing face 5 on the housing during the swivelling motion of the piston.
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In a radial piston engine having pistons bearing against the circumference of an eccentric, which pistons execute a swivelling motion upon the rotational motion of the eccentric and are in engagement with a guide body, which bears on the radially outer end by a radially outwardly convex spherical-annular bearing face against a concave spherical-annular bearing face in the housing or cylinder cover. To attain complete piston relief, the bearing arrangement is designed such that the guide body (2) is provided with an upper end face (8) which is acted on by the pressure medium over a hydraulically effective plane (de) extending perpendicularly to the longitudinal axis of the guide body (2). The hydraulically effective plane lies in the area of the bearing face (5) on the housing (6) or intersects the face for all swivelling positions of the piston (3).
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TECHNICAL FIELD
This disclosure relates to electrical power generation and utilization, and more particularly to distributed electrical power generation and utilization systems. The disclosure relates even more particularly to power quality concerns associated with certain generators and load-types connected to the utility grid.
BACKGROUND ART
Entities other than the utility power grid now frequently generate electrical power for local or dedicated uses, as well for connection to the utility grid to generate revenues and/or offset costs. Such systems may be referred to as having a dual, or multiple, sourced power bus.
In some electric power generating systems, the manner of managing the energy that will operate the electric generator may require auxiliary equipment, such as pumps and fans. An example is a power system which recovers heat, from such sources as geothermal wells, food processing plants or landfills, or the like, utilizing an Organic Rankin Cycle system.
For economic efficiency, it is desirable that a low cost generator provide power for all auxiliary equipment, while at the same time providing power which has shape (little or no harmonic distortion), power factor (PF), and frequency that are all suitable for interface with the utility power grid. Synchronous generators are typically more expensive and require additional controls compared with other, cheaper generators such as induction generators which, because of their construction, are less expensive than synchronous generators. However, induction generators have an inherently lower power factor (PF) than what is typically acceptable to utility grids. Moreover, to the extent certain types of non-linear loads, such as variable-speed drives with diode front ends, are associated with the auxiliary equipment, high levels of harmonic distortion may occur in the current.
An example of the conditions described in the foregoing paragraph may be seen in the characterization of the “prior art” (FIG. 1 therein) described in U.S. Pat. No. 7,038,329 (hereinafter '329) to S. J. Fredette, et al for “Quality Power From Induction Generator Feeding Variable Speed Motor”, the disclosure of which is incorporated herein by reference to the extent consistent and appropriate. Similar thereto is the following characterization herein of that “prior art” as it is depicted in FIG. 1 herein.
Referring to FIG. 1 herein of the “prior art”, there is depicted a single line of a typically multi-phase (typically 3-phase) power system in which an induction electric power generator 10 , driven by some form of prime mover 12 , is connected, or connectable, with the utility power grid 14 via power bus 16 including switch 18 , typically a breaker or contactor. Moreover, there is depicted broadly in block form, one or more non-linear loads 20 , typically including variable speed drives with diode rectifier front ends and associated with the auxiliary loads, operatively connected to the power bus 16 . Those non-linear loads, and particularly the variable speed drives with diode rectifier front ends, are the same or similar to elements 11, 12, 13 and 16 of FIG. 1 of the aforementioned '329 patent. Because the induction generator requires reactive power to operate, the reactive power is provided by a power factor correction capacitor (C pfc ) 22 in order to maintain the power factor at the interface with the utility grid above limits imposed by accepted standards. The power factor limits are normally above 90%, and mainly above about 95%. The power factor correction capacitor(s) 22 is typically connected in shunt with the non-linear loads 20 . Still further, to address the significant levels of harmonic distortion in the current that may be introduced by the non-linear loads 20 , one or more harmonic filter(s) 24 , is/are connected in series with the non-linear loads 20 . A source inductance (L s ) 26 is represented in the power bus 16 as being the inductance of the power grid 14 and any interface transformer at or near the installation site, and an illustrated source resistance 27 is of similar origins.
As shown in FIG. 1 herein, as well as in FIG. 1 of the aforementioned '329 patent, the power factor correction capacitor (C pfc ) 22 and the harmonic filter(s) 24 are separate and distinct from one another. Stated another way, one may be said to be external to the other. Indeed, although the harmonic filter 24 may include a filter capacitor or capacitance in combination with one or more inductive impedance elements to provide the requisite filtering of the harmonics, such capacitor is separate from the power factor correction capacitor (C pfc ) 22 .
The prior art configuration of FIG. 1 will be further understood in the context of prior art FIG. 2 , which is substantially the same as FIG. 1 but configured to illustrate the harmonic filter 24 and the power factor correction capacitor 22 in greater detail and as separate from one another. The AC power grid and the induction power generator are collectively represented by section block 100 containing the AC source 114 , the inductive source impedance 126 , the source resistance 127 , and induction generator 110 . Correspondingly, the current to the various loads, including the non-linear loads, is represented by the current source symbol 120 . Intermediate the AC source 114 and the output load current 120 are separate section blocks 122 and 124 , representing the power factor correction capacitor 22 and the harmonic filter 24 , respectively, of FIG. 1 .
The power factor correction block 122 includes a power factor correction capacitor 22 having a detuning inductor (L det ) 30 in series therewith, and is connected across the AC source 114 and across the induction generator 110 . The inductor 30 is required to form a resonant tank so as to limit harmonic currents from flowing to the capacitor(s) and thereby causing excessive heating, which may be life-limiting.
Similarly, the harmonic filter section block 124 representing the harmonic filter 24 of FIG. 1 is also connected across the AC source 114 in a general “T” network including, more specifically, a “bridged-T”. The cross arm of the general T harmonic filter section block 124 includes several inductances arranged or depicted in series, including an input inductance (L in ) 32 shown connected at one end to the junction of the source inductance 126 or the source resistance 127 and the detuning inductance 30 , and at the other end to the cross arm of a bridged-T comprising a parallel-bridged arrangement of a further inductance (L 1 ) 34 connected in parallel with a series connection of a resistance (R) 36 and a filter inductance (L f ) 38 . The cross arm of the general T filter network is completed by the connection at the junction of inductances 34 and 38 of one end of a still further inductance (L 2 ) 40 , the other end of which is connected to one side of the non-linear load(s) represented by the current source 120 . A filter capacitor (C f ) 42 is connected at one end to the junction between the resistance 36 and the filter inductance 38 and is thereafter connected in shunt with the power source 114 and current source 120 to complete the “vertical arm” of the bridged-T filter.
While the afore-described arrangement is effective in maintaining acceptable power factor in the presence of the induction generator and of also reducing or eliminating the harmonic distortion introduced by the non-linear loads, especially as represented by the variable speed drives with diode rectifier front ends, it nonetheless comes at significant parts count and cost of equipment. More specifically, the ratings required of the filter capacitor(s) and the power factor correction capacitor(s) cause them to be relatively large and expensive. Although the insulated gate bipolar transistor switched bridge and associated control circuitry of the aforementioned '329 patent do provide a good quality of power without power factor correction and with little or no harmonic distortion, that circuitry itself comes at a significant cost or expense, such that it may not be a particularly acceptable trade-off.
Accordingly, what is needed is an arrangement in which an induction generator and associated non-linear loads are connectable to the utility power grid and operate with an acceptable power factor and minimal harmonic distortion, yet are reliable and cost effective in attaining that result.
SUMMARY
The present disclosure provides a distributed electrical power generating and utilizing system having an induction generator driven by a prime mover and requiring reactive power to operate for providing electrical power on a bus, the bus having a gross load and also being connectable to a utility power grid by a switch, such as a circuit breaker or contactor; the gross load including at least a non-linear electrical load component; and also connected to the bus is a harmonic filter having a power factor-correcting capacitor integrated therewith for collectively compensating harmonic distortion caused by the non-linear load component and for correcting power factor to compensate for reactive power required by at least the induction generator. The integrated capacitor(s) in the harmonic filter contain(s) series inductance to form a tank circuit to reduce harmful effects of harmonic currents on the capacitor life. Further, the capacitor required of the harmonic filter will, if sized appropriately, also serve as the power factor correction capacitor. Multiple such capacitors may be switched into or out of the circuit to improve dynamic voltage stability at light loading conditions. Typically, a harmonic filter having a power factor-correcting capacitor integrated therewith is provided for each phase of the power generating system.
The non-linear load component may typically include variable speed drives with diode rectifier front ends.
A process flow routine is disclosed for guiding the design of the harmonic filter with integrated power factor correction. Values for input variables such as power of the generator, power of variable speed drives, power factor of generator, power factor of grid, quality factor, resonance, anti-resonance, and source/grid inductance, resistance and % impedance are selected to calculate the requisite values for the capacitance, inductance and resistance associated with the integrated harmonic filter and power factor-correcting capacitor.
The foregoing features and advantages of the present disclosure will become more apparent in light of the following detailed description of exemplary embodiments thereof as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a simplified schematic block diagram of one phase of an exemplary electric power generation system having an induction generator powering at least non-linear loads and providing power to a power utility grid, and depicting a harmonic filter and separate power factor correction capacitor as known in the prior art;
FIG. 2 is a further depiction of the prior art system of FIG. 1 , illustrating the harmonic filter and separate power factor correction capacitor in further detail;
FIG. 3 is an illustration similar to FIG. 2 of one phase of an exemplary electric power generation system having an induction generator powering at least non-linear loads and providing power to a power utility grid, and illustrating the harmonic filter having a power factor-correcting capacitor integrated therewith in accordance with the present disclosure;
FIG. 4 is a simplified flow diagram illustrating the process and parameters for guiding the design of the FIG. 3 harmonic filter having a power factor-correcting capacitor integrated therewith in accordance with the present disclosure; and
FIG. 5 is a frequency response graph showing a filter designed with integrated power factor correction capacitor(s) vs. a filter designed with external power factor correction capacitor(s).
DETAILED DESCRIPTION
Referring to FIG. 3 , there is illustrated one phase of an exemplary electric power generation system having an induction generator powering at least non-linear loads and providing power to a power utility grid, and particularly illustrating the harmonic filter having a power factor-correcting capacitor integrated therewith in accordance with the present disclosure. It will be noted that in many respects the system of FIG. 3 is similar to or the same as that of FIGS. 1 and 2 . This is particularly so with respect to the inclusion, implied herein but not again shown for the sake of brevity, of an induction generator providing power to the non-linear loads including, for example, variable speed drives with diode rectifier front ends, and being connected, or connectable, with the utility power grid via a power bus. However, the system of FIG. 3 differs in that the harmonic filter for each phase has the power factor correction capacitor, or capacitors, integrated therewith, and thus avoids at least the cost of a separate capacitor for that latter function, as had been the case with the prior art.
Referring to FIG. 3 in greater detail, the AC power grid and the induction power generator are collectively represented by voltage source 214 and the induction generator is represented by voltage source 210 . Associated with that voltage source are a source inductance 226 and a source resistance 227 . Correspondingly, the current to the various loads, including the non-linear loads, is represented by I 0 , and is depicted as being associated with the non-linear loads represented broadly by block 220 that includes the symbol of a rectifier to represent a variable speed drive and associated diode rectifier front end, similar to 120 in FIG. 2 . Intermediate the AC voltage source 214 and the output load current 220 is a generalized T filter 224 which includes the more specific bridged-T harmonic filter 224 ′.
Although the component configuration of the generalized T filter 224 of FIG. 3 is substantially the same as that of FIG. 2 , it now integrates the component(s) and function(s) of both power factor correction and harmonic filter into this singular harmonic filter configuration. More particularly, the cross arm of the generalized T harmonic filter section block 224 includes several inductances arranged or depicted in series, including an input inductance (L in ) 232 shown connected at one end in series with the source inductance 226 and source resistance 227 and at the other end to the cross arm of a bridged-T comprising a parallel-bridged arrangement of a further inductance (L 1 ) 234 connected in parallel with a series connection of a resistance (R) 236 and a filter inductance (L f ) 238 . The cross arm of the generalized T filter network is completed by the connection at the junction of inductances 234 and 238 of one end of a still further inductance (L 2 ) 240 , the other end of which is connected to one side of the non-linear load(s) represented by the current source 220 . A filter capacitor (C f ) 242 is connected at one end to the junction between the resistance 236 and the filter inductance 238 and is thereafter connected in shunt with the voltage source 214 and the load current source 220 to complete the “vertical arm” of the bridged-T filter.
Importantly, the filter capacitor 242 is sized to serve the additional function of power factor correction, such that both the functions of harmonic filtering and power factor correction are integrated into a single capacitor, or bank of capacitors, without the costly requirement of a separate power factor correction capacitor. Principal factors in the sizing of the capacitor(s) are the power, P, of the non-linear loads and reactive power, Q, of the induction generator, etc. This capability is further facilitated by the fact that the integrated capacitor(s) 242 in the harmonic filter 224 already contains series inductance to form a tank circuit to greatly reduce the effects of harmonic currents from either the non-linear loads or the utility grid on the capacitor'(s) life. That series inductance is that depicted as the inductances 232 , 238 , and 240 in FIG. 3 . Still further, and depending on the requirement for power factor correction, one or more additional capacitors 242 ′ can be switched, as by switch 250 , into and out of connection directly in parallel with the basic filter capacitor 242 to improve voltage stability on the system at light loading conditions. More specifically, capacitors may be switched out at lighter loads, thereby reducing the reactive current provided by the capacitor and thus preventing voltage instabilities at the grid interface.
Referring to FIG. 4 , a simplified flow diagram illustrates the process and parameters for guiding the design of the FIG. 3 harmonic filter having a power factor-correcting capacitor integrated therewith in accordance with the present disclosure. The flow diagram is depicted in a very general sense, and utilizes a number of input variables to calculate the component values of the various inductances, capacitance(s) and resistance(s) that make up the general harmonic filter 224 , and especially the bridged-T portion 224 ′ of that filter. Block 460 indicates the use of input variables for generator nameplate power (PF gen ), generator nameplate power factor (PF gen ), required grid power factor (PF grid ), and power to variable speed devices (P vsd ) in the calculation or computation at block 464 of values for the reactive power for the generator and for the grid (Q gen and Q grid, respectively). Further input variables, seen in block 468 , include the quality factor, Q, and the resonance and anti-resonance frequencies, designated Res and Anti, respectively. The resonance and anti resonance frequencies are the frequencies at which the filter is designed to get the appropriate attenuation of harmonics. These input variables, in combination with the calculated values of Q gen and Q grid from block 464 , are utilized at block 472 to calculate component values for the filter capacitor (C f ) 242 , the filter inductance (L f ) 238 , the inductance (L 1 ) 234 , and the resistance (R) 236 . Still further, input variables, seen in block 476 , include the source inductance (L s ) 226 , the source resistance (R s ) 227 , and % Z, which is the measure of grid “stiffness” and is an important factor in sizing the filter. These input variables, in combination with the calculated values of C f , L f , L 1 and R from block 472 , are utilized at block 480 to calculate component values for input inductance (L in ) 232 and the further inductance (L 2 ) 240 . The component values calculated in blocks 472 and 480 are then provided on line 482 to a function block 484 at which is conducted a Bode or frequency response and circuit simulation analysis. If that analysis provides desired results, the process is complete, as indicated by the Finish arrow 486 . If the response analysis is not within the desired range, adjustment is made to one or more of the variables in blocks 468 and/or 476 , as indicated by the Adjust arrow or line 488 .
The array of equations that follows is intended to supplement the foregoing general description of the FIG. 4 flow diagram for guiding the design of the FIG. 3 harmonic filter having a power factor-correcting capacitor integrated therewith. Those equations are:
P grid = P gen - P vsd ( Eq . 1 ) Q grid = P grid tan ( cos - 1 ( PF grid ) ) ( Eq . 2 ) Q gen = P gen tan ( cos - 1 ( PF gen ) ) ( Eq . 3 ) C f = Q gen - Q grid ω V LL 2 ( Eq . 4 ) L f = 1 C f ω s 2 ( Eq . 5 ) R = Q s ω s C f ( Eq . 6 ) L 1 = ( ω p R C f Q p - 1 ) L f ( Eq . 7 ) L in = ( Z % V LL 100 ω 3 I vsd ) - L s ( if L in < 0 , then L in = 0 ) ( Eq . 8 ) L 2 = L in ( if L in < 0 , L 2 = L s ) , ( Eq . 9 )
where the parameters not mentioned earlier but included in the equations include: V LL , which is the line-to-line voltage, which in north America is 480V; Z % , which is the percentage of impedance from a normalized (per unit) set and is the measure of grid “stiffness”, and is an important factor in sizing the filter; √3I vsd , where I vsd is the current to the variable speed device(s), and the square root of 3 is used because the illustrated system is 3 phase and when you compute power using V LL it requires the square root of 3. Further still, Q p and Q s are the series and parallel quality factors corresponding to the resonance and anti resonance points. ω s and ω p are the series and parallel (resonance and anti resonance) frequencies. Note that the series resonance is the higher frequency (lower impedance) portion of FIG. 5 , while the parallel resonance is the lower frequency (higher impedance).
Referring briefly to FIG. 5 , there is illustrated a frequency response graph showing a filter designed with integrated power factor correction capacitor(s) vs. a filter designed with external power factor correction capacitor(s). The resonance and anti resonance frequencies are selected such that the filter design yields appropriate attenuation of the harmonics. Most significantly, using the design process described with reference to FIG. 4 and yielding the integrated harmonic filter and power factor correction functions of FIG. 3 , it is to be noted in FIG. 5 that the performance of the system having the disclosed integrated PFC performs very nearly the same as a system for which the PFC is external to (or separate from) the harmonic filter.
Although the disclosure has been described and illustrated with respect to the exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made without departing from the spirit and scope of the invention.
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A distributed electrical power generating and utilizing system includes an induction generator driven by a prime mover requiring reactive power to operate for providing electrical power on a bus. The bus has a gross load and is also connectable to a utility power grid by a switch. The gross load includes at least a non-linear electrical load component, typically including a variable speed device and associated diode rectifier front end. The bus includes a harmonic filter having a power factor-correcting capacitor integrated therewith for collectively compensating harmonic distortion caused by the non-linear load component and for correcting power factor to compensate for reactive power required by at least the inductive generator.
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FIELD OF THE INVENTION
The present invention refers to a plant and a method for supplying machines with dyes for the continuous dyeing of textile materials.
BACKGROUND OF THE INVENTION
It is well known to those skilled in the art that the continuous dyeing of textile materials such as carpets, fabrics and unwoven materials, is operated by deeping these materials in a selected dyeing bath and ensuring a continuous and constant level of the bath within the same dyeing machine which includes the means for feeding the material under treatment while the bath is supplied with dye. The dyeing bath consists of a solution comprising a set of components such as chemicals, auxiliary and dyeing products, as well as water, in proportions corresponding to the formulations or recipes which are each time chosen, the same bath being prepared in suitable containers outside the machine which is continuously supplyed therewith.
The solutions to be fed to the dyeing machine are prepared mostly manually, which is possibly a cause for some inaccuracy in the metering of components. This may heavily reduce the possibility of having baths comprising solutions with steady and periodically restored characteristics, contrary to what is normally required for carrying out this type of treatment.
An automated plant for the preparation of solutions intended for dyeing machines is disclosed in the European Patent No. 203182. This plant is so constructed as to allow the flow of dyeing solutions from a plurality of stocking tanks, to be diverted among a plurality of different outlets. Besides, associated to each of said tanks is a close loop line for continuously recirculating the relevant solutions. However, dispite the structural and operational complexity of this known plant, it is not entirely excluded that the solutions circulating within the relevant conduits may become contaminated, before being fed to the machine using them, as they enter in contact with solutions of different titre circulating within the same conduits.
SUMMARY AND OBJECTS OF THE INVENTION
The main object of the present invention is to provide a plant allowing the fully automatic preparation and feeding of baths to dyeing machines with no possibility for the solutions to be contaminated before being delivered to the machine using them.
This result has been achieved, according to the invention, by providing an apparatus or plant having a plurality of dye tanks. A metering/dissolving device is connected to the plurality of dye tanks for preparing different dye solutions in each of the plurality of dye tanks. The dye solutions are prepared from dye products in the form of powders and/or granules. A plurality of primary auxiliary tanks are provided for holding chemical and auxiliary solutions that may be desired in the preparation of the dye solutions. An auxiliary manifold selectively receives the chemical and auxiliary solutions from the primary auxiliary tanks and then feeds the combination of chemical and auxiliary solutions to auxiliary tanks which include motor driven stirrers. The auxiliary manifold has a connection for receiving washing liquid to clean the auxiliary manifold once the proper amounts of chemical and auxiliary solutions have been selected and transferred to the auxiliary tanks. The washing liquid used is one of the ingredients of the dye solution and the washing liquid used to clean the auxiliary manifold is also fed to the auxiliary tanks.
A plurality of pumps are connected to each of the dye and auxiliary tanks for removing a respective solution from a respective tank. A main manifold is connected to a plurality of pumps and receives a solution from the plurality of pumps. A mixer arranged in the manifold mixes the solutions in the manifold and from there the mixed solution is fed to a dye machine which consumes the dye. A programable control unit is connected to the pumps and the metering/dissolving device in order to selectively, continuously, and automatically prepare and supply dye to the machine consuming the dye.
The present invention makes it possible to always ensuring, in a fully automatic way, the most accurate dyeing of textile materials under work, without any contamination of the solutions circulating within the conduits upstream of means provided for ultimately mixing the same solutions. Moreover, as the final mixing of the solutions to be fed to the dyeing machine is operated just upstream of the latter, it is possible to supply the same machine with different solutions which exhibit long lasting characteristics of immiscibility and which, accordingly, cannot be stored being mixed beforehand. It is also possible to achieve a significant reduction of electric power, thanks to the fact that the water used for washing the conduits and the means for dissolving the powdered and/or granulated dyes may be used also for achieving the final titre of the solutions preparared in the respective tanks. The plant according to the invention is of relatively simple construction and is able to accomodate a high number of tanks for dye solutions, chemicals and auxiliary products at different strengths thereby widening its production capacity.
These and other advantages and characteristics of the invention will be best understood by anyone skilled in the art from a reading of the following description in conjunction with the attached drawings given as a practical exemplification of the invention, but not to be considered in a limitative sense, with
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically a possible embodiment of the plant according to the invention;
FIG. 2 shows schematically a system for controlling and operating the plant of FIG. 1;
FIG. 3 shows schematically a plant according to the invention in relation to a further embodiment;
FIG. 4 shows schematically a system for controlling and operating the plant of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reduced to its basic structure, and reference being made to the figures of the attached drawings, a plant according to the invention comprises in combination:
a plurality of tanks ( 1 ) disposed in a first station (A) for stocking chemicals and auxiliary products in a liquid state: each of said tanks ( 1 ) exhibiting an outlet conduit ( 3 ) on which a valve ( 4 ) is inserted whose outlet is connected to a common manifold ( 2 ) collecting the products discharged from said tanks ( 1 ), said manifold ( 2 ) being also associated to a conduit ( 31 ) admitting water for the washing of same manifold and feeding a positive-displacement pump ( 6 ) provided with relevant flowmeter ( 7 );
a plurality of mixers ( 5 ), provided in a second station (B) located downstream of said first station (A), which are supplied with the products exiting from the manifold ( 2 ) via corresponding conduits ( 19 ) which branch off from corresponding three-way valves ( 8 ) to which the products exiting from the pump ( 6 ) are made to arrive, the mixers ( 5 ) being also associated to a water-feeding line ( 41 ) with relevant meter ( 42 ) and shut-off valves ( 43 ); said mixers being schematically represented in the figures of the attached drawings. In particular, the figures show the tanks containing the liquid products coming from the manifold ( 2 ) and relevant motor-driven stirrers with inclined axes and level gauges;
means or device ( 12 , 13 ) in a third station (C) for metering and dissolving the powdered or granulated dyes for the obtainment of dyeing solutions in preset strengths to be fed to corresponding containers ( 14 ) of a fourth station (D) via a conduit ( 17 ) provided with a plurality of three-way valves ( 16 ) from each of which a conduit branches out for feeeding each of said containers ( 14 ), also leading to same containers being a plurality of conduits which admit water coming from a corresponding line ( 22 ) provided with relevant flowmeter ( 23 ) and a three-way valve ( 24 ) for each one of containers ( 14 ): the said means ( 13 ) for dissolving the powdered or granulated dye being supplied with the necessary water via a corresponding conduit ( 20 ) with flowmeter ( 21 ) and delivering the thus obtained dyeing solutions by means of a positive-displacement pump ( 40 ) to which the conduit ( 17 ) is connected; the containers ( 14 ) of station (D) being schematically represented likewise the containers ( 5 ) of station (B). In particular, the figures show schematically the said containers, stirrers and level gauges associated thereto;
a manifold ( 26 ) inside which a screw feeder ( 27 ) is installed for simultaneously feeding and mixing the incoming liquid products, which manifold ( 26 ) receives the liquids coming out from the containers ( 5 ) of said second station (B) and from containers ( 14 ) of said fourth station (D), and may also receives water from a tank ( 340 ) provided with respective outlet conduit ( 34 ) connected to the manifold ( 26 ): The supply of manifold-mixer ( 26 ) with liquids exiting from said stations (B) and (D)
and delivered to corresponding outlet conduits ( 28 )—and with the water from conduit ( 34 ) being ensured by corresponding positive-displacement pumps ( 29 ) to which respective flowmeters ( 30 ) are associated.
According to the embodiment illustrated by way of example in FIG. 1 of the attached drawings, the containers ( 5 ) of station (B) wherein the solutions are prepared with the products (such as organic acids, inorganic bases, surfactants, softners and/or other auxiliary products) stored inside tanks ( 1 ) of stations (A), lead to a single conduit ( 28 ) for feeding the manifold ( 26 ): upstream of the respective pump ( 29 ), the contents of containers ( 5 ) all flow into a three-way valve from which said single conduit ( 28 ) branches off. The containers ( 14 ) of station (D), wherein the dyeing solution are prepared, are disposed in groups of three units, so that each group will correspond to a colour and each unit to a preset stregth of the relevant dye. The outlet of each of the three tanks ( 14 ) of each group of station (D) exhibits a corresponding shut-off valve ( 37 ), the outlets of all said valves ( 37 ) being connected to the pump ( 29 ) of the relevant group.
Provided on the outlet of manifold ( 26 ), that is, intermediate between the manifold ( 26 ) and the machine (M), is a discharge section ( 32 ) to allow the products present therein to be drained off as necessary without reaching the machine (M). The machine (M), shown only schematically in the figures of the accompanying drawings, is of conventional type in which the material to be dyed is made to advance continuously at a preset speed as the dyeing bath is being fed. The advancement speed of the material to be dyed is adjusted, to meet specific requirements of the dyeing program in progress, by means of regulation and control units to be described later on.
The opening and closing of each valve of the plant are automatically controlled by an electronic programmable unit (U) associated to an electronic file of recipes (AR) storing the colour recipes, that is, the formulations by weight, of the solutions to be prepared within both stations (B) and (C) , as well as the water amounts to be delivered through each of the water-feeding conduits. The plant's valves are therefore of electronically and electromechanically-operate type. Associated to each pump of the plant is a corresponding encoder, not shown for the sake of clarity in the figures of the attached drawings. Each encoder is connected to said unit (U) for controlling the instantaneous velocity of the motor of each pump in the plant. Similarly, each flowmeter of the plant is connected to the programmable unit (U). It will be appreciated that said flowmeter are of a type able to generate electrical signals corresponding to the flowrates to be measured.
According to a second embodiment of the present invention, and reference being made to FIGS. 3 and 4 of the accompanying drawings, the products within the tanks ( 1 ) may be delivered directly to the manifold-mixer ( 26 , 27 ) instead of transiting through said pre-treatment station (B). In this case, the manifold ( 2 ) is omitted and each tank ( 1 ) is connected directly to the manifold-mixer ( 26 , 27 ) via the respective outlet conduit. Fitted on each of these conduits is a corresponding positive displacement pump ( 10 ) with a flowmeter ( 11 ) and a solenoid valve ( 100 ) associated to the programmable unit (U).
The powdered or granulated dyes metering and dissolving group ( 12 , 13 ) of may be of any suitable type. For example, it may be of a type disclosed in the U.S. Pat. No. 5,642,940 (corresponding to the document IT PT/95/A/002), to which reference can be made for a description in greater detail.
With reference to the embodiment illustrated in the drawing of FIG. 1 —and assuming that the machine (M) is to receive a dyeing bath including solutions from both stations (B) and (D)—the operation of the plant according to the invention is as follows. As far as the preparation of solutions with auxiliary products being stored in the tanks of station (A) are concerned, these products, being selected according to a preset formulation, are fed each time to the manifold ( 2 ) through an aperture in the corresponding valves ( 4 ) and for a time predetermined in relation to the amount of same products to be removed. Afterwards, the products in question are delivered via the pump ( 6 ) to respective containers ( 5 ) in the station (B) by passing through the flowmeter ( 7 ). The transit lines of the products withdrawn each time from the tanks ( 1 ) are correspondingly configured by the valves ( 8 ) whose ways are open or closed depending on the corresponding and programmed opening and closing signals emitted by the central unit (U). Also arriving to said containers ( 5 ) is the water for washing the manifold ( 2 ): the washing of this manifold being operated—subsequently to the discharge of the products from the tanks ( 1 ) each time selected—by means of the unit (U) and in relation to the formulation to be obtained. The amount of water which arrives to the selected containers ( 5 ) through the manifold ( 2 ), is measured by the meter ( 7 ). After the selective removal of products from the tanks ( 1 ) of station (A) and the subsequent washing of manifold ( 2 ), if X indicates the amount of water necessary for preparing the required solution in the container ( 5 ) each time selected, and Y indicates the amount of water required for washing the manifold ( 2 ) and delivered into said container, the amount of water necessary to titrate the solution, as established by the program, will be equal to X-Y and will be withdrawn from the line ( 14 ). The solution thus obtained within the container ( 5 ) in question (wherein the relevant motor-driven stirrer is made to operate) is then fed to the manifold-mixer ( 26 , 27 ) by the relevant pump ( 29 ) and quantified by the corresponding meter ( 30 ).
As for the preparation and delivery of the dyeing solutions, the procedure is as follows.
The solutions prepared with the powders (or granules) dissolved in the unit ( 13 ) of station (C) and with the water from the conduit ( 20 ) are fed to the tanks ( 14 ) of station (D), in a sequence preset in relation to the selected work program and which provides, in general, for each group of tanks in the station (C), for the preparation and delivery of solutions prepared with the same powders (or with the same granules) but in different strengths. The selection of the tanks ( 14 ) intended to hold the dyeing liquids is operated by the central unit (U) by activating, in a selective and programmed manner, the valves ( 16 ) of conduit ( 17 ) which connects the means ( 12 , 13 ) of station (C) to the tanks ( 14 ) of station (D).
Following the preparation of each dyeing solution in the station (D), there is operated the washing of the dissolution unit ( 13 ) by the water coming from conduit ( 20 ), the amount of such water being assessed by the meter ( 21 ). The water used for washing the unit ( 13 ) is then fed to the same containers ( 14 ) which have received the last prepared solution. The amount of this washing water is taken into account, likewise in the preceding case, when preparing the final solutions in the tanks ( 14 ) of station (D). In other words, if Y′ is the amount of water utilized for washing the dissolution unit ( 13 ) and X′ is the amount of water necessary to obtain the solution with the required strength within the tank ( 14 ), which has received the product prepared in the dissolution unit ( 13 ), the amount of water fed to said tank ( 14 ) via the conduit ( 22 ) will be X′-Y′.
It will be evident that the electrical signals, each time generated by the flowmeters of the plant, are stored by the central unit (U) upon each washing cycle together with the relevant amounts of washing water as necessary to carry out the above computations.
All the plant's positive-displacement pumps are intended for delivering the products going through the respective lines, as well as for regulating the flow thereof. The flow adjustment is operated by controlling the speed of the respective motors. The different solutions thus fed to the manifold-mixer ( 26 , 27 ) and then to the machine (M) may also be of a type unsuited for maintaining a long-term mixing condition owing to the fact that—soon after being mixed by the means associated to the manifold ( 26 )—they are immediately utilized by the machine (M).
Moreover, the present plant makes it possible to rationalize the consumption of water in a particularly effective way.
All this brings about lower consumptions and a higher economy of the plant.
Practically, all the construction details may vary in any equivalent way as far as the shape, dimensions, elements disposition, nature of the used materials are concerned, without nevertheless departing from the scope of the adopted solution idea and, thereby, remaining within the limits of the protection granted to the present patent for industrial invention.
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Plant for supplying machines with dyes for the continuous dyeing of textile materials, comprising means for preparing a dyeing bath, the dyeing bath consisting of a mixture of dyeing products, chemicals and/or auxiliary products in aqueous solution, said means comprising an apparatus ( 12, 13, 14 ) for the preparation of dyeing solutions in preset strengths starting from said dyeing products, a plurality of tanks ( 1 ) for said chemicals and/or auxiliary products to which one or more pumps ( 6; 10 ) are associated for the removal of respective products, and an array of conduits for water supply. The outlets of said means are connected to a manifold ( 26 ) downstream of which is a dyeing machine (M) to be supplied, and to which manifold ( 26 ) means ( 27 ) are associated for mixing the products arriving thereat: the means for the preparation of the dyeing bath being associated to a programmable electronic unit (U). (FIG. 2 ).
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 102007052974.2, filed Nov. 7, 2007, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present invention relates to a restraint system having at least one airbag module and an airbag having at least one chamber for front vehicle occupants in a vehicle, a space at a distance to the windshield between dashboard and front vehicle occupants being fillable using the airbag by unfolding. The invention also relates to a production method of a restraint system.
BACKGROUND
Situating restraint systems in a dashboard on the passenger side of a vehicle is known. The restraint system is usually implemented as an airbag module and is used to restrain the upper body, in particular the chest area including the head, from a hard impact on the dashboard in case of a crash. Furthermore, the following prior art is known.
For example, EP 0 861 762 B1 describes a passenger airbag having an inflatable airbag which is divided into three separate inflatable chambers, a central and two lateral chambers. US 2005/0161918 A1 describes an airbag device for front vehicle occupants having an upper and a lower inflatable section. US 2006/0163848 A1 describes an airbag having an upper lengthened section, which covers an A-column and thus protects the head of the vehicle occupant in case of crash. DE 199 04 100 A1 describes an airbag configuration having a space in front of the passenger seat which is free of the dashboard. The airbag is situated in a centrally situated console below the windshield or on an A-column for the passenger or additionally also for the driver having a diagonal movement direction in each case.
In view of the foregoing, it is at least one object to provide a restraint system which improves the vehicle comfort and the passive safety according to the current and future requirements and provides more interior space. In addition, other objects, desirable features, and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.
SUMMARY
The at least one object, other objects, desirable features, and characteristics, are achieved in that the airbag module is fastenable to a vehicle body structure forming the front vehicle interior, the restraint system unfolding in the inflated state from a dashboard-free space in the direction of the vehicle occupant. This has the advantage that the vehicle interior in front of the vehicle occupant may be designed variably, thus increasing the vehicle comfort. The restraint system is situated as far forward as possible in the vehicle interior. A larger vehicle interior usable in manifold ways is thus provided. The airbag module having an airbag may protect a front vehicle occupant just as well as a typical airbag according to the prior art, which is located at a significantly shorter distance directly in front of the front vehicle occupant in the dashboard. The airbag having at least one chamber or, in the event of multiple chambers, having a main chamber is advantageously inflated in the vehicle longitudinal direction. A direct and short restraint path is thus implemented opposite to the main forward movement of the vehicle. A compensated inflation procedure diagonally or transversely to the vehicle longitudinal direction is avoided.
The restraint system is advantageously situated on a windshield crossbeam, which supports a bottom side of the windshield, or a splash board on the vehicle body structure forming the front vehicle interior. The windshield crossbeam or the splash board has the required rigidity and strength to withstand the forces generated by the gas generator of the airbag.
The restraint system is situated on the passenger side. This has the advantage that the otherwise typical dashboard, which occupies a large space in the area in front of the passenger, may essentially be left out on the passenger side and its free space may be designed individually according to the requirements of the customer. The vehicle interior in front of the passenger no longer necessarily has to have a dashboard to integrate the typically housed passenger airbag as a restraint system.
The airbag is thus preferably essentially implemented as enlarged by the depth T of a dashboard exclusively situated on the driver side. The airbag has a so-called thorax chamber. A thorax chamber essentially restrains the chest and head area of a front vehicle occupant from a hard impact with vehicle interior parts. The airbag module is dimensioned overall corresponding to such an enlarged airbag. An airbag module having an airbag according to the invention may thus be situated very far forward to the windshield and protect the front vehicle occupants in a typical way.
According to a preferred embodiment, the airbag is implemented as lengthened by approximately 300 mm to 500 mm depending on the vehicle type. This lengthening is the relocation of the airbag module toward the area of a windshield base in relation to a typical airbag module configuration. A windshield base is to be understood as a windshield crossbeam, which may also comprise a splash board.
According to a further preferred embodiment of the invention, the airbag has a lateral extension for cushioning in relation to one or more lateral A-columns. This is important because current aerodynamically designed vehicle bodies have increasingly implemented the A-column with a small distance to the head. The lateral extension for cushioning in relation to an A-column is also important in particular because, according to an embodiment of the present invention, the dashboard is essentially implemented on the driver side up to the central console and is not provided on the passenger side, so that the passenger may shift his seat very far forward in this area and may thus independently decrease the head distance to the A-column. To be protected in case of a frontal crash with and without lateral energy introduction, a lateral extension on the airbag is therefore extremely advantageous as an additional lateral A-column cushion.
A further especially preferred embodiment of the invention has an airbag having an upper extension for cushioning in relation to a front roof frame structure. This additional clearly pronounced upper extension is important essentially for the same reasons as the extension for cushioning in relation to an A-column, on the one hand because the modern aerodynamic vehicle body structures currently run close to the head and on the other hand because the passenger may independently move the head distance to the front roof frame further forward, because the passenger shifts the seat further forward than is the case in typical vehicles having a dashboard on the passenger side.
To protect the passenger in relation to the possibly closer central console because of a passenger seat adjusted forward, the airbag preferably has a lateral extension for cushioning in relation to the central console. To also protect the foot extremities of a front vehicle occupant, the airbag has a lower extension for cushioning foot extremities.
According to a further preferred embodiment of the invention, a separate leg airbag module is situated for the foot area, which is particularly coupled to the thorax chamber for activation with the airbag module. A separate leg airbag module has the advantage that the foot area is also rapidly protected in case of a frontal crash, because the build up of a restraint cushion is to occur very rapidly, in particular in fractions of a second.
According to a further preferred embodiment, the airbag has a thorax chamber and/or a head chamber. Head and thorax are the preferred body areas which are to be restrained using an airbag. The other body areas are restrained using a belt system.
According to a further preferred embodiment of the invention, above all for countries in which using seatbelts is not required, the airbag is implemented in such a way that the thorax chamber of the airbag, in particular together with the airbag of the leg airbag module, envelops the entire front contour of a vehicle occupant. A front vehicle argument is thus restrained in case of a frontal crash of the vehicle, even if his safety belt is not buckled.
In a further preferred embodiment, the airbag is implemented as a multi-chamber airbag, this has the advantage that the airbag unfolds and is inflated in stages. In a special embodiment, the multi-chamber airbag has tear seams which partition off the individual chambers. The tear seams are designed in such a way that they tear open from the velocity of the inflowing gas inflating the airbag and also inflate the individual chambers. In another embodiment, overflow openings may alternatively or additionally be provided in the multi-chamber airbag.
In a special embodiment, the airbag has catch straps, this has the advantage that the airbag or parts of the airbag may be kinematically controlled and its extension may be exactly redirected in regions.
According to a further preferred embodiment, the airbag module has a gas generator having one or more triggering stages.
According to a further preferred embodiment, the airbag module has a variable continuous gas generator.
According to a special embodiment, the airbag has at least one or more light airbag fabrics or different light airbag fabrics for each airbag section. This has the advantage that the airbag, as a function of its strain as well as airbag/chamber pressures, is lightly retained and occupies the least possible packing volume of the folded airbag in the vehicle.
Because the volume of the airbag according to an embodiment of the invention is very large, it is especially expedient to fold the airbag in a chamber under vacuum. This additionally reduces the packing volume by approximately 30%.
The at least one object, other objects, desirable features, and characteristics, are also achieved by a production method of a restraint system having the features described above in that, for a single chamber or multi-chamber airbag, extensions on the airbag are tucked therein to fold together the airbag.
It is obvious that the features cited above and to be explained hereafter are usable not only in the particular specified combination, but rather also in other combinations.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and
FIG. 1 shows a perspective view of a front vehicle interior having a restraint system according to an embodiment of the invention;
FIG. 2 shows a perspective view of a front vehicle interior having a dashboard on the driver side;
FIG. 3 shows a schematic cross-sectional view of the restraint system according to an embodiment of the invention;
FIG. 4 shows a perspective view of the restraint system according to an embodiment of the invention having an extension on the thorax chamber;
FIG. 5 shows a perspective view of the restraint system according to an embodiment of the invention having at least three extensions on a thorax chamber; and
FIG. 6 shows a perspective view of a completely inflated airbag.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background and summary or the following detailed description.
FIG. 1 shows a perspective view of a dashboard 1 , which extends over the driver and passenger sides and projects on both sides essentially equally far from a windshield (not shown) into a vehicle interior. The restraint system 3 according to an embodiment of the invention is located behind a panel 2 of a windshield crossbeam in particular on the passenger side and optionally also on the driver side. The restraint system 3 comprises an airbag module having a gas generator and an airbag, which is situated concealed behind a cover 4 . The cover 4 is torn open upon detection of an accident and the airbag is inflated to protect the front passenger. The configuration of an airbag module is fastenable to the windshield crossbeam, which supports the windshield on the bottom side, and/or to a front vehicle body structure which follows the external vehicle body contour and forms the front vehicle interior.
FIG. 2 shows a perspective view of a special design of the dashboard 1 . The dashboard 1 is essentially only implemented on the driver side, including the central console 17 . The dashboard 1 has been left out on the passenger side. The vehicle body structure forming the front vehicle interior in front of the passenger seat, which comprises a splash board 15 , a windshield crossbeam 6 , and a front side wall, is covered by a simple panel 2 , which does not significantly project into the inner chamber.
As is obvious from FIG. 2 , an enormous space increase results on the passenger side. The passenger may thus shift the passenger seat extremely far forward into the depth T of the dashboard 1 . Dispensing with the dashboard 1 on the passenger side thus also provides a very great leg freedom for the passenger. Distances from the passenger to a hard vehicle body structure, such as an A-column (not shown), which may also comprise multiple A-columns, and a front roof frame structure, are thus significantly decreased. The distance to the central console 17 may also be shorter. The path from the airbag is simultaneously enlarged if the passenger sits at the level of the driver, because the airbag module 3 is situated relocated further forward in the range from approximately 300 mm to approximately 500 mm in relation to typical vehicles. According to an embodiment of the invention, the airbag and the entire airbag module 3 are adapted to this altered vehicle interior design. The airbag protects the passenger, as shown in the following figures, in especially hazardous accident situations, which result from the altered vehicle interior design. The altered vehicle interior design has the advantage of weight reduction, cost savings, and consumption and CO2 emission reduction.
FIG. 3 schematically shows the vehicle interior on the passenger side in cross-section, having a schematically shown passenger in two seat positions I, II. In a first seat position I, in which the passenger has shifted the passenger seat extremely far forward, and in a second seat position II, in which the passenger seat is situated approximately at the level of the driver seat, and is typically occupied in vehicles which have a dashboard 1 projecting into the vehicle interior on the passenger side, as shown in FIG. 1 .
The restraint system 3 is situated on an external windshield crossbeam 6 . The restraint system 3 comprises, in the special embodiment shown in FIG. 3 , two airbag modules 7 , 8 . The airbag module 7 is housed in a trough which is open on top. The airbag module 7 comprises a large airbag 9 , enlarged by the depth T of the dashboard 1 , which is to restrain the thorax and the head of the passenger. A further airbag extension 10 is implemented on the airbag 9 to support the head of the passenger on the front roof frame structure 11 . This is important, because the passenger is seated significantly closer to the front roof frame structure 11 in the seat position I, as shown in FIG. 3 .
The airbag 9 is located in a folded state behind a panel 2 of the windshield crossbeam 6 . Upon triggering of the airbag module 7 , a cover 4 is folded against the windscreen 12 by tearing open of the panel 2 . And the airbag 9 is guided parallel to the windshield into the passenger interior.
As a special design, FIG. 3 shows a leg airbag module 8 , which is fastened to the windshield crossbeam 6 from below. The panel 2 of the windshield crossbeam 6 also covers the leg airbag module 8 . The leg airbag module 8 is used to support and protect the lower extremities of the passenger and in particular protects the knee and foot areas of the passenger. The lower extremities are placed very far into proximity to the windshield crossbeam 6 in the seat position I. The airbag module 7 and the leg airbag module 8 are coupled to one another for activation in case of a crash. They are thus triggered essentially simultaneously.
FIG. 4 shows the restraint system 3 according to an embodiment of the invention in a perspective design having an inflated airbag 9 , a further airbag extension 13 being implemented on the side on the airbag 9 . The airbag extension 13 is used to cover the A-column, which may possibly comprise two columns, an A1 and an A2 column. The restraint system 3 may thus also be referred to as a so-called “corner airbag”. The corner airbag covers the entire inner vehicle corner of the passenger side and offers a protection potential for a frontal impact and additionally for superimposed angled crashes (angled impact), i.e., for the cases in which the occupants are moved by the lateral energy introduction in the direction of the A-column, but a possible laterally provided head airbag is not triggered by the system, because the corresponding sensors do not recognize a side crash.
FIG. 5 shows the restraint system 3 according to an embodiment of the invention in a perspective view according to the cross-sectional view of FIG. 3 . In FIG. 5 , the cover 4 , which covers the airbag module 7 , is folded open and the airbag 8 , which forms a thorax chamber, is inflated. An airbag extension 10 , which supports the head against the upper windshield and the front roof frame structure (not shown in this figure) and possibly against the area of the roof adjoining the roof frame, is also shown. The airbag 9 , which is implemented as a single-chamber airbag, has lateral airbag extensions 10 and 13 , which are tucked into the airbag 9 during the production of the restraint system 3 to fold together the airbag 9 . As described in FIG. 4 , an airbag extension 13 is located on the airbag 9 to protectively cover the corner to the A-column.
FIG. 5 also shows the leg airbag 14 resulting from the leg airbag module 8 shown in FIG. 3 . The leg airbag 14 protects the lower extremities in relation to the hard front vehicle body structure of the vehicle interior, which is implemented above all by a splash board 15 . The airbag 9 may also be implemented as a multi-chamber airbag and have overflow openings to the airbag extensions 13 and 10 and also additional tear seams to the airbag extensions 10 and 13 .
FIG. 6 shows a perspective view of a further alternative embodiment of the restraint system 3 having a main chamber, the so-called thorax chamber, which implements the airbag 9 , and having airbag extensions on four sides which are significantly enlarged and expanded in relation to the prior art. The leg airbag 14 is attached directly to the airbag 9 in this special embodiment. A further airbag 16 offers an impact protection for the passenger in relation to the central console 17 . The airbag 9 is clearly visibly implemented as enlarged in depth according to an embodiment of the invention in relation to the previously known prior art in this figure, because the airbag is fastened to the windshield crossbeam 6 . The airbag 9 may advantageously completely envelop a front contour of the passenger and thus supports the belt system significantly better. In particular, the representation in drawing of all figures is referred to as essential for the invention. The figures only show a schematic illustration, which is not to scale.
While at least one exemplary embodiment has been presented in the foregoing summary and detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing detailed summary and description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents.
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A restraint system is provided that includes, but is not limited to at least one airbag module having an airbag having at least one chamber for front vehicle occupants in a vehicle, a space at a distance from the windshield between dashboard and front vehicle occupant being fillable using the airbag by unfolding. To improve the vehicle comfort and the passenger safety according to the current and future requirements and provide more interior space, the airbag module is fastenable to a vehicle body structure forming the front vehicle interior, the restraint system being implemented using an airbag enlarged by a depth (T) of a dashboard.
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RELATED APPLICATION
[0001] The present application is continuation of U.S. patent application Ser. No. 13/160,407 filed Jun. 14, 2011, which claims the benefit of French Application No. 10/54699 entitled “Autonomous Intracardiac Capsule And Its Implantation Accessory” and filed Jun. 14, 2010, both of which are hereby incorporated by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to “active implantable medical devices” as defined by the 20 Jun. 1990 Directive 90/385/EEC of the Council of the European Communities, particularly to devices that continuously monitor a patient's heart rhythm and deliver to the heart, if necessary, electrical stimulation, resynchronization, cardioversion and/or defibrillation pulses in response to a rhythm disorder detected by the device, and even more particularly to the implantation of autonomous capsules that are implanted in a heart chamber with no physical, wired connection to a remote device, for remote monitoring of the patient.
BACKGROUND
[0003] Autonomous capsules, also referred to as “leadless capsules,” including without limitation autonomous intracardiac capsules (collectively hereinafter referred to as a “capsule”), are distinguished from wired electrodes and sensors that are placed at the distal end of a lead, and connected by a conductor traversing the length of the lead to a device connected at the opposite (proximal) end of the lead. Such capsules are, for example, described in US Patent Publication No. 2007/0088397 A1 and PCT Publication WO 2007/047681 A2 (Nanostim, Inc.) and US Patent Publication No. 2006/0136004 A1 (EBR Systems, Inc.).
[0004] These capsules are usually cylindrical structures having a long axis and a diameter. They are usually attached directly to the heart tissue by a projecting helical anchoring screw. The anchoring screw axially extends from the cylindrical body of the capsule and is designed to penetrate the heart tissue by screwing into the implant site.
[0005] Of course, to enable data exchange with a remote device, such capsules incorporate a transmitter/receiver for wireless communication with the remote device. A remote device in this context may be an active implantable medal device (e.g., a housing of stimulation pulse generator) or an external device such as a programmer or other device for monitoring a patient.
[0006] The capsule can also incorporate a sensor to locally measure the value of a parameter such as, for example, the oxygen level in the blood and/or the acceleration of the heart wall. These capsules can also be detection/stimulation capsules with means to collect depolarization potentials of the myocardium and/or deliver pacing pulses to the site where the capsule is implanted. Such a detection/stimulation capsule then includes an appropriate electrode, which can be, for example, an active portion of the anchoring screw.
[0007] In general, the capsule may be an epicardial capsule, attached to the outer wall of the heart, or an endocardial capsule, attached to the inner wall of a ventricular or an atrial cavity. However, It should be understood that the present invention is not limited to a particular type of capsule, and it applies equally to any type of capsule, regardless of its functional purpose.
[0008] In the case of an endocardial capsule, the difficulty of implantation is increased because the implantation path involves going through the peripheral venous system. With the assistance of fluoroscopy, the capsule may be directed to a selected implant site, a known method that is both precise and perfectly secure. Once the implant site is reached and the capsule is anchored in the wall, the operator may then operate the “release” of the capsule, and disconnect it from an associated implantation accessory.
[0009] US Patent Publication No. 2009/0204170 A1 (Cardiac Pacemakers, Inc.) describes a capsule for electrical stimulation and an accessory tool for its implantation, in which the capsule is guided by a catheter to the implant site within a directing tube pressed against the heart wall, and then progressively screwed into the heart wall by a driving stylet extending into the lumen of the catheter.
[0010] The general acceptance by persons of ordinary skill in the art of the use of endocardial capsules relies on an ability to provide a delivery system that is capable of securing the implantation of these capsules, according to the following:
[0011] An implantation procedure similar to current practice, allowing practitioners to make use of well-known and well-controlled lead manipulation gestures: e.g., subclavian puncture, insertion and manipulation of a catheter through preformed stylets during an approach to the selected implantation site, fixation with screws or tines, etc.;
[0012] Standard environment in the operating room;
[0013] Limiting the risk of “carotage” of tissue due to an excessive tightening that may damage or, even worse, puncture the wall (especially in the case of implantation in a thin wall such as the atrial septum);
[0014] Possibility of postoperatively withdrawing and/or repositioning the capsule in case of problems, even after a release of the capsule from its delivery system;
[0015] Limiting the consequences of a capsule migration in case of displacement during the acute phase of an intervention; and
[0016] Certainty of a good anchoring of the capsule before removing the implantation accessory.
OBJECT AND SUMMARY
[0017] The present invention is directed to a system comprising a capsule and an in situ implantation accessory, a combination in itself known, particularly from the US Published Patent Application 2009/0204170 A1, and improvements thereto. In accordance with the present invention, the capsule preferably comprises a tubular cylindrical body having at one end a projecting helical anchoring screw axially extending from the cylindrical body and, at least one coupling finger secured to the cylindrical body that extends radially outward. The helical anchoring screw is configured to penetrate into the tissue of the wall of a cavity, ventricle or atrium, of the heart. The implantation accessory has at its distal end a disconnectable means for supporting and guiding the capsule to the implantation site, and for rotational driving of the capsule to allow simultaneous driving of the anchoring screw and screwing it into the wall of the heart cavity.
[0018] In accordance with a preferred embodiment, the implantation accessory includes a lead body with a sheath of deformable material having at its distal end a helical guide forming said disconnectable means for supporting, guiding, and rotating the capsule. The helical guide extends axially from the lead body and is attached to the latter in rotation and in translation. The inside diameter of the helical guide is homologous to the outside diameter of the cylindrical body of the capsule so as to house the latter inside, with the at least one coupling finger protruding between the coils of the helical guide. The helix direction of the helical guide is opposite to that of the anchoring screw.
[0019] In a first embodiment, the helical guide is a projecting helix axially extending from the distal end of the lead body, including a resiliently compressible helix in the axial direction and whose helix pitch is increased in its free distal end portion.
[0020] Preferably, the capsule comprises two coupling fingers, one located towards the distal end of the capsule and the other located towards the proximal end of the capsule. The spacing between the two coupling fingers along the axial direction of the capsule is selected to provide a compression of the helix when the cylindrical body of the capsule is completely housed inside the helical guide. Advantageously, when the cylindrical body of the capsule is completely housed inside the helical guide, this assembly also includes a protective soluble coating covering the capsule equipped with its anchoring screw within the helical guide. More preferably, the capsule includes a reset ramp extending from the coupling finger located at the distal end. The reset ramp forms a portion of a helical thread with a helix direction opposite to that of helical guide, and is able to contact at its proximal end and engage with free end of the helical guide.
[0021] In a second embodiment, the distal end of the lead body has a hollow cylindrical tube extending axially and forming a housing for containing the capsule, the helical guide being a helical groove formed in the inner surface of the housing, and means are provided to deploy the capsule anchoring screw by a pin-driven drive.
[0022] Preferably, the helix pitch of the helical guide is increased in its free distal end portion. Also preferably, in this embodiment, as in the first embodiment, the capsule has two coupling fingers, one towards the distal end and the other towards the proximal end, and the spacing between the two coupling fingers in the axial direction is selected to provide a compression of the helix when the cylindrical body of the capsule is completely housed inside the helical guide.
[0023] In another embodiment, the system of the present invention may further include a flexible wire disposed within and running along a lumen of the lead body having a distal end, connected to the capsule, and a proximal end, extending out the proximal end of the lead body. The flexible wire preferably has in the vicinity of the connection point to the capsule a portion or length made of a resorbable material.
[0024] In one embodiment, the capsule can be a capsule for detection/stimulation comprising means for detecting depolarization potentials and/or delivering stimulation pulses and coupled to at least one electrode carried by the capsule, wherein the electrode is an active part of the anchoring screw, and transmitter/receiver wireless communication means for communicating with a remote device.
BRIEF DESCRIPTION OF DRAWINGS
[0025] Further features, characteristics and advantages of the present invention will become apparent to a person of ordinary skill in the art from the following detailed description of preferred embodiments of the present invention, made with reference to the drawings annexed, in which like reference characters refer to like elements and in which:
[0026] FIG. 1 is a perspective view of a first embodiment of a system of a capsule and an implantation accessory in accordance with the present invention in a configuration wherein the two elements are separated;
[0027] FIG. 2 shows the system of FIG. 1 , in a standalone configuration wherein the capsule is coupled to the implantation accessory before implantation;
[0028] FIG. 3 shows the system of FIG. 2 , in a configuration during implantation of the capsule in a heart cavity;
[0029] FIG. 4 is a perspective sectional view of a second embodiment of an implantation accessory in accordance with the present invention before implantation;
[0030] FIG. 5 shows the accessory of FIG. 4 , with the capsule housed in the implantation accessory;
[0031] FIG. 6 is an enlarged view of the distal portion of the implantation accessory of FIG. 4 ;
[0032] FIG. 7 illustrates a third embodiment of a system of a capsule and an implantation accessory in accordance with the present invention including a flexible wire; and
[0033] FIGS. 8 a and 8 b are perspective views, in two different orientations, of the embodiment of FIG. 1 illustrating a reversibility of the implantation of the capsule.
DETAILED DESCRIPTION
[0034] Examples of preferred embodiments of the present invention will now be described with reference to the drawings. In FIG. 1 , reference 10 designate a capsule having a cylindrical body 12 having an axis and which is provided at one end with a helical anchoring screw 14 axially extending from the tubular body 12 and secured to it in rotation and translation. Anchoring screw 14 preferably includes a distal portion 16 formed along a length of about 1.5 to 2 mm of non-touching turns for penetrating into the cardiac tissue. Distal portion 16 is connected to tubular body 12 via a transition portion 18 having a mechanical bending flexibility, for example, a part formed of contiguous turns in the absence of any stress on the screw.
[0035] Anchoring screw 14 may be an electrically active screw. In this regard, at least at its distal end, anchoring screw 14 may serve as a detection and/or stimulation electrode. Alternately, screw 14 may simply be a passive screw only for anchoring the cylindrical body 12 in the wall of the cardiac cavity.
[0036] The cylindrical body 12 typically includes various control and power circuits, for signal processing and wireless communication to enable the exchange of signals with a remote device, which may or may not be implanted. These aspects are in themselves known, and as they form no part of the present invention, they will not be described in further detail. One skilled in the art is referred to the various publications cited at the beginning of this description for more details on the structure and function of capsules.
[0037] Cylindrical body 12 is cylindrical and preferably includes at least one coupling finger shaped as an axially projecting protuberance, the function of which is explained below. In the examples shown, capsule 10 preferably comprises two such coupling fingers, finger 20 being distally located, and finger 22 being proximally located, with a spacing or gap between fingers 20 and 22 in the axial direction having a predetermined value (the importance of which is explained below). It should be understood that the form of these coupling fingers 20 , 22 can be adapted to give them a softened, atraumatic profile.
[0038] Cylindrical body 12 typically has a length from about 5 to 10 mm and a diameter from about 1 to 2 mm (i.e., 6 French). Proximal end 24 of capsule 10 can be rounded or domed for, on the one hand, making it atraumatic and, on the other hand, facilitating its coupling with the implantation accessory.
[0039] FIGS. 1-3 further illustrate a first embodiment of the implantation accessory 26 used for the implantation of capsule 10 .
[0040] Accessory 26 generally comprises a body 28 that is structurally similar to a conventional monopolar lead body in that it includes along its entire length, a coiled conductor 30 that is covered by a sheath 32 . Sheath 32 is typically made of polyurethane to reduce friction when the lead body is inserted into a guide catheter or the venous system, and to provide better sensitivity and better transmission of torque. In the context of the present invention, however, it should be understood that conductor 30 preferably has no electrical function; rather conductor 30 only contributes to the mechanical behavior of lead body 28 provides radio-opacity to aid in detection of the lead body position, e.g. by fluoroscopy.
[0041] The conductor assembly 30 /sheath 32 cooperate to provide lead body 28 with a torsional rigidity sufficient to transmit a torque from its proximal end to its distal end to rotate the distal end. It is possible, alternatively or in addition, to introduce in the lumen of lead body 28 a screwing stylet, in particular when the sheath 32 does not present a sufficient torsional stiffness, to rotate directly the distal end of the lead body from the proximal end.
[0042] The distal end of lead body 28 is provided with a tip 34 which is secured to a helical guide 36 formed, in this first embodiment, of a number of turns (helix) 38 of an elastic material (e.g., an alloy of the M35N or nitinol type). As a result, helix 38 is compressible in the axial direction, similar to a helical compression spring.
[0043] Typically, helix 38 has a reverse pitch compared to the pitch of helical anchoring screw 16 of the capsule, e.g., a left pitch if anchoring screw 16 has a right pitch. In addition, helix 38 has at its free distal end a slightly elongated pitch, for example, on the most distal turn 40 .
[0044] At the opposite end, helix 38 is connected to tip 34 by a transition portion 42 having a bending flexibility, for example, a portion 42 formed of adjacent turns in the absence of any force acting on helix 38 .
[0045] During manufacturing, body 12 of capsule 10 is screwed into helix 38 , thus resulting in the configuration shown in FIG. 2 . The gap between coupling fingers 20 and 22 is sized to ensure, in this configuration, a slight compression of helix 38 when coupling finger 20 engages the distal coil 40 which, as explained above, has an elongated pitch compared to the rest of helix 38 .
[0046] The entire distal portion is preferably covered with a soluble coating 44 , for example, polyethylene glycol (PEG). Soluble coating 44 is provided to protect anchoring screw 14 , helix 38 and the surrounding tissue during insertion of the system assembly into and through the venous system. To limit the dissolution time, it is possible to provide the soluble coating with a stepped profile, with the result that the coating around anchoring screw 14 is less thick than elsewhere.
[0047] During implantation, the assembly as shown in FIG. 2 is introduced to the cavity using a conventional procedure. Lead body 28 being of a standard construction, the practitioner will find its manipulation will have the classic feel of manipulation of a monopolar lead body with respect to, for example, torque, flexibility and slip.
[0048] Once soluble coating 44 is completely dissolved, the physician positions the tip of anchoring screw 14 against the heart wall, and starts screwing, by clockwise rotation (corresponding to a right pitch of the anchoring screw 14 ). The torque is transmitted from the proximal end of lead body 28 and allows, in a first step, the penetration of the anchoring screw 14 into the tissue of the wall 46 of the cavity of the heart. The corresponding value of torque for this operation is designated as C screwing • FIG. 3 shows the configuration of the assembly after complete screwing: the front of capsule 10 abuts against heart wall 46 and thus halts the progression of anchoring screw 14 , also generating a significant increase of the reaction torque.
[0049] With an anchoring screw of a standard lead, as the practitioner continues rotation of the lead body and of the screw, the torque increases and exceeds a limit C coring . Anchoring screw 14 then risks tearing the tissue under the local effect of rotation of the screw without any advance of the screw, causing a laceration to the tissues and, in extreme cases, perforation of the wall with the risk of tamponade.
[0050] In contrast, in accordance with the present invention: the physician can pursue without risk the rotation, always clockwise in this embodiment, of lead body 28 because the extra torque occurring due to the reaction of screw 14 anchored in tissue 46 is absorbed by the connection between helix 38 and capsule 10 . Specifically, the elasticity in compression of helix 38 is chosen to define a sliding torque C sliding below the limit C coring . Thus, when the couple C sliding is reached, further clockwise rotation of lead body 28 starts its rotation around capsule 10 , due to the reversed pitch of helix 38 . The latter then gradually emerges from capsule 10 by unscrewing (due to the reversal of the pitch). Note that the slightly increased pitch size of last turn 40 can generate a compression of the turns of helix 38 between coupling fingers 20 and 22 (arrows 48 ), and hence an increasing supporting force of these coupling fingers, until the release of distal finger 20 , a situation that defines a release torque C release allowing then the decoupling of capsule 10 and of lead body 28 (arrow 50 ).
[0051] The geometry of the various elements that make this interaction, as well as the elasticity in compression of helix 38 , are selected to verify the relationship:
[0000] C screwing <C sliding <C release <C coring C screwing designating the screwing torque in the tissues, C sliding designating the additional torque absorbed by the connection between the helix and the capsule, C release designating the couple met for the release of the distal finger, and C coring designating the torque limit beyond which the rotation of the anchoring screw may cause a tearing of the tissues of the wall.
[0056] It should be understood that the release system, located near anchoring screw 14 and thus at the distal end of the assembly, is not dependent on the torsional behaviour of lead body 28 , at the difference, for example, of a system for limiting torque that would be placed proximally.
[0057] Moreover, it is noted that during the release, the compressed length helix 38 is maximum, which ensures maximum reproducibility of the release torque.
[0058] The mechanism as described above allows absorbing the gradual rise of the torque due to the reaction of the anchoring screw 14 once it is fully inserted in the wall of the heart chamber, with a double benefit of (i) certainty of complete screwing of capsule 10 , and (ii) removing of any risk of tamponade.
[0059] Advantageously, the whole operation is transparent to the physician, because a single simple rotational movement from the proximal end of lead body 28 ensures both the complete fixation of the capsule and its release.
[0060] A second embodiment of the accessory in accordance with the present invention will now be described with reference to FIGS. 4-6 . The second embodiment is particularly well suited to embodiments wherein lead body 28 is a standard system known as a pin driven system. A pin driven system is one wherein the practitioner holds in one hand the proximal end of the lead body and in the other hand turns, directly or through a tool, the pin extending from the proximal end. Specifically, the plug is secured to the axial conductor 30 extending within lead body 28 , this conductor being then free to rotate relatively to sheath 32 and being connected at its distal end to the tip 34 .
[0061] In addition, lead body 28 has at its distal end a cylindrical tube 52 . Tube 52 has an inner diameter homologous with the outside diameter of capsule 10 (see FIG. 5 ) and a length allowing it to contain the capsule, including anchoring screw 14 , inside the hollow tube.
[0062] This second embodiment advantageously does not require use of a soluble PEG coating to protect the screw, because screw 14 can be retracted within tube 52 for the duration of the intravenous transit.
[0063] Tube 52 is preferably hollow and provided with a helical groove 54 (seen in particular in the enlarged view of FIG. 6 ) formed in the inner surface of tube 52 opening into an internal circular recess. Coupling finger 20 thus slides in this helical groove when the connector pin is activated (i.e., employing the pin-driven technique), driving screw 14 out of tube 52 .
[0064] The helical guide forming a spring is shown at 56 . It is in the form of a flat ribbon 56 in an elastically deformable in compression material with a proximal end 58 secured to the tip 34 . It has a free distal end 60 which has on its last turn a pitch size slightly increased in the same manner as turn 40 described in the first embodiment.
[0065] The direction of the pitch of helical groove 54 is the same as that of anchoring screw 14 (right pitch), however the pitch of flat spring 56 forming a helical guide is a reversed pitch (left pitch).
[0066] With this configuration, the rotation of the connector pin at the proximal end of lead body 28 rotates tip 34 and simultaneously capsule 10 and spring 56 in a forward helical movement relative to tube 52 . This results in a gradual deployment of screw 14 from tube 52 , and then a screwing of screw 14 into wall 46 of the heart cavity, until the front of capsule 10 abuts against wall 46 .
[0067] The further screwing causes, by the action of helical spring 56 on coupling fingers 20 and 22 , the separation of capsule 10 from spring 56 , allowing the gradual release of capsule 10 with the same function of disengagement described above with respect to the first embodiment, which prevents tissue damage by the anchoring screw.
[0068] Kinematics and stresses on the torque values described in detail for the first embodiment are applicable equally to this second embodiment.
[0069] FIG. 7 illustrates a preferred embodiment that can be implemented with either of the first or second embodiments described above, and is designed to allow a repositioning, in the short or in the medium term, of capsule 10 after its initial implantation and release. In this embodiment, separate from the connection between the separable lead body 28 and capsule 10 , a flexible wire 62 is connected at its distal end to capsule 10 and passed through the lead body so that its proximal end extends out the proximal end of the lead body (not shown).
[0070] Once capsule 10 is implanted, its proper functioning is tested, including if appropriate, the proper establishment of wireless communications between capsule 10 and a remote device (not shown). When capsule 10 is secured, and proper functioning is determined, lead body 28 is completely removed, and an excess length of flexible wire 62 is left to protrude outside the patient, under preferably a protective dressing.
[0071] In this regard, flexible wire 62 may be used to retrieve the capsule in case of a displacement in acute phase, by simply pulling on wire 62 .
[0072] Flexible wire 62 more preferably comprises a region 64 made of a resorbable material at its point of connection with capsule 10 , for example, over a length of 3 to 5 mm. This then allows the final withdrawal of flexible wire 62 after a suitable time period, by simply pulling, e.g., one month after surgery.
[0073] All or part of the flexible wire 62 may contain an active DSP agent (e.g., Dexamethasone Sodium Phosphate or a like agent to control tissue inflammation (as known to be used in a conventional pacing lead)), or a surface processing intended to stop any spread of infection between the emerging wire part (under the dressing) and the wire part inserted into the venous system.
[0074] Further, in the case of a negative functionality test immediately after implantation or in the event of a later malfunction, it is possible to reengage helical guide 36 on the capsule through the guiding of flexible wire 62 and to the rounded shape of rear part 24 of capsule 10 . Capsule 10 can then be unscrewed from wall 46 by rotating lead body 28 in a counterclockwise direction and relocated to another site by applying the same system and principle as described above, by namely a clockwise rotation.
[0075] Flexible wire 62 can preferably be colored with different colors for each of the implanted capsules in order to more easily identify the relevant capsule (e.g., atrial, ventricular) in the event of an extraction and reimplementation operation.
[0076] Advantageously, the present invention thus provides two safety functions for the release of the capsule. The first safety function results from the release system that avoids coring of the heart wall. The second safety function arises by giving the practitioner the opportunity, even after a capsule release, to recover, in the short or medium term, the capsule in case of difficulty, using the flexible wire.
[0077] FIGS. 8 a and 8 b , illustrate according to two different orientations, an alternate embodiment providing reversibility of the implantation of the capsule, in order if necessary to couple again lead body 28 to capsule 10 so as to unscrew it to remove it and possibly relocate it to another site.
[0078] Upon replacing the lead body on the capsule, the resetting of helical guide 36 may include to accommodate on capsule 10 in the distal region a compression ramp 66 extending from distal coupling finger 20 . Ramp 66 has, as illustrated in FIGS. 8 a and 8 b , a helical shape 68 extending over the length of a fraction of a turn, with a right pitch (opposite the pitch of helix 38 ) and having a proximal side 70 against which free end 72 of helix 38 slides. Compression ramp 66 is necessitated by the fact that, in its absence, helix 38 , uncompressed when docking with the capsule 10 and then screwing on proximal coupling finger 22 , would engage distal coupling finger 20 by its distal end, so that the release mechanism described above would no longer work.
[0079] One skilled in the art will understand that the present invention can be practiced by other than the embodiments disclosed herein, which are provided for the purposes of illustration only but not of limitation.
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A system and method for implantation of an autonomous intracardiac capsule. The autonomous capsule includes a cylindrical body with an anchoring screw for penetrating a tissue wall, and at least one coupling finger radially projecting outwards. An implantation accessory includes a lead body and a helical guide, for guiding and driving by rotation the capsule. This helical guide is integral with the lead body, and its inner diameter is sufficient to contain that cylindrical body of the capsule therein. The helix direction of the helical guide is opposite to that of the anchoring screw such that continued rotational motion imparted on the lead body drives the anchoring screw into the target tissue and then emerges the capsule from the helical guide. The helical guide is resiliently compressible in axial direction, and its helix pitch is increased in the free distal end portion.
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FIELD
[0001] The present disclosure relates to an internal combustion engine and more particular, to an internal combustion engine having an efficient cam phaser actuation supply system.
BACKGROUND
[0002] This section provides background information related to the present disclosure which is not necessarily prior art.
[0003] Camshaft phasers have been widely used in internal combustion engines to very valve timing to achieve purposes such as lower emissions, increase peak power at high revolution speeds and improve idle quality. Camshaft phasers are normally operated using pressurized hydraulic fluid which require engine operation. Accordingly, camshaft phaser systems are typically not capable of operation during engine off conditions. Engine start-up can be adversely affected due to a broad range of temperatures and can be improved by reducing the compression ratios at start-up. Accordingly, it is desirable to provide a camshaft phaser system that is capable of camshaft adjustment during engine off conditions in order to improve engine start-up with low-cost and minimum adverse impact on engine parasitic losses.
SUMMARY
[0004] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
[0005] An internal combustion engine for a vehicle is provided including an engine block defining a plurality of cylinders. A cylinder head is mounted to the engine block and defines intake ports and exhaust ports in communication with the cylinders. A valve train system includes a plurality of intake valves disposed within the intake ports and a plurality of exhaust valves disposed within the exhaust ports. One or more camshaft and a plurality of valve lift mechanisms are operable to open the plurality of intake valves and the plurality of exhaust valves. A hydraulic cam phaser includes at least one of an advance chamber and a retard chamber for receiving hydraulic fluid for selectively advancing or retarding a rotational position of the camshaft. The hydraulic actuation system includes a hydraulic accumulator in selective communication with at least one of the advance and retard chambers of the hydraulic cam phaser. A first system oil pump provides lubrication oil to the entire engine, and the hydraulic actuation system includes a second oil pump for supplying oil to said hydraulic accumulator. The first system oil pump and the second oil pump are driven by an engine drive system. The second oil pump is controlled with a clutch device connecting the second oil pump to the engine drive system. The internal combustion engine includes a controller which controls actuation of the clutch device to actuate the clutch device during deceleration of the vehicle.
[0006] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0007] 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.
[0008] FIG. 1 is a sectional view of an engine assembly according to the principles of the present disclosure; and
[0009] FIG. 2 is a schematic diagram of a hydraulic cam phaser actuation supply system according to the principles of the present disclosure.
[0010] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0011] Example embodiments will now be described more fully with reference to the accompanying drawings.
[0012] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
[0013] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0014] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “in communication with” another element or layer, it may be directly on, engaged, connected or in communication with the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly in communication with” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0015] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
[0016] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0017] An exemplary engine assembly 10 is illustrated in FIG. 1 and may include an engine structure 12 , a crankshaft 14 , a plurality of pistons 16 , engine bearings 18 ( FIG. 2 ) and a valvetrain assembly 20 . The engine structure 12 may include an engine block 22 and a cylinder head 24 . The engine structure 12 defines a plurality of cylinder bores 26 (one cylinder is illustrated for simplicity). However, it is understood that the present teachings apply to any number of piston-cylinder arrangements and a variety of reciprocating engine configurations including, but not limited to, V-engines, inline engines, and horizontally opposed engines, as well as both overhead cam (both single and dual overhead cam) and cam-in-block configurations.
[0018] The pistons 16 are each located in one of the cylinder bores 26 . The cylinder head 24 cooperates with the cylinder bores 26 and the pistons 16 to define a plurality of combustion chambers 30 . The engine structure 12 defines one or more intake ports 34 and one or more exhaust ports 36 in the cylinder head 24 in communication with the combustion chambers 30 .
[0019] With reference to FIG. 1 , the valvetrain assembly 20 may include a first camshaft 42 , a second camshaft 44 as well as first and the second valve lift mechanisms 50 , 52 associated with each of the intake and exhaust ports 34 , 36 , respectively.
[0020] As shown in FIG. 2 , a cam phaser 46 can be connected to the first or second camshaft 42 , 44 . It should be noted that each of the first and second camshafts 42 , 44 can have a cam phaser 46 associated therewith, although FIG. 2 only shows one cam phaser 46 . An intake valve 58 may be located in the intake port 34 and the first valve lift mechanism 50 may be engaged with the intake valve 58 . An exhaust valve 60 may be located in the exhaust port 36 and the second valve lift mechanism 52 may be engaged with the exhaust valve 60 . Additional intake and exhaust ports may be provided in each cylinder along with additional intake and exhaust valves disposed therein. The cam phaser 46 can be a mid-park or end-park cam phaser as is generally known in the art, although other cam phaser designs can be used.
[0021] With reference to FIG. 2 , the cam phaser actuation hydraulic supply system 70 for advancing or retarding the cam phaser 46 for adjusting the rotational position of the camshaft 42 according to the principles of the present disclosure will now be described. The hydraulic supply system 70 includes a lubrication system 71 having a main oil pump 72 which can be a variable displacement pump. The main oil pump 72 can be utilized for providing lubrication oil to the valvetrain assembly 20 as well as other engine components. The main oil pump 72 draws oil from sump 74 and delivers oil through a main passage 76 through a check valve 78 and filter 80 . From the filter 80 , the oil can be delivered to various components of the valvetrain assembly 20 and returned to the sump 74 as is known in the art.
[0022] A secondary positive displacement oil pump 82 can be engaged to be driven by the engine drive system 83 that drives the main oil pump 72 via an electro-hydraulic clutch system 84 . The clutch system 84 can be engaged by a two port/two position solenoid valve 86 for selective actuation of the clutch 84 to engage the secondary pump drive 88 for driving the secondary oil pump 82 . The solenoid valve 86 receives filtered oil from the main oil pump 72 via passage 90 . Passage 90 is also connected to the supply port 92 of the secondary oil pump 82 . The outlet 94 of the secondary oil pump 82 is connected to a hydraulic accumulator 100 . The hydraulic accumulator 100 is in communication with the cam phaser 46 through a three position valve 102 . As is known in the art, the three position valve associated with the cam phaser 46 has three positions that include a first position for advancing the cam phaser 46 , a second position for retarding the position of the cam phaser 46 , and a third intermediate position that allows for modulation of the cam phaser position. It should be noted that other cam phaser arrangements and valve arrangements can be utilized including normally advanced or normally retarded position cam phasers.
[0023] An optional pressure reducing valve 104 can be provided in the passage between the hydraulic accumulator 100 and the cam phaser 46 that allows the cam phaser to operate at a different pressure than the accumulator 100 . In addition, a two port/three position proportional valve 106 can optionally be used for selective charging of the cam phaser system and or discharging of the accumulator 100 . It is noted that the three position arrangement of the two port/three position proportional valve 106 includes a first closed position 106 a, a second restricted flow position 106 b, and a third accumulator discharge position 106 c. As an alternative to the proportional valve, a one-way check valve can be used with limited function.
[0024] The hydraulic system of the present disclosure is configured to provide a low-cost solution to enable aggressive cam phaser movement over a broad range of operating conditions including engine “off” conditions. In the engine “off” condition, the main oil pump 72 is not being driven and is incapable of providing oil to the cam phaser 46 . Accordingly, the accumulator 100 stores pressurized oil that can be used during engine “off” conditions to adjust the position of the cam phaser 46 .
[0025] The internal combustion engine 10 is provided with a controller 110 that monitors vehicle operating conditions via inputs 112 . During vehicle and engine deceleration, the controller 110 provides output signals via connection 114 to engage the two port/two position solenoid valve 86 for engaging the electro-hydraulic clutch 84 to drive the secondary oil pump 82 and charge the hydraulic accumulator 100 . Therefore, braking energy can be utilized for charging the accumulator 100 by regeneration rather than providing any parasitic losses that reduce fuel efficiency. The hydraulic accumulator 100 is selectively charged during engine deceleration so that when the engine is in an “off” condition, the stored pressurized fluid in the accumulator 100 can be utilized for adjusting the cam phaser 46 prior to the next engine startup. The ability to adjust the cam phaser 46 prior to engine startup allows for improved engine starting with an adjustment to a lower compression ratio at startup. Accordingly, the system of the present disclosure provides for full cam phasing authority both prior to engine start and during engine operation. The system of the present disclosure also minimizes any adverse impact on engine parasitic losses by recharging the accumulator 100 during vehicle decelerations. The system also provides for a hydraulic isolation of the cam phaser 46 for providing stable control of the cam phaser 46 . By using a dedicated secondary oil pump 82 , the main oil pump 72 can be operated at a lower pressure for providing adequate lubrication to the engine bearings and valve-train components while providing improved fuel economy. The secondary oil pump 82 and accumulator 100 also allows the freedom to operate the cam phaser 46 at higher operating pressures for improved phaser response without adversely affecting the optimized main oil pump 72 operating pressure for the rest of the engine. The system also allows for the use of a mid-park cam phaser to meet stop and start goals thereby mitigating the need for complex “dual park” cam phaser designs. The present disclosure allows for potential of compression release for improved starting over broad temperature ranges.
[0026] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
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A hydraulic cam phaser includes at least one of an advance chamber and a retard chamber for receiving hydraulic fluid for advancing or retarding a rotational position of the camshaft. The hydraulic actuation system includes a hydraulic accumulator in selective communication with the at least one of the advance and retard chambers of the hydraulic cam phaser. A first system oil pump provides lubrication oil to the valvetrain system, and the hydraulic actuation system includes a second oil pump for supplying oil to the hydraulic accumulator. The second oil pump is controlled with a clutch device connecting the second oil pump to the engine drive system. The internal combustion engine includes a controller which controls actuation of the clutch device to actuate the clutch device during deceleration of the vehicle.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Non-provisional application Ser. No. 14/487,850 filed Sep. 16, 2014 that in turn claims priority benefit of U.S. Provisional Application Ser. No. 61/878,442 filed Sep. 16, 2013; the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention in general relates to building products for weatherproofing window and door installations and in particular, to a sill pan adapted to waterproof a sill surface and a method for forming the sill pan.
BACKGROUND OF THE INVENTION
[0003] The incursion of unwanted air and/or moisture into buildings and homes around door and window joints is a major concern for builders, property owners, and occupants. The penetration of air and/or moisture is a serious concern, and may result in exterior and interior damage if not prevented or corrected in a timely manner. In addition, heat losses caused by air leakage around building openings have taken on new significance due to today's high energy costs. Sealing such openings has typically been accomplished by caulking or using putty-like compound around openings between door and window frames to seal the gaps and prevent inward seepage of air and/or water into a building.
[0004] An existing approach to sealing window joints is the use of a sill pan to flash windows into a window opening. The sill pan is typically made of metal and is formed in an off-site fabrication shop based on measurements made of the opening at the building site. Typically, there are variations in the size for each window so each pan is somewhat unique. Furthermore, if the measurement is not precise, the pan will not fit correctly, and must be remade or swapped around to make sure the sill pans fit each opening. An additional problem with metal sill pans is that sill pans create a thermal short from outside to inside of the window to be sealed due to the pans large mass, and creates condensation on the inside of the window at the sill.
[0005] A recent more common practice is the use of polyvinyl chloride (PVC) for sealing panels for windows. The PVC is made in two pieces that slide so they can be used in residential applications, which have become more common. The PVC based sill pans slide to fit the opening and are then sealed with glue or sealant to make a watertight assembly. The PVC based products can have built-in shims and other elements to create a slope for directing water drainage. The PVC material is usually thicker than metal. However, plasticized PVC can also have compatibility problems with bitumen based membranes. Furthermore, the PVC based sill product has openings at the point of connection of the two pieces that can be prone to leakage. Both the aluminum and plastic sill pans need to be bonded to the underlying surface so no water can pass underneath, which is typically achieved with non-skinning butyl beads or tapes.
[0006] A further trend has been the increased use of vinyl windows in recent years. However, it has generally been recognized that vinyl windows take in water and can leak at the sills notwithstanding the weep holes built into the frame at the sill. Therefore, the use of vinyl windows has significantly increased the use of sill pans, not just flashing membranes. Many manufacturers now encourage the use of sill pans. An available option is to create a pan from a self-adhered membrane cutting it to fit. A self-adhered membrane that is cut to fit has the advantage of sealing to the underside of the window and forming the product in the field that it is not rigid. The self-adhered membrane will not allow drainage since the window will create a seal unless shims are put under the window to create sufficient space to create drainage. Many manufacturers of vinyl windows want the window to be fully supported which means shims do not work with their vinyl window designs. Furthermore, the membrane is not very durable and the cutting of the membrane can create joints and pinholes that must be filled with sealant to make sure a seal is created.
[0007] While many materials and approaches for sealing window and door joints have been tried, there still exists a need for a material and method of application that can be used for a sill pan that has the advantages of a self-adhered membrane, but can drain without shims, and has sufficient sealing materials to seal around nail holes, while being thin enough to properly function and provide end and back dams without cutting the material.
SUMMARY OF THE INVENTION
[0008] A method for forming a sill pan is provided that includes the measurement of a width and length of an opening sill to be sealed. A piece of flexible sill pan material is cut based on the measured opening sill. Fold lines and cuts are created in the piece to form the sill pan. The resulting sill pan is readily formed to have at least one attribute of self-adherence, draining without shims, nail hole self-sealing, and provision of dams without resort to frame cutting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIGS. 1A-1D illustrate a method for forming a sill pan from a sheet material according to embodiments of the invention; and
[0010] FIG. 2 is a side perspective cut away view of an installed sill pan according to embodiments of the invention.
DESCRIPTION OF THE INVENTION
[0011] The present invention has utility for sealing window and door joints and provides a material and method of forming and application of the seal that can be used for a sill pan that has the advantages of a self-adhered membrane, but can drain without shims, and has sufficient sealing materials to seal around nail holes, while being thin enough to properly function and provide end and back dams without cutting the material.
[0012] Embodiments of the inventive sill pan may be formed from a waffled aluminum membrane that has a thick butyl backed adhesive on the back, or other materials that inhibit moisture and can be used in the inventive method of forming sill pans. The waffled aluminum membrane is sold as a roll good that can be cut with scissors. The roll goods can be taken to an application or construction site and cut to size as required. In the inventive method for forming a sill pan, instead of cutting and sealing to form the pan, the material is folded to form the end and back dams so there is no hole or bonded surface. In the inventive method, the end dams and back dams of a sill pan may be formed to any required height. In forming the sill pan, the waffled aluminum membrane material is rigid enough to stand up by itself, so that the majority of a backing may be removed leaving the last one-inch, so the material can be turned up when the sill trim at the back of the window interior is installed. Alternatively in an embodiment, the back dam may be formed with a metal angle to which the back dam can be immediately bonded creating a free standing back dam. The waffle pattern on the face of the aluminum membrane creates a drainage course. If water were to travel through the window the pan will pick it up. The waffle pattern in the membrane material allows the water to drain to the exterior without putting the window to be sealed on shims. The pan can be sloped by gently sloping the sill framing or adding a continuous wood ‘chair’ with very gentle sloping. The thick butyl backing of the membrane material acts to seal around penetrations. The aluminum surface is compatible with all materials currently in use as a flashing material. Packaged as a rolled good, the aluminum membrane allows for the expansion of the sill to the exterior to any amount the installer requires.
[0013] In installations where metal sills are usually exposed, embodiments of the inventive sill pan are more appropriate for a ‘nail-on’ window that used to be sealed with a nailing flange on all four sides. The concept used by builders today is to leave the sill open to allow and water that enters to drain out instead of entering the building, but to avoid air from entering the building to create an exterior air barrier. The waffled aluminum membrane material achieves the desired sealing performance by allowing drainage at the bottom, and sealing the window to the back dam with a butyl or polyurethane seal. Self-adhered membranes typically have a polyethylene face that serves as a water impervious barrier, and is not a good surface for sealant bonding. However, while the aluminum face of the waffled aluminum membrane material, used in embodiments of the inventive sill pan, also has a zero perm it still also provides a good sealing surface. The aluminum membrane is thick enough to provide rigidity, but thin enough to cut with scissors and to create a thin profile.
[0014] Referring now to the figures, FIGS. 1A-1D illustrate an inventive method for forming a sill pan 32 . It is noted that a waffled or dimpled aluminum membrane is the material used in the example embodiment shown; however additional sheet materials may be used to carry out the inventive method. In FIG. 1A , a rectangular sheet of flexible sill pan material 10 with the dimple or waffle side 12 showing is laid out and cut to a required size for a window sealing application. In general the inner 11 and outer 13 edges are along the long dimension of the cut sheet 10 . In FIG. 1B , the smooth surface 14 of the flexible sill pan material 10 is shown, and the surface is measured and marked as follows with a first fold line 16 that defines the height of a back dam 20 at a first distance measured from the inner edge, and a second fold line 18 that defines a rectangular area 17 on opposing sides of the flexible sill pan made up of folded segments 26 and 28 (see FIG. 1C ) that define side flaps and the end dams, respectively. The first fold line 16 is parallel to the long side of the rectangular sheet 10 . The pair of second fold lines 18 are perpendicular to the first fold line 16 and are parallel to short side dimension of the sheet 10 at a second distance (D 2 ) measured from the side edges 19 . In FIG. 1C , a third fold line 22 is added that is parallel to the first fold line 16 at a third distance (D 3 ) as measured from the outer edge, and bisects the sheet 10 . Fold line 22 defines the width of the seat 30 of sill pan 10 for seating the window frame, and the downward flap 24 that extends down the wall 34 (see FIG. 2 ) below the window sill. The fold along third fold line 22 also creates a drip edge. Additionally in FIG. 1C , the back dam 20 is folded upward along fold line 16 relative to the seat 30 . In FIG. 1D , a cut is made along second fold lines 18 that extend from the outer edge 13 until the third fold line 22 , and the segments 26 and 28 that form the side flaps and the end dams, respectively are bent upward and perpendicular to the seat 30 . The side flaps 26 are subsequently bent away from the seat 30 and made perpendicular to the end dams 28 . The opposing ends 15 of back dam 20 that are defined by the area between the inner edge 11 , first fold line 16 , and second fold lines 18 are folded upward after a small cut is made to first fold line 16 that extends from the side edges 19 to the second fold line 18 . The upward opposing ends 15 seal against the end dams 28 . The entire sill pan 32 formed above is now ready to be placed in the opening for the window sealing application.
[0015] FIG. 2 is a side perspective cut away view of an installed sill pan 32 in a building wall opening 34 prior to placement of a window frame (not shown) according to embodiments of the invention. As shown the downward flap 24 extends down the wall 34 . Metal angle 36 provides vertical support to back darn 20 , and seat section 30 of the flexible sill pan 32 fits onto the sill 38 of the window opening. A toe bead of sealant 38 is placed at the right angle bend between the seat 30 and back darn 20 . When placing the window frame the bottom rear edge of the window frame is set into the toe bead of sealant 38 .
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A method for forming a sill pan is provided that includes the measurement of a width and length of an opening sill to be sealed. A piece of flexible sill pan material is cut based on the measured opening sill. Fold lines and cuts are created in the piece to form the sill pan. The resulting sill pan is readily formed to have at least one attribute of self-adherence, draining without shims, nail hole self-sealing, and provision of dams without resort to frame cutting.
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BACKGROUND OF THE INVENTION
The invention relates to a method and an apparatus for providing a temporary enrichment of the fuel-air mixture fed to an internal combustion engine during acceleration. The method and apparatus of the invention may be used with a fuel mixture preparation system of any kind and is based on monitoring the pressure changes in the induction manifold of the engine during acceleration. The invention relates particularly well to continuous electronic injection systems in which the fuel-air ratio is controlled by a control pressure of hydraulic fluid and wherein the control pressure is altered by the method and apparatus of the invention so as to superimpose on the control process already present an additional change for the purpose of fuel mixture enrichment. The continuous fuel injection system to which this invention may be particularly adapted may especially be operating under the control of an oxygen sensor which monitors exhaust gas composition, i.e. a so-called λ control process.
Known fuel mixture preparation systems for internal combustion engines of motor vehicles normally include a provision for admitting additional fuel for engine acceleration. In the simplest case, a carburetor may be equipped with a so-called accelerator pump which supplies additional raw fuel when the gas pedal is depressed. In known electronic fuel injection systems, an enrichment during acceleration may take place on the basis of the motions of a baffle plate in the induction manifold which responds to the changing air flow rate and which may be part of a so-called air flow rate meter.
OBJECT AND SUMMARY OF THE INVENTION
It is a principal object of the invention to provide a method and an apparatus for enrichment of the fuel-air mixture during engine acceleration. It is another principal object of the invention to provide a fuel mixture enrichment system which is distinguished with respect to the prior art by the absence of transducer systems and switching systems previously required in so-called transition enrichment systems. In particular, it is an object of the invention to provide fuel enrichment without the necessity of installing a solenoid valve, a pressure switch and a thermal switch as previously required. It is yet another object of the invention to describe an apparatus for selecting the time interval during which the enrichment of the fuel-air mixture takes place.
These and other objects of the invention are attained by monitoring the induction tube pressure with a differential pressure cell which responds to the rapidity of application of the gas pedal. The actuation of the differential cell is then processed into an electrical signal which is used to alter the control signal that governs the operation of the fuel injection valves in the sense of enriching the fuel-air mixture.
The invention will be better understood as well as further objects and advantages thereof become more apparent from the ensuing detailed description of a number of preferred embodiments taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a circuit diagram of a portion of a known fuel injection system for continuous fuel injection including two embodiments of the invention;
FIG. 1a is an illustration of a third embodiment of the invention;
FIG. 2 illustrates a circuit for a fourth embodiment of the invention;
FIG. 3 is a diagram illustrating the voltage pulses at various points of the system; and
FIG. 4 is a circuit diagram illustrating a fifth embodiment of the invention including an electronic temperature switch.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The basic principle of the present invention is that when the gas pedal is depressed and the engine is intended to be accelerated, the induction tube pressure undergoes a sudden change and it is this change which is exploited to admit additional fuel to enrich the fuel-air mixture. In principle, the fuel mixture preparation system may be a carburetor or continuous or intermittent fuel injection systems. The invention is however particularly suited to be used with a continuously injecting electronic fuel injection system, for example Applicants' "K-Jetronic" system. The preferred embodiments of the present invention will thus relate directly to the aforementioned continuous injection system. This system includes fuel injection valves and other components that are not explicitly shown in the drawing. The known continuous fuel injection system also includes a control circuit which obtains its primary control signal from an oxygen sensor located in the exhaust system. The detailed description of this circuit will be given below. A primary component of the improvement due to the present invention is a differential pressure switch, identified by the numeral 1 in FIG. 1, and indicated only schematically to represent the class of electrical switches which respond to differential pressure. Such a pressure switch may, for example, be a bicameral switch divided by a diaphragm, one of the chambers being exposed to induction tube pressure and the other to the ambient atmosphere. When the throttle is open, the induction tube pressure rises, whereby the diaphragm is displaced and actuates the switch 1. Generally, the switch is intended to return to its original state after a period of time and for this purpose the pressure chamber of the switch has a small opening which permits it to reassume pressure equilibrium. The basic behavior of the switch is essentially digital, i.e. it is either on or off, but its time of duration may be variable. However, the opening in the diaphragm permitting reestablishment of pressure equilibrium cannot be made arbitrarily small so that the times during which the switch 1 is closed cannot be made arbitrarily long. For this reason, a preferred exemplary embodiment of the invention to be described further in detail below permits an extension of the time of closure of the switch or of the switching signal beyond the actuation time of the differential pressure switch.
The overall circuit depicted in FIG. 1 relates to one possible embodiment of an electronic continuous injection system which is based on the control signal of a so-called λ-sensor, i.e. an oxygen sensor, located in the exhaust system of the engine. The overall control system described in FIG. 1 regulates a so-called control pressure which engages fuel metering components, not shown, in the sense of changing the degree of enrichment of the fuel-air mixture. A control valve 2 which is subject to the influence of the processed signal from an oxygen sensor 3 changes the control pressure which generally opposes a constant fuel pressure and thereby changes the fuel-air ratio. Generally, an increase of the control pressure results in a leaning out of the fuel-air mixture. The portion of the fuel injection system shown in FIG. 1 is only that part which actuates and controls the control valve 2 on the basis of the λ-sensor signal. The improvement due to the present invention is directly associated with this part of the known fuel injection system.
In FIG. 1, the output signal of the λ-sensor 3 is fed to an impedance converter 4 whence it passes to the input of a comparator 5 whose other input receives a reference voltage via a second impedance converter 6. The base of the transistor 6 is connected to elements 7 all serving to vary the voltage applied to the second input of the comparator 5. The output of the comparator 5 is a rectangular signal which is either high or low depending on the momentary value of the λ-sensor signal. The output signal from the comparator is fed to an intermediate amplifier 8 and thence to an integrator 9 constituted by an operational amplifier 11 with a feedback capacitor 10. The output 12 of the operational amplifier 11 will be an increasing or decreasing sawtooth voltage, Depending on the frequency of switchover of the comparator output signal. The sawtooth voltage from the integrator is used to provide an additional control of the fuel-air mixture ratio. In order to condition the signal from the integrator 9 for this purpose, it is fed to a comparator 14 at an input 15 where it also receives the output of an oscillator 16. The comparator 14 controls a transistor 17 which is turn activates a Darlington transistor 18 which directly actuates the aforementioned control valve 2 in series with a resistor 19. The oscillator 16 may be of general construction and will not be further described. Its output signal is a sawtooth voltage at a relatively low frequency, for example 70 Hz. Disregarding for a moment the influence of the integrator output signal on the comparator 14, the latter may be adjusted by voltage divider resistors 20 and 21 such that the collector of its output transistor 22 will be a rectangular voltage with equal keying ratio, i.e. a symmetrical pulse of ratio 1:1. When the sawtooth signal from the integrator 9 is now superimposed on the oscillator signal at the input to the transistor 15, the keying ratio, i.e. the width of the "on" portion of the pulse with respect to the "off" portion of the pulse is changed, and the times during which the valve 2 will be energized will differ from the time during which it is open, while still being subject to the overall control of the λ-sensor. The signal which activates the pressure control valve 2 has a sufficiently high frequency so that the pressure of the control fluid does not fluctuate, due partly also to the integrating effect of the mechanical inertia of the system. By changing the keying ratio, i.e. the pulse width of the control voltage for the output transistor 18, the valve 2 changes the control pressure for the fuel metering system and thus effectively changes the fuel quantity metered out and the ratio of fuel-to-air.
It is at this point that the method and apparatus according to the present invention engages the fuel preparation system. In a first exemplary embodiment, the invention provides the aforementioned differentiating pressure switch 1 that has an electrical contact which is connected in series with two resistors 30 and 31, the entire combination being connected in parallel with the transistor 17 as illustrated in FIG. 1. Whenever the differentiating pressure switch 1 is closed due to an increase in pressure in the induction tube, the fuel-air ratio is temporarily increased because the transistor 17 is bypassed and the output transistor 18 is directly actuated, thereby opening the valve 2. This action causes a decrease of the control pressure and thus an enrichment of the fuel-air mixture. Whenever the pressure switch 1 is closed, the feedback control process is effectively interrupted and the valve 2 is no longer being actuated at the frequency of the oscillator 16. By effectively short circuiting the transistor 17, the mixture is enriched by a factor equal to one half of the control range of the closed loop, if under normal closed loop control the actuation pulses were approximately symmetric. The presence of the resistors 31 and 30 prevents damage to the circuit if the pressure switch were to be short circuited or connected accidentally to the positive supply line.
In a second and alternative variant of the present embodiment, the temporary enrichment may take place in dependence on the engine temperature, for example the cooling water temperature. This variant is shown in FIG. 1 in dashed lines and includes a pressure switch 1'. The pressure switch 1' is connected in series with a thermal switch 35 which opens if the engine reaches a predetermined temperature but which is closed in a specified region of the warm-up phase so that a temporary enrichment may take place. For the example of a thermal switch 35 which closes a contact to ground, it is shown to be connected such that it engages the base of the transistor 17 in the appropriate manner. If both the thermal switch 35 and the differentiating pressure switch 1' is closed, the transistor 17 always conducts and the valve 2 is constantly opened by the conducting output circuit 18 and the control pressure of the engine will be reduced, thereby increasing the fuel within the mixture. A transistory enrichment of this type will be effective only when the thermal switch is closed, i.e. during the warm-up phase of the engine.
Whenever an internal combustion engine is being operated under feedback control of a λ-sensor, there will be times when such closed-loop control is not feasible, for example because the λ-sensor is not capable of delivering a useable control signal. This condition may often occur when a cold engine is being started and during portions of the warm-up running.
Accordingly, a second exemplary embodiment of the invention, illustrated in FIG. 1a, shows a circuit in which the temporary enrichment takes place only when the fuel injection system has been switched over from closed-loop control to open-loop control. When this is the case, some electronic semiconductor elements, for example the transistor 36 in FIG. 1a, will be rendered conducting by suitable signals at the base 37. The present invention makes use of this open-loop status by connecting a diode 38 and a further resistor 39 in series with the aforementioned differentiating pressure switch (1") from the collector of the transistor 36 via a further resistor 40 to the base of the transistor 17 which finally controls the output Darlington 18. Accordingly, if the differentiating pressure switch closes for a short period of time, the temporary enrichment of the mixture can occur only if, at the same time, the entire fuel injection system is being operated in open-loop control, i.e. when the transistor 36 conducts. In such an embodiment, the thermal switch 35 can be dispensed with because the open-loop control is itself an indication that the engine is being started or run up, i.e. from a cold condition.
It has been pointed out above that the maximum temporary enrichment of the fuel-air mixture is equal to one-half the normal control range. However, it may be, for example during rapid acceleration and during warm-up, that substantially higher enrichment factors are required to operate the engine smoothly and without hesitation. The fuel required for this type of acceleration, for example an increase of fuel by a factor of 20 to 30 percent, may also be obtained by extending the period of time during which the excess fuel is being delivered. The extension of this time may be obtained by an increase in the volume of the pressure switch 1 or by a decrease of the equalizing aperture in the diaphragm. However, these variables are subject to limitations; for example the increase of the size of the cell is unfavorable because it becomes more expensive and too large for practical installation and very small openings in the diaphragm are difficult to make and maintain at the required small tolerances due to soiling, etc.
In a third exemplary embodiment of the invention, these disadvantages are avoided and the excess fuel is provided by multiplying the time of increase generated by the differential pressure switch with a fixed factor. In the simplest case, this is done by associating with the pressure switch a timing circuit which serves to prolong the effective switching time of the pressure switch, preferably proportionally. The period of time during which the differentiating pressure switch remains effective depends on the rapidity with which the gas pedal is actuated, i.e. on the rate of change of the induction tube pressure as well as the magnitude of the pressure increase. In the third embodiment of the invention illustrated in FIG. 2, there is shown an electronic timing circuit for multiplying the effective enrichment time by a given factor. In this embodiment, the pressure switch 1 actuates a so-called Miller integrator 40 which consists of two transistors 43 and 44 and an integrating capacitor 45 which connects the collector of the transistor 44 to the base of the first transistor 43. The input of the Miller integrator, i.e. the base of the transistor 43, is connected to the differentiating pressure switch at the tap of two series resistors 41 and 42, and if suitable, in series with the previously mentioned thermal switch 35. The presence of the thermal switch 35 is optional if no temperature-dependence of the enrichment is desired.
If the pressure switch 1 closes, for example for a duration t1 (see FIG. 3) the capacitor 45 discharges to ground and the rate of discharge is determined by the resistor 42 and the capacitor 45. As soon as the pressure switch 1 reopens, the Miller integrator recharges the capacitor 45 via the resistor 41 whose magnitude and that of the capacitor 45 are exclusively responsible for the determination of the charging time constant. Accordingly, the size of the resistors 41 and 42 determines the multiplication factor for the desired total enrichment time. The collector of the transistor 44 is connected via series resistors 47 and 48 to the base of a transistor 46 from the collector of which is taken the final effective enrichment time t2. The curve U c in FIG. 3 illustrates the voltage at the capacitor 45 while the curve U s illustrates the switching threshold of the transistor 46. The collector of the transistor 46 is connected via the resistor 49 to the base of the transistor 17 of FIG. 1 which then conducts during the period t2 and which provides the maximum available enrichment as previously discussed. If the duration of the switching signal from the differential pressure switch 1 is greater, for example as illustrated in FIG. 3 by the pulse t1', the total charge accumulated on the capacitor 45 will be greater, thus increasing the charging and discharging times resulting in an output pulse t2' of increased length.
The person skilled in the art will appreciate that the polarity of the semiconductors shown in the diagrams could be reversed if a suitable alternation of the supply voltages were to take place. In such a case, the Miller integrator for example could be switched to a positive voltage rather than to ground which may be useful if a thermal switch 35 is not present.
The effect of the timing circuit or the output of the transistor 46 may be used at some other part of the circuit of FIG. 1 provided that it causes the valve 2 to be actuated in the sense of providing temporary enrichment.
In a fourth embodiment of the invention, the mechanical thermal switch 35 may be replaced by an electronic temperature switch which senses the, for example, cooling water temperature of the engine and may be an NTC resistor. A circuit including this resistor is shown in FIG. 4 which illustrates an NTC resistor 50. It is connected to an electronic temperature switch 51 that controls a transistor 52 connected in series with the differentiating pressure switch 1. All other associated circuit elements are identical to those of the illustration of FIG. 2 and will not be further discussed. A circuit employing an electronic temperature switch 51 may be especially desirable if such an NTC resistor is also used to control the warm-up phase of the engine. In the embodiment illustrated in FIG. 4, the transistor 52 will conduct below a certain temperature level and thus permit the differentiating pressure switch 1 to engage the timing circuit. The internal structure of the electronic temperature switch 51 is known. In the known circuit, the effective resistance of the NTC resistor is converted to a proportional voltage which causes the blockage of the transistor 52 at a certain temperature, thereby making the enrichment circuit ineffective.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention.
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The fuel mixture preparation system of an internal combustion engine, especially a continuous fuel injection system, is engaged during intended engine accelerations by a pressure sensor in the induction manifold which responds to increasing manifold pressure to close a switch. The switch closure affects a pressure control valve that changes the control pressure in the fuel injection system and thereby causes temporary fuel enrichment until the differential pressure in the pressure sensor has returned to equilibrium. The signal from the pressure sensor may be extended arbitrarily by interposition of an electronic timing circuit which is constructed as an integrating circuit so that its output signal, when processed by a comparator, will produce a proportionally extended actuation signal for the control valve.
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FIELD OF THE INVENTION
This invention relates to pharmacy bottles and, more particularly, a pharmacy bottle that conveys the maximum amount of information to a patient receiving prescription medication.
BACKGROUND OF THE INVENTION
For a patient that buys prescription medication, the amount of information and warnings conveyed to the patient is overwhelming. Typically, there is a label stuck to the bottle with various information and warnings thereon. For example, the prescribing physician will be named, the patient will be named, the type and dosage of medication will be given, as well as, how often the patient should take the medication each day. There probably will be a reminder concerning refills and warnings about the medication.
Because there is not enough room on the label that is stuck on the bottle to give all of the warnings and side effect of the medication, the bottle containing the medication is typically put in a bag and stapled to the top of the bag is additional product information or warnings. As a practical matter, normally the patient tears open the bag, gets out the bottle containing the medication and throws the bag with all of the product information and/or warnings stapled thereto away. It is very rare that a patient reads the product information or warnings that are stapled to the bag before it is thrown away.
If it was practical to put more product information or warnings with the container that has the medication therein, typically the patient will stand a much higher probability of reading the product information or warnings. If the product information or warnings are stapled to the bag, normally such product information or warnings are never read.
As an example of an attempt by the industry to add more information to the label, U.S. Pat. No. 7,311,205 by Adler et al shows a generally wedge shaped bottle with a curved top that allows the label to be wrapped thereover. The bottle opening is at the bottom. Due to a recess between the label and the bottle, additional product information can be inserted in that recess. However, since the bottle as shown in U.S. Pat. No. 7,311,205 has been on the market, it has received a large amount of criticism by the consuming public.
One of the largest manufacturers of containers for prescription drugs is Berry Plastics Corporation. While Berry Plastics has a complete line of prescription containers that can be selected by “family” or “size” on their website of www.berryplastics.com, the containers have the problem of insufficient room to put all of the information concerning the medication on the container so it can be seen by the patient. The most common line by Berry Plastics is the “Friendly & Safe” prescription container with the locking top. The Friendly & Safe prescription containers come in a number of different sizes. Regardless of the size, the problem of sufficient surface area to put all of the information needed on a pharmacy container still exists.
While a lack of space to put proper warnings and/or information on the prescription container is a problem, many patients take their medication by shape of the pill, shape of the bottle or other external factors other than reading the label itself. If there are multiple people in the household taking prescription medication, such as an elderly couple, some times the individuals get confused and take the other persons medication. While various systems have been devised to avoid the confusion, mistakes still occur.
The best reminder system would be one the patient can devise for themself. For example, an elderly couple, both of whom take prescription medication, might have different colors for their bottles or caps. As an example, the wife can take the color red and the husband take the color green. Therefore, all of the medication in the red capped container is for the wife and all of the medication in the green capped container is for the husband.
Another example may be different colors being used as reminders of when to take the medication. The color black could be used for medication to be taken in the evening and the color white for medication to be taken in the morning.
Whatever system is being used, there is a drastic need to convey information in an easy to understand form to the patient that is taking the prescription medication. Some information such as warnings should be given in detail. However, other information such as whose medication it is may be conveyed by colors. Whatever system is used, the object is to convey the maximum amount of information to the patient in a manner the patient will absorb and utilize.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a pharmacy bottle that conveys the maximum amount of information to the patient.
It is another object of the present invention to provide a pharmacy bottle for prescription medication where essentially all of the vertical surfaces of the pharmacy bottle may be used to convey information to the patient.
It is yet another object of the present invention to provide a pharmacy bottle for prescription medication that conveys the maximum amount of information to the patient on the vertical surfaces area thereof, but also has a slot where additional information can be inserted.
It is even another object of the present invention to provide a pharmacy bottle for prescription medication that has a slot access to a space between an internal wall and an external wall where ancillary information sheets can be inserted for the patient.
It is yet another object to provide a pharmacy bottle for prescription medications where the most critical information is communicated to the patient in the vertical surface area of the pharmacy bottle, but a slotted space in the wall contains ancillary information sheets for the patient about the prescription medication.
It is a further object of the present invention to provide colored rings that can be attached the cap of a pharmacy bottle for prescription medications, the colored rings being selectable by the patient to provide quick visual reminders to the patient when taking the prescription medication
It is still another object of the present invention to provide colored rings for a pharmacy bottle of prescription medication, which colored rings are clipped into pre-existing slots in the cap for the pharmacy bottle.
A new pharmacy bottle for prescription medication has been designed to maximize the amount of information communicated to the patient receiving the prescription medication. Essentially all of the vertical surfaces for the prescription bottle are available to receive labels adhered thereto. These labels will contain information to be conveyed to the patient such as (a) name of the doctor, (b) name of the patient, (c) name of the drug, (d) dosage of the drug, (e) refills of the drug, (f) frequency with which the drug is to be taken, (g) bar code for the drug, and/or (h) warnings for the drug. These are just some of the information that should be conveyed to the patient or pharmacist about the prescription medication.
Further, general information should be conveyed to the patient concerning the drug, such as how the drug is used, side effects, drug interactions, just to give a few some examples. However, all of the additional information concerning the drug typically will not fit on the label attached to the bottle. If the size of the print for the information on label is reduced, the likelihood of the information ever being read by the patient is likewise reduced. By having an inner wall and an outer wall of the pharmacy bottle, the additional information concerning the prescription medication can be put on an ancillary information sheet and inserted through a slot into that space with a tab extending from the slot so the ancillary information sheet can be subsequently retrieved by the patient. Thereafter, if there is a missed dose, overdose, drug interaction, or drug side effects, the patient can quickly retrieve the ancillary information sheet from the slot by pulling on the tab extending therefrom. The patient can then read the additional information on the ancillary information sheet concerning the prescription medication and act accordingly.
One way of providing the additional information is a “bottle within a bottle” with a space therebetween. The external wall of the outer bottle would have a slot or slots therein into which the ancillary information sheet may be inserted, but leaving a tab portion extending outside the slot. The ancillary information sheet may be on a single printed sheet, folded printed sheets, or multiple printed sheets the size being determined by the amount of information to be conveyed. This additional information is referred to in this application as an “ancillary information sheet,” which can be removed at any time and read by the patient. The information contained on the ancillary information sheet is in addition to the information contained on the label that is attached to the pharmacy bottle.
While the ancillary information sheet can be inserted on the side of the pharmacy bottle, also an ancillary information sheet can be inserted from the top into a top slot between an internal wall and an external wall of the pharmacy bottle. Single or multiple ancillary information sheets can included in one or more slots.
For the less observant patient that does not read the information contained on the label, colored rings may be attached to the bottle cap. The most common type of bottle cap is sold under the mark “Friendly & Safe” by Berry Plastics Corporation. The Friendly & Safe cap has interlocking tabs and probably constitutes the majority of the caps used in the pharmacy industry for prescription medication in solid form such as pills or tablets. By having interlocking extensions that fit in the indentations of the Friendly & Safe cap, colored rings can be attached to the cap. The colored ring or rings could be selected based upon the preferences of the patient. For example, if more than one patient lives in a household, each of which has their own prescription medication, a different colored ring can be used by each patient. When picking up the medication, the appropriately colored ring could be attached to the Friendly & Safe cap.
Assume the patient wants different colored rings to remind themselves of when the medication is to be taken. For example, a black ring could be used to indicate the medication is to be taken in he evening or at night or a white ring could be used to indicate the medication is to be taken in the morning. The tabs extending downward from the colored ring can lock into the indentations of the Friendly & Safe cap. Multiple colored rings could be used on a cap if desired. The purpose of the colored rings is to ensure the right patient is taking the right medication at the right time. This is a quick visual indication to the patient.
While only certain shaped pharmacy bottles are shown, the variety of shapes are almost endless with slots being formed between an internal wall and an external wall through which ancillary information sheets can be inserted. The pharmacy bottles can be rectangular or circular. The bottle caps or the cover for the opening in the pharmacy bottle could be of any type. The objective is to convey as much information to the patient receiving the prescription medication as possible, yet still convey the information in a form that has the highest probability of being utilized and understood by the patient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of a pharmacy bottle for prescription medication.
FIG. 1B is another perspective view of the pharmacy bottle for prescription medication as shown in FIG. 1A .
FIG. 1C is a perspective view of different colored rings that can be attached to the bottle cap as shown in FIGS. 1A and 1B .
FIG. 2 is a front view of the pharmacy bottle shown in FIGS. 1A and 1B with the cap exploded therefrom.
FIG. 3 is a top view of the pharmacy bottle shown in FIGS. 1A and 1B .
FIG. 4 is a side view of the pharmacy bottle shown in FIGS. 1A and 1B .
FIG. 5 is a cross-sectional view of FIG. 2 along section lines 5 - 5 .
FIGS. 6A and 6B are a pharmacy bottle for prescription medication dispensed in pill form with a slideable top opening.
FIG. 7 is a perspective view of a circular pharmacy bottle for prescription medication with the bottle cap exploded therefrom.
FIG. 8 is a top view of the pharmacy bottle shown in FIG. 7 .
FIG. 9 is a cross-sectional view of FIG. 8 taken along section lines 9 - 9 .
FIG. 10 is a front view of a rectangular pharmacy bottle for prescription medication.
FIG. 11 is a cross sectional view of FIG. 10 taken along section line 11 - 11 .
FIG. 12 is a top view of the pharmacy bottle shown in FIG. 10 .
FIG. 13 is a side view of the pharmacy bottle shown in FIG. 10 .
FIG. 14 is a typical label that may be applied to the external vertical surfaces of the pharmacy bottle shown in FIGS. 1A and 1B .
FIG. 15 is a typical ancillary information sheet that may be inserted in the slot of the pharmacy bottle shown in FIGS. 1A and 1B .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1A , 1 B, 2 , 3 , 4 , and 5 in combination, a pharmacy bottle 10 is shown with a safety cap 12 thereon. The safety cap 12 may be the “Friendly & Safe” type manufactured by Berry Plastics Corporation. The pharmacy bottle 10 is rectangular in shape with rounded external corners 14 (see FIG. 3 ) between the front surface 16 , left side 18 , back surface 20 and right side 22 . A label 24 is stuck to the pharmacy bottle 10 and wrapped around the front surface 16 , left side 18 , back surface 20 and right side 22 . A typical such label 24 is shown in FIG. 14 . The rounded external corners 14 allow the label 24 to be wrapped around and stuck to the external surfaces pharmacy bottle 10 in one simple motion by the pharmacist or technician.
By use of a rectangular pharmacy bottle 10 , the maximum amount of information can be conveyed on the label 24 for good comprehension by the patient receiving the prescription medication. For example, in referring to the prescription medicine being prescribed for John Doe as illustrated in FIG. 14 , information that is desirable to be contained on the label 24 is illustrated. On the front surface 15 would be all of the warnings that would typically be conveyed to the patient. On the left side 18 would be given the patient's name and when to take the medication. On the back side surface 20 , the doctor's name, patient's name, type of drug, dosage, refills, and expiration date would be indicated. While this is referred to as the “back surface,” it is the surface the patient will have the greatest tendency to review. On the right side 22 would be the bar code information that is important to the pharmacy selling the medication. With the use of the label 24 on the pharmacy bottle 10 , a maximum amount of information can be conveyed to the patient in a manner the patient could readily comprehend.
Normally when a pharmacist gives a pharmacy bottle containing prescription medication to the person picking up the prescription, additional information concerning the prescription such as side effects or what to do in the event of overdosage or skipped medication, is contained in additional information sheets. However, the patient upon receiving the prescription medication almost always tears open the bag and throws away the additional information. The additional information is rarely read by the patient.
The present invention shows a pharmacy bottle 10 that has a slot 28 in which an ancillary information sheet 26 can be inserted. The pharmacy bottle 10 has an external wall 30 spaced apart from and internal wall 32 (see FIG. 5 ). The slot 28 connects to the space 34 formed between the external wall 30 and internal wall 32 . By having rounded internal corners 36 , an ancillary information sheet 26 can be inserted through slot 28 and wrapped around the internal wall 32 in a manner as shown in FIG. 5 . By proper planning on the size of the ancillary information sheet 26 , a tab 38 will remain visible by extending beyond the slot 28 . The tab 38 may contain the patient's name or the type of medication thereon. The ancillary information sheet 26 wraps around between the external wall 30 and the internal wall 32 until it reaches a terminating wall 40 (see FIG. 5 ).
A typical ancillary information sheet 26 is shown in FIG. 15 . The patient's name and the drug being prescribed may be on opposite sides of the tab 38 . The ancillary information sheet 26 as shown in FIG. 15 is folded along the center line. The ancillary information sheet 26 will give considerable additional information about the prescription medication than is physically possible to put on the label 24 . Thereafter, if the patient wants to read further information about the medication, the patient can do so, including such things as side effects, drug interactions, precautions or other drug related information.
To hold the ancillary information sheet 26 in place, side tabs 42 are provided on either side thereof (see FIG. 15 ). The side tabs 42 will deform when inserted through slot 28 , but thereafter resist the removal of the ancillary information sheet 26 . With a slight tug, the patient can overcome the resistance of the side tabs 42 and remove the ancillary information sheet 26 from the slot 28 .
The internal wall 32 , in combination with the safety cap 12 and a bottom for the pharmacy bottle 10 , forms a totally enclosed container for the prescription medication. No access is provided to the inside of the totally enclosed container except by removing the safety cap 12 . There is no connection between the space 34 formed between the external wall 30 and the internal wall 32 and the inside of the pharmacy bottle 10 . This lack of connection prevents contamination of the prescription medication.
In FIG. 1A , a colored ring 44 is shown exploded above the safety cap 12 . The safety cap 12 has indentions 46 formed therein. The indentions 46 form internal tabs (not shown) that connect with locking lugs 48 as shown in FIG. 2 . Extending inward and down from the colored ring 44 are interna” ring tabs 50 . The internal ring tabs 50 fit into the indentations 46 in the safety cap 12 . By use of the internal ring tabs 50 inserted into the indentations 46 , the colored ring 44 can be secured on the safety cap 12 .
By having a selection of colored rings such as (a) white colored ring 52 , (b) black colored ring 54 , (c) red colored ring 56 , (d) green colored ring 58 , (e) blue colored ring 60 or (f) brown colored ring 62 as shown in FIG. 1C , the patient can select whatever color the patient so desires to provide reminders to the patient. For example, if there is more than one person in the household, a different colored ring 44 can be used to indicate the particular patient's medication. If a visual reminder is desired to provide the patient information as to which time of day a particular medication should be taken, for example black colored ring 54 could indicate the medication is taken in the evening and white colored ring 52 could indicate the medication is taken in the morning.
Even a combination of colored rings can be used. For example, the outermost colored ring can indicate the particular patient and the innermost colored ring could indicate the time of day the medication should be taken.
To add to the convenience of the pharmacy bottle 10 and to make it more user friendly in the medicine cabinet, a circular indentation 64 is provided in the bottom thereof. The circular indentation 64 has arcing walls 66 on either side thereof. The circular indentation 64 and the arcing wall 66 are just enough so that the safety cap 12 with any colored rings 44 thereon will fit inside of the circular indentation 64 . This allows similar shaped pharmacy bottles to be stacked inside of a medicine cabinet where the patient resides.
Referring now to FIGS. 6A and 6B in combination, a pharmacy container 68 is shown for solid medication such as pills. The pharmacy container 68 has a label 24 adhered thereto similar to the label 24 described in conjunction with FIGS. 1A and 1B . Also, the pharmacy container 68 has an ancillary information sheet 26 again, similar to the ancillary information sheet 26 described in conjunction with FIGS. 1A and 1B . An ancillary information sheet 26 is shown in FIG. 15 and a typical label 24 is shown is FIG. 14 .
The pharmacy container 68 does not have the traditional screw on cap, but instead has a slideable lid 70 to close opening 72 in top 74 . Opening 72 has tabs 76 on either side thereof. The tab 76 abuts raised portions 78 on either side of sliding slideable lid 70 to keep the opening 72 closed when medication is not being retrieved from pharmacy container 68 . FIG. 6A illustrates the slideable lid 70 in the closed position. FIG. 6B illustrates the slideable lid 70 in the opened position. The pharmacy container 68 as shown in FIGS. 6A and 6B is stackable within the pharmacy cabinet. Also, the pharmacy container 68 has the maximum space available for the label 24 to convey the most information to the patient. Also, ancillary information sheet 26 is inserted through slot 28 into a space similar to space 34 as described in conjunction with FIGS. 1A , 1 B, 2 , 3 , 4 and 5 .
Referring now to FIGS. 7 , 8 , and 9 in combination, another alternative design is shown for a pharmacy bottle 80 . The pharmacy bottle 80 has a safety cap 12 , the same as illustrated in FIG. 1A . The pharmacy bottle 80 which is of a cylindrical shape, has an external cylinder 82 and internal cylinder 84 . The external cylinder 82 is approximately the same size and shape as a thirty dram prescription container with a Friendly & Safe cap as manufactured by Berry Plastics Corporation. However, the external cylinder 82 has a slot 86 therein through which an ancillary information sheet 26 can be inserted. The ancillary information sheet 26 is similar to the ancillary information sheet shown in FIG. 15 .
While the ancillary information sheet 26 will have further information about the prescription medication, the ancillary information sheet 26 may have other information as well. For example, coupons or discounts for related medication could be included to increase sales of the pharmacy. Other marketing information could be included to increase sales of other products, related or unrelated.
The internal cylinder 84 is of a smaller diameter then external cylinder 82 and may have a diameter similar to the diameter of a twenty dram prescription medication bottle as manufactured by Berry Plastics Corporation, except there are no locking tabs at the top thereof. The internal cylinder 84 inside of external cylinder 82 defines a cylindrical space 88 therebetween. Therefore, when the ancillary information sheet 26 is inserted through slot 86 , it is directed by the internal cylinder 84 into the cylindrical space 88 and wraps therearound as can be seen in the top view of FIG. 8 and the cross-sectional view of FIG. 9 . The external cylinder 82 will have locking tabs 90 thereon for engaging the safety cap 12 in the same manner as described in connection with FIG. 2 . The label 92 that is applied to the pharmacy bottle 80 would contain the traditional information thereon as is normally contained on labels adhered to thirty dram bottles.
Referring to FIGS. 10 , 11 , 12 , and 13 in combination, a square pharmacy container 94 is illustrated. The square pharmacy container 94 may have the traditional safety cap 12 attached to top thereof to close the top opening 96 . The side walls of the square pharmacy container 94 consists of a front wall 98 , left side wall 100 , back wall 102 and right side wall 104 . The walls 98 , 100 , 102 and 104 are thicker than most pharmacy containers so that slots 106 , 108 , 110 and 112 are formed in each of the walls 98 , 100 , 102 and 104 , respectively. While the depth of the slots 106 , 108 , 110 , and 112 can be any depth, the most desirable depth would be slightly short of the height of the square pharmacy bottle 94 so that the slots 106 , 108 , 110 , or 112 does not extend through the bottom thereof. Into each of these slots 106 , 108 , 110 , and 112 , can be inserted ancillary information sheets 114 , 116 , 118 and 120 , respectively. The ancillary information sheets 114 , 116 , 118 and 120 can put additional drug information thereon and be inserted into the respective slots 106 , 108 , 110 , and 112 . If the pharmacy wants to convey additional information (such as sales or coupons) to the patient, it can also be inserted in one of the slots 106 , 108 , 110 or 112 .
The traditional information for most drugs will be contained on the stick on label 122 that wraps around the square pharmacy container 94 . An example of the traditional information, but arranged in a different format, is shown in the label 24 in FIG. 14 .
In the present invention, the objective is to convey as much information to the patient as possible either in the stick on label or in ancillary information sheets that remain with the pharmacy bottle. To keep the ancillary information sheets with the pharmacy bottle, a slot is provided in the pharmacy bottle in which the ancillary information sheet may be inserted. Colored rings may be attached to the bottle to provide further quick visual reminders to the patient when taking the medication.
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A pharmacy bottle for prescription medication is shown that conveys information thereon to the patient that is clear and understandable. Colored rings are attachable to the cap of the pharmacy bottle to convey general information. Increased surface area of the pharmacy bottle is provided for more specific information to be conveyed to the patient via the label adhered thereto. Further, more detailed information about the prescription is conveyed to the patient by ancillary information sheet(s) inserted through slot(s) into space formed in walls of the pharmacy bottle. One end of the ancillary information sheet(s) forms a tab extending from the slot(s) that may be pulled by the patient to remove the ancillary information sheet from the space via the slot(s) for review by the patient.
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This invention was made under U.S. Government Contract N00014-77-C-0634 and is subject to the provisions of ASPR 7-104.18, December, 1969, and ASPR 7-302.23(b) long form August, 1977.
The present invention relates to novel N,N'-bis(trifluoromethylsulfonyl)oxamide compounds, superior compositions containing said compounds which are useful for generating chemiluminescence by reaction with a hydroperoxide, and a process for generating chemiluminescence by reacting said superior compositions thereby.
The art has shown (Rauhut et al, U.S. Pat. No. 4,226,738) that N,N'-bis[(trifluoromethyl)sulfonyl]oxamides when reacted under particular conditions provide chemiluminescence, while the aryl-substituted oxamides described therein provide high light capacity and efficiency, as measured by the chemiluminescence quantum yield, the alkyl-substituted oxamides have chemiluminescence quantum yields which are very low, about 4.5 percent, or lower.
There is a need, therefore, for alkyl-substituted N,N'-bis[(trifluoromethyl)sulfonyl]oxamides that will furnish higher light capacities and significantly higher quantum efficiencies.
SUMMARY OF THE INVENTION
In accordance with the present invention, there are provided novel compounds represented by formula (I) ##STR1## wherein R and R' independently represent substituted alkyl of 1 to 6 carbon atoms wherein the substituents are selected from trihalomethyl, C 1 -C 6 alkoxycarbonyl, or C 6 -C 10 arylalkoxycarbonyl wherein the alkoxy moiety is of 1 to 6 carbon atoms.
In accordance with the present invention, there are also provided compositions for reaction with a peroxide component to generate chemiluminescence comprising (a) a compound of formula (I), as previously defined, (b) an organic fluorescer compound, and (c) a diluent, said ingredients being present in proportions and concentrations sufficient to produce chemiluminescence when reacted with said peroxide component.
In accordance with the present invention, there is also provided a process for generating chemiluminescence comprising reacting the composition described hereinabove with a peroxide component.
Chemiluminescent compositions of the novel compounds of formula (I) find a wide variety of applications in emergency lighting devices (see U.S. Pat. No. 3,800,132) for the home, on the road, in coal mines, on lifevests, and on aircraft escape slides.
The compounds of the present invention can be used to provide long lasting chemiluminescence. They are particularly distinguished from the alkyl-substituted oxamides of U.S. Pat. No. 4,226,738 in that they provide superior chemiluminescence quantum yields, about 10 to 20%, versus about 1 to 5%, or lower, for the prior art oxamides.
DESCRIPTION OF PREFERRED EMBODIMENTS
The compounds of the present invention are readily prepared by reacting about two molecular proportions of the appropriate trifluoromethanesulfonamide with oxalyl chloride in the presence of an acid-binding agent by methods well-known in the art.
Methods for the preparation of N-substituted trifluoromethanesulfonamides are known in the art (see Harrington et al, U.S. Pat. Nos. 3,558,698; 3,629,332; 3,799,968; 3,865,844; 3,897,449; 3,920,444; and Moore et al, U.S. Pat. No. 3,609,187).
Examples of the compounds of formula (I) include the following:
N,N'-bis[[(phenylmethoxy)carbonyl]methyl]-N,N'-bis[(trifluoromethyl)sulfonyl]oxamide,
N,N'-bis[(methoxycarbonyl)methyl]-N,N'-bis[(trifluoromethyl)sulfonyl]oxamide,
N,N'-bis[(ethoxycarbonyl)methyl]-N,N'-bis(trifluoromethyl)sulfonyl]oxamide,
N,N'-bis(2,2,2-trifluoroethyl)-N,N'-bis[(trifluoromethyl)sulfonyl]oxamide,
N,N'-bis(2,2,2-trichloroethyl)-N,N'-bis[(trifluoromethyl)sulfonyl]oxamide,
and the like.
The term "chemiluminescence," as employed herein, is defined as the generation of electromagnetic radiation between about 300 and 1200 nanometers by means of a chemical reaction.
The term "composition for reaction with a peroxide component to generate chemiluminescence," as employed herein, is defined as a mixture of a compound of formula (I) and a fluorescer compound in a diluent in concentrations sufficient to produce chemiluminescence when combined with a peroxide component. Thus, the initial concentrations of the compound of formula (I), fluorescer compound, and the ingredients of the peroxide component in the reaction mixture must be sufficient to produce chemiluminescence.
The fluorescer compounds contemplated herein may be broadly defined as those which do not readily react with the peroxide component employed in this invention or with the compound of formula (I).
Typical suitable fluorescent compounds for use in the present invention are those which have a spectral emission falling between 300 and 1200 nanometers and which are at least partially soluble in the diluent employed. Among these are the conjugated polycyclic aromatic compounds having at least 3 fused rings, such as: anthracene, substituted anthracene, benzanthracene, phenanthrene, substituted phenanthrene, naphthacene, substituted naphthacene, pentacene, substituted pentacene, perylene, substituted perylene, violanthrone, substituted violanthrone, and the like. Typical substituents for all of these are phenyl, lower alkyl, chlorine, bromine, cyano, alkoxy (C 1 -C 16 ), and other like substituents which do not interfere with the light-generating reaction contemplated herein.
Numerous other fluorescent compounds having the properties given hereinabove are well-known in the art. Many of these are fully described in "Fluorescence and Phosphorescence," by Peter Pringsheim, Interscience Publishers, Inc., New York, N.Y., 1969. Other fluorescers are described in "The Colour Index," Second Edition, Volume 2, The American Association of Textile Chemists and Colorists, 1956, pp. 2907-2923. While only typical fluorescent compounds are listed hereinabove, the person skilled in the art is fully aware of the fact that this invention is not so restricted, and that numerous other fluorescent compounds having similar properties are contemplated for use herein.
The preferred fluorescer compound is a 9,10-bis(phenylethynyl)anthracene, as disclosed in U.S. Pat. No. 3,888,786, which is incorporated herein by reference.
The 9,10-bis(phenylethynyl)anthracene compounds contemplated herein may be defined as 9,10-bis(phenylethynyl)anthracene, or chloro, bromo, fluoro, or lower alkyl substituted bis(phenylethynyl)anthracenes. The preferred compound is selected from 9,10-bis(phenylethynyl)anthracene or chloro-substituted 9,10-bis(phenylethynyl anthracenes. More preferably, the compound is selected from 9,10-bis(phenylethynyl)anthracene, 1-chloro-9,10-bis(phenylethynyl)anthracene, or 2-chloro-9,10-bis(phenylethynyl)anthracene.
Illustrative of the 9,10-bis(phenylethynyl)anthracenes which can be used in this invention are the following:
9,10-bis(phenylethynyl)anthracene,
1-chloro-9,10-bis(phenylethynyl)anthracene,
2-chloro-9,10-bis(phenylethynyl)anthracene,
1,5-dichloro-9,10-bis(phenylethynyl)anthracene,
1,8-dichloro-9,10-bis(phenylethynyl)anthracene,
1-bromo-9,10-bis(phenylethynyl)anthracene,
1-fluoro-9,10-bis(phenylethynyl)anthracene,
1-methyl-9,10-bis(phenylethynyl)anthracene,
and the like.
The term "diluent," as used herein, is defined as a solvent, or vehicle, for the compound of formula (I), and the fluorescer compound.
The term "peroxide component," as used herein, means a solution of a hydrogen peroxide compound, a hydroperoxide compound, or a peroxide compound in a suitable diluent.
The term "hydrogen peroxide compound" includes (1) hydrogen peroxide and (2) hydrogen peroxide-producing compounds.
The composition for reaction with a peroxide component to generate chemiluminescence can contain any fluid diluent which solubilizes the compound of formula I and the fluorescer compound to provide initial concentrations in the reacting system of about 10 -3 M to about 10 M, preferably about 10 -2 M to about 1 M, of the compound of formula (I), and about 10 -5 M to about 10 -1 M, preferably about 10 -4 M to 10 -2 M, of the fluorescer compound. The diluent must be relatively unreactive toward the other ingredients of the chemiluminescent mixture.
The concentrations of the compound of formula (I) and the fluorescer compound in the composition for reaction with the peroxide component is about 1.1-2.5, preferably about 1.2-1.3, times the concentrations of the same materials in the reacting system described above. Typical diluents, or solvents, which can be used include esters, ethers, aromatic hydrocarbons, chlorinated aliphatic and aromatic hydrocarbons such as those disclosed in U.S. Pat. No. 3,749,679. The preferred diluent is dibutyl phthalate. Solvent combinations may, of course, be used but such combinations should not include strongly electron donating solvents.
Hydrogen peroxide is the preferred hydroperoxide and may be employed as a solution of hydrogen peroxide in a solvent or as an anhydrous hydrogen peroxide compound such as sodium perborate, sodium peroxide, and the like. Whenever hydrogen peroxide is contemplated to be employed, any suitable compound may be substituted which will produce hydrogen peroxide.
Diluents which can be employed in the peroxide component include any fluid which is relatively unreactive toward the hydroperoxide, the compound of formula (I) and the fluorescer compound, and which accommodates a solubility to provide at least 0.01 M hydroperoxide solution. Suitable diluents for the hydroperoxide component include water; alcohols, such as ethanol, tertiary butanol, or octanol; ethers, such as diethyl ether, diamyl ether, tetrahydrofuran, dioxane, dibutyldiethyleneglycol, perfluoropropyl ether, and 1,2-dimethoxyethane; and esters, such as ethyl acetate, ethyl benzoate, dimethyl phthalate, dioctylphthalate, propyl formate. Solvent combinations can, of course, be used such as combinations of the above with anisole, tetralin, and chlorobenzene, providing said solvent combination accommodates hydroperoxide solubility. However, strong electron donor solvents such as dimethylformamide, dimethyl sulfoxide, and hexamethylphosphoramide should not, in general, be used as a major diluent for the peroxide component.
The preferred diluent for the peroxide component is a mixture of about 80-volume percent dimethyl phthalate and about 20-volume percent tertiary butanol.
The hydrogen peroxide concentration in the peroxide component may range from about 0.2 M to about 15 M. Preferably, the concentration ranges from about 1 M to about 2 M.
The lifetime and intensity of the chemiluminescent light emitted can be regulated by the use of certain regulators such as:
(1) by the addition of a catalyst which changes the rate of reaction of hydroperoxide with the compound of formula (I). Catalysts which accomplish that objective include those described in M. L. Bender, "Chem. Revs.," Vol. 60, p. 53 (1960). Also, catalysts which alter the rate of reaction or the rate of chemiluminescence include those accelerators of U.S. Pat. No. 3,775,366, and decelerators of U.S. Pat. Nos. 3,691,085 and 3,704,231, or
(2) by the variation of hydroperoxide. Both the type and the concentration of hydroperoxide are critical for the purposes of regulation.
Preferably, a weakly basic accelerator, such as sodium salicylate, is included in the peroxide component to control the lifetime of the chemical lighting system. The concentration of weakly basic accelerator used in the peroxide component may range from about 10 -6 M to about 10 -2 M, preferably from about 10 -4 M to about 10 -3 M.
The initial concentration of the ingredients of the peroxide component in the reacting system is about 0.15 to 0.60 of the concentrations in the peroxide component since the peroxide component comprises about 15 to about 60-volume percent of the reaction mixture.
The concentration of the hydrogen peroxide compound in the chemiluminescent reaction is at least equal to the molar concentration of the compound of formula (I) and is preferably 1.2 to 5.0 times the concentration of the compound of formula (I) in the reacting system described above. The optimum concentrations must be determined experimentally for each specific system.
The following examples are illustrative of the present invention. All parts are by weight unless otherwise indicated.
EXAMPLE 1
Preparation of N-(Ethoxycarbonyl)Methyl-Trifluoromethanesulfonamide
Trifluoromethanesulfonic anhydride (164 grams; 0.58 mole) is added dropwise to a stirred suspension of ethyl glycinate hydrochloride (69 grams; 0.49 mole) and triethylamine (120 grams; 1.17 mole) in methylene chloride (500 mls) at 0° C. under a nitrogen atmosphere. The reaction mixture is allowed to warm up to room temperature upon completion of the addition, and stirred thereat for 20 hours. The white solid precipitate is separated by filtration and the filtrate is evaporated to obtain 308.1 grams of a semi-solid which is subsequently extracted with diethyl ether (3×400 mls). The combined ethereal extracts are then evaporated to obtain 67.87 grams of crude product. Recrystallization of the crude product from cyclohexane gives the desired product, m.p. 73°-75° C.
Calculated for C 5 H 8 NO 4 SF 3 : C,25.55%; H,3.40%; N,5.96%. Found: C,25.77%; H,3.70%; N,5.96%.
In the manner described above using the appropriately substituted amines, the following compounds are prepared:
N-[(phenylmethoxy)carbonyl]methyl-trifluoromethanesulfonamide,
N-2,2,2-trifluoroethyl-trifluoromethanesulfonamide,
N-2,2,2-trichloroethyl-trifluoromethanesulfonamide, and
N-(methoxycarbonyl)methyl-trifluoromethanesulfonamide.
EXAMPLE 2
Preparation of N,N'-Bis[(ethoxycarbonyl)methyl]-N,N'-Bis[(trifluoromethyl)sulfonyl]Oxamide
A solution of oxalyl chloride (2.18 grams; 0.017 mole) in 20 mls of dry tetrahydrofuran is added dropwise to a solution of the product of Example 1 (6.2 grams; 0.026 mole) and triethylamine (2.7 grams; 0.027 mole) in 50 mls of dry tetrahydrofuran at 0° C. under a nitrogen atmosphere. After the addition is completed, the mixture is stirred at room temperature for 3 hours, and filtered to remove triethylamine hydrochloride. The resulting filtrate is then evaporated to obtain 6.88 grams of crude product. Recrystallization of the crude product from cyclohexane gives the desired product, m.p. 88°-90° C.
Calculated for C 12 H 10 N 2 O 10 S 2 F 6 : C,27.48%; H,2.67%; N,5.34%. Found: C,27.69%; H,2.74%; N,5.21%.
EXAMPLE 3
Preparation of N,N'-Bis(2,2,2-trifluoroethyl)-N,N'-Bis[(trifluoromethyl)sulfonyl]Oxamide
A solution of oxalyl chloride (2.62 grams; 0.021 mole) in 10 mls of dry tetrahydrofuran is added dropwise to a solution of N-2,2,2-trifluoroethyl-trifluoromethylsulfonamide (7.75 grams; 0.034 mole) and triethylamine (3.5 grams; 0.035 mole) in 50 mls of dry tetrahydrofuran at 0° C. under a nitrogen atmosphere. After the addition is completed, the mixture is stirred at room temperature for 18 hours, and filtered to separate triethylamine hydrochloride. The tetrahydrofuran filtrate is then evaporated to obtain 7.86 grams of an oil. Vacuum sublimation of the oil gives 2.5 grams of the desired product, m.p. 43°-45° C.
Calculated for C 8 H 4 N 2 O 6 S 2 F 12 : C,18.60%; H,0.78%; N,5.43%. Found: C,19.18%; H,0.67%; N,5.56%.
EXAMPLE 4
Preparation of N,N'-Bis[[(phenylmethoxy)carbonyl]methyl]-N,N'-Bis[(trifluoromethyl)sulfonyl]Oxamide
A solution of oxalyl chloride (1.89 grams; 0.015 mole) in 20 mls of dry tetrahydrofuran is added dropwise to a solution of N-[(phenylmethoxy)carbonyl]methyl-trifluoromethanesulfonamide (7.09 grams; 0.025 mole) and triethylamine (3.0 grams; 0.03 mole) in 80 mls of dry tetrahydrofuran at 0° C. under a nitrogen atmosphere. After the addition is completed, the mixture is stirred at room temperature for 4 hours, and filtered to separate the precipitate. Evaporation of the filtrate to dryness gives 6 grams of crude product. Recrystallization of the crude product from a mixture of hexane and cyclohexane gives the desired product, m.p. 53°-55° C.
Calculated for C 22 H 18 N 2 O 10 S 2 F 6 : C,40.74%; H,2.78%; N,4.32%. Found: C,40.47%; H,2.37%; N,4.47%.
EXAMPLES 5-7
Determination of Chemiluminescence
A solution (7.5 mls) of 1-chloro-9,10-bis(phenylethynyl)anthracene (CBPEA) and one of the reactants made in Examples 2-4, in dibutyl phthalate, is mixed with 2.5 mls of hydrogen peroxide and sodium salicylate disclosed in 80% dimethyl phthalate-20% tertiary butanol, by volume, to provide a reaction mixture having initial concentrations of 0.01 M of the reactant under study, 6.75×10 -3 M CBPEA, 0.38 M hydrogen peroxide, and 3×10 -4 M sodium salicylate. Quantitative measurements of the chemiluminescence is carried out by measuring the intensity of the light emitted at 555 nanometers by means of a Hirt-Roberts radiometer-spectrophotometer. The results obtained are shown in Table I.
TABLE I______________________________________ Light QuantumExample Reactant Capacity.sup.(a) Yield.sup.(b)______________________________________5 Compound of Example 2 42 12.806 Compound of Example 3 41 12.717 Compound of Example 4 32.5 10.0______________________________________ .sup.(a) Lumenhours per liter of emitting solution .sup.(b) Einsteins per mole × 10.sup.2
EXAMPLES 8 AND 9
The procedure of Examples 5-7 is followed in every detail except that 9×10 -3 M rubrene is used instead of CBPEA. The results obtained are shown in Table II.
EXAMPLES 10 AND 11
The procedure of Examples 5-7 is followed in every detail except that prior art oxamide reactants are used for comparison. The reactants used and the results obtained are shown in Table III. Comparison of these results with those in Table I, shows that the compounds of the invention provide significantly higher light capacity and quantum yield than the prior art reactants.
TABLE II______________________________________ LightExample Reactant Capacity Quantum Yield______________________________________8 Compound of Example 2 40.1 19.49 Compound of Example 3 30 14.4______________________________________
TABLE III______________________________________ Quan-Ex- Light tumample Reactant Capacity Yield______________________________________10 N,N'--bis(2-chloroethyl)-N,N'--bis- 12.2 3.68 [(trifluoromethyl)sulfonyl]oxamide11 N,N'--bis(3-chloropropyl)-N,N'--bis- 4.97 1.48 [(trifluoromethyl)sulfonyl]oxamide______________________________________
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N,N'-bis(trifluoromethylsulfonyl)oxamides are described with 2,2,2-trifluoroethyl, (ethoxycarbonyl)methyl, and [(phenylmethoxy)carbonyl]methyl substitution at the amido nitrogen atoms. These compounds, when used in chemiluminescent formulations, furnish superior light capacity and quantum efficiency. Preparation of the compounds and their use for chemiluminescence are described.
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FIELD OF THE INVENTION
This invention relates to industrial dampers of the type used in flue gas ducting systems and, in particular, provides improvements to the type of damper utilizing a sliding blade mechanism and inflatable seal.
BACKGROUND OF INVENTION
The devices of the type disclosed herein are used principally in industrial settings having exhaust duct systems with large cross sectional dimensions wherein exhaust gases must be processed by scrubbers and/or precipitators before they can be released to the air through a smokestack. An example of use for the damper of the present system would be in a power plant where combustion by-products must be released. Such combustion by-products may contain sulfur dioxide, carbon monoxide, carbon dioxide and other noxious and corrosive compounds. In addition to corrosive compounds present in the exhaust gases, temperatures within the ducts may reach highs in the range of 300° to 700° F.
It is desirable in such settings that the flow of combustion by-products through individual ducts be interrupted at various times for the purpose of performing maintenance on the scrubbers and precipitators within the exhaust system. Therefore, a typical application of the damper of the present invention would be within a duct in an exhaust system from an industrial plant to isolate a scrubber and/or a precipitator from the normal flow of combustion by-products. Because the ducts carrying the combustion by-products may be relatively large, for example, on the order of twenty-five to four hundred square feet in cross sectional area, it is possible that maintenance workers may be required to physically enter the duct to perform maintenance operations. It is therefore necessary that a seal be provided such that combustion by-products do not leak past the damper and into the area where maintenance workers may be present.
Typical prior art dampers of the type for which improvements are shown by this invention consist of a frame which is secured inline in a duct carrying combustion by-products. A blade typically slides into the cross sectional area of the duct from an area outside of the duct to close the duct, thereby interrupting the flow of the combustion by-products past the damper. In addition, to better seal the duct against leaks of the combustion by-products past the damper blade, a seal within the damper contacts the blade and is forced against the blade by an inflation pressure provided by compressed air which may be inserted into a hollow area of the seal. To open the damper it is known in the art to evacuate the air from within the seal to cause the seal to collapse away from the blade, thereby allowing the blade to be retracted to open the duct.
Such a damper is shown in U.S. Pat. No. 4,561,472 (Dryer et al.). The damper of the '472 patent is typical of those shown in the many patents of the prior art and improvements thereto are disclosed by this invention. Other similar dampers are also shown in U.S. Pat. No. 4,235,256 (Crawshay), U.S. Pat. No. 4,163,458 (Bachmann) and U.S. Pat. No. 4,022,241 (Fox).
One problem with the damper disclosed by Dryer et al. is that a failure of the seal may be precipitated by a failure of the compressed air system, which may allow the seal to deflate, thereby allowing combustion by-products to leak around the blade. A further problem with the prior art dampers of the type disclosed by Dryer et al. is that the blade, which may be subjected to differential pressure gradients and be relatively heavy, on the order of 4 plus tons, may contact the seal cartridge frame during retraction and engagement, causing galling to develop between the blade and the seal cartridge frame. This is particularly troublesome in corrosive environments where alloy materials must be utilized. Further, the mechanism for raising and lowering the blade in the prior art systems is prone to fouling by the collection of dust and dirt and through corrosion of the mechanism by continued exposure to the corrosive elements present in the combustion by-products. Lastly, the flexible seals of the prior art are typically permanently affixed to the frame of the damper, making it difficult to repair or replace the seal when necessary. These and other problems with the prior art are addressed by the current invention.
SUMMARY OF INVENTION
The device of the present invention is an improved damper of the type shown in the prior art and consists primarily of a frame which is provided with mounting flanges with holes sized for fasteners to attach to adjacent ductwork flanges. The invention includes a removable seal cartridge installed within and parallel to the frame. The seal cartridge inserts into the frame as a single unit, and may be removed and inserted through a lower access cover or a removable bonnet panel. A gasket may be attached to the seal cartridge and placed between it and the frame.
A bonnet is attached to the frame and is disposed directly above the frame, but outside of the cross sectional area of the duct. When the damper is in the open position, a blade plate is stored in the bonnet. When the damper is in the closed position, the blade plate translates into the area of the frame inside the duct with a motion which is essentially parallel to the frame. The bonnet provides an integrated area in which to store the blade plate when the damper is open and eliminates the need for seals between the lower frame section of the damper and the upper blade storage section of the damper.
In one improvement over the prior art, the opposing edges of the blade parallel to the direction of movement are formed into a rack system consisting of a toothed edge. The toothed edges of the blade plate engage with specially designed pinion wheels to impart a linear force to the blade plate thereby causing it to translate into and out of the area within the frame to open and close the damper, depending upon the direction of rotation of the pinion wheels. The invention employs circular pinions fabricated of pinion wheel sides fixated with a plurality of pinion pins. The pinion wheel sides also act as a guide for the blade plate as it translates into and out of the duct. The blade plate edges are each cut as a linear rack of a shape and dimension such that any thermal expansion of the blade is accommodated. The engagement of the pinion wheels with the blade is self-cleaning and virtually maintenance free. The use of pinion pins is an improvement over pinion gears in that solid matter and effects of corrosion do not deteriorate performance of the drive over time.
Compressed air is injected into or evacuated from the seal cartridge to operate the seal. The seal, when in the inflated position, engages the blade plate to form an air-tight barrier. When the air is evacuated from the seal cartridge, the seal collapses due to negative air pressure and the blade plate may be retracted into the bonnet. The seal cartridge is fitted with an air fitting for injection of compressed air into the seal cartridge and for evacuation of air from the seal cartridge. In another improvement over the prior art, the seal membrane of the present invention is able to maintain contact with the blade plate even in the event of a failure of the compressed air system, thereby providing a failsafe seal.
The seal cartridge is fitted with a blade guide composed of a hardened metal along which the blade plate rides as it translates into and out of the damper. The hardened metal blade guide prevents the cold welding or galling between the heavy blade plate and the seal cartridge which was a problem with prior art designs.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the damper of the present invention installed in an attached duct.
FIG. 2 is an isometric view of the damper of the present invention.
FIG. 3 shows a cut-away close-up view of the pinion wheel and motor assembly.
FIG. 4 is a side sectional view of the seal cartridge.
FIG. 5 is an isometric cut-away view of the seal cartridge installed in the frame.
FIG. 6 is a front elevational view of the damper.
FIG. 7 is a rear elevational view of the damper.
FIG. 8 is a right elevational view of the damper.
FIG. 9 is a bottom view of the damper.
FIG. 10 is an isometric cut-away view of the accessory lifting mechanism for removing the seal cartridge from the frame.
FIGS. 11 a , 11 b and 11 c are side elevational, front elevational and isometric views respectively of the pinion wheel construction.
FIG. 12 is a side cross section view of the damper having the blade plate in the open position.
FIG. 13 is a side cross section view of the damper having the blade plate in the closed position.
FIG. 14 is a schematic view of an exemplary system for inflating and deflating the air chamber of the seal cartridge.
DETAILED DESCRIPTION
The damper 1 of the present invention is shown in detail in FIG. 2 and in situ installed in duct 2 in FIG. 1 . Damper 1 consists essentially of frame 10 , having a lower section 5 , as shown in FIG. 6 , disposed within the cross sectional area of attached duct 2 , and an upper section 6 , disposed adjacent to lower section 5 and outside of the cross sectional area of duct 2 . In a normal installation, upper section 6 will be above lower section 5 , but, in practice, there is no reason why upper section 6 cannot be disposed to the right, to the left, or below lower section 5 . Frame 10 can be attached to duct 2 by any conventional means known in the prior art, such as through the use of bolts or folded flanges.
Seal cartridge 12 is situated within lower portion 5 of frame 10 , as shown in FIG. 5 and can be removed by opening seal access port 22 , located at the lower extremity of frame 10 , as shown in FIG. 9 . Seal access port 22 allows seal cartridge 12 to be removed for maintenance and/or replacement. Seal cartridge 12 may also be removed for maintenance and/or replacement by use of a blade lift attachment 25 , shown in FIG. 10 , which allows blade plate 16 to lift seal cartridge 12 out of frame 10 when bonnet 14 is removed. Blade lift attachment 25 is hooked over blade plate 16 and attached to holes defined in ears 74 , which are affixed to seal cartridge 12 .
When in place, seal cartridge 12 is secured to frame 10 via a series of bolts extending through holes defined in the bottom of U-shaped flange 62 (not shown) which align with a corresponding series of holes defined in frame 10 . The bolts are secured with nuts. Preferably, to reduce leaks of compressed air from air chamber 65 , the nuts are welded to the inside of U-shaped flange 62 around the holes defined therein. Alternatively, seal cartridge 12 may be secured within frame 10 by one or more clamps (not shown).
When in position within lower portion 5 of frame 10 , seal cartridge 12 provides an opening 13 through which material within attached duct 2 can flow when damper 1 is in the open position.
Upper portion 6 of frame 10 consists of enclosed bonnet 14 which will normally extend above and outside of attached duct 2 . Bonnet 14 houses blade plate 16 when damper 1 is in the open position, as shown in cross sectional view in FIG. 14 . Bonnet 14 is integral with lower portion 5 and thereby eliminates the need for additional seals between frame 10 and blade plate 16 .
When damper 1 is in the open position, as shown in the cross-sectional view in FIG. 13 , blade plate 16 is disposed within bonnet 14 , guided by frame members 24 , and area 13 in lower portion 5 of frame 10 is free of obstruction. To close damper 1 , blade plate 16 is translated into lower position 5 of frame 10 , and is situated between frame 10 and seal cartridge, occupying space 76 as shown in FIG. 5 , thereby obstructing the flow of material through opening 13 . This is shown in a cross-section in FIG. 12 . To provide an air-tight seal, seal membrane 70 is inflated with a compressed air to force it into contact with blade plate 16 .
Blade plate 16 is configured with a linear rack of toothed openings 17 on opposing sides thereof, which engage pinion wheels 18 disposed on opposite sides of frame 10 and extending through bonnet 14 . Pinion wheels 18 are housed in housings 20 which extend from the sides of bonnet 14 . In some embodiments of the invention, only one side of blade 16 may have linear rack 17 defined thereon and only one pinion wheel 18 . Such a configuration may be used, for example, where damper 1 is situated such that upper portion 6 of damper 1 extends from the side of duct 2 instead of from the top, and where the motion of blade plate 16 is horizontal as opposed to vertical.
Pinion wheels 18 are shown in FIGS. 11 a - c , and consist of pinion wheel sides 84 attached radially with pinion wheel hub 80 , through which shaft 100 passes, and which, in turn, is eventually driven by motor 30 (see FIG. 3 ). A plurality of pinion pins 82 are disposed between pinion wheel sides 84 at a point between pinion wheel hub 80 and the outer radius of pinion wheel sides 84 , and are held in place thereby. The actual number, size and spacing of pinion pins 82 may be varied without departing from the spirit of the invention, and is dependent upon, among other factors, the size and weight of blade plate 16 . The spacing, size and frequency of slots 17 in the linear racks located along the sides of blade plate 16 must, of course, correspond with the frequency, size and shape of pinion pins 82 in pinion wheels 18 . Additionally, hub 80 may be optional; pinion wheel sides 84 may be attached directly to the shaft of a motor or geared drive.
Rack 17 on each edge of blade plate 16 are cut of such a shape and dimension such that thermal expansion of blade plate 16 is accommodated. Pinion wheels 18 on either side of blade plate 16 counter rotate with respect to each other, thereby allowing blade plate 16 to move upward into bonnet 14 or downward into lower section 5 of frame 10 . The movement of blade plate 16 is guided by blade guide 24 and also by pinion wheel sides 84 , as shown in the cut-away view of FIG. 3 .
Pinion wheels 18 are driven in counter rotating directions in the preferred embodiment by motor 30 , which is linked to drives 32 . Drives 32 for respective pinion wheels on the left and right side of damper 1 are connected by connecting rod 34 , and, optionally, by flexible joints (not shown) located between drives 32 and connecting rod 34 . Therefore, the motion of pinion wheels 18 is mechanically synchronized to insure that both sides of blade plate 16 are raised and lowered simultaneously. Alternate methods of rotating pinion wheels 18 , such as the use of varying number of motors and varying configurations of linkages are contemplated to be with the scope of this invention.
The engagement between pinion pins 82 and linear racks 17 is virtually maintenance free. The use of pinion pins 82 represents an improvement over the prior art pinion gears in that solid matter and the effects of corrosion do not deteriorate the performance of the drive over time.
Seal cartridge 12 is shown in detail in FIGS. 4 and 5 and consists primarily of frame 10 upon which is mounted seal membrane 70 . Seal membrane 70 is composed, in the preferred embodiment, of a reinforced fluoroelastic material with reinforcing fibers oriented radially about the center of the seal. Fluoroelastomers (FKM) used in the preferred embodiment of the invention are of the type manufactured in the United States by Dupont Dow Elastomers, L.L.C. of Wilmington, Del. under the trade name Viton® and by Dyneon, L.L.C of Oakdale, Minn. under the trade name Fluorel®. FKM is often used as expansion joints in ducts. Preferably, the corners of seal membrane 70 are shaped as a quarter circle having a radius essentially compatible with the overall seal proportions. The reinforcing fibers in the seal membrane may be stainless steel, nickel alloy, fiberglass, polyester, Kevlar® or any other high-strength material. In some instances, it may be preferable that the reinforcing material be a corrosion-resistant material.
Seal membrane 70 is attached to U-shaped flange 62 using bolts 68 a and 68 b as shown in the cross-sectional view of seal cartridge 12 in FIG. 4 , thereby forming air chamber 65 . Alternatively, welded studs may be used in place of bolts 68 a and 68 b to attach seal membrane 70 to U-shaped flange 62 . Compressed air can be forced into air chamber 65 or evacuated from air chamber 65 via air valve 19 shown in FIG. 4 . Seal membrane 70 is shown in its normal position in FIG. 4 . This positioning of seal membrane 70 is assumed in the absence of negative air pressure within air chamber 65 , that is, when compressed air is introduced into air chamber 65 , or when there is a neutral air pressure in air chamber 65 . As a result, the contact between seal membrane 70 and blade plate 16 will be maintained even in the event of a failure of the compressed air system, or in the event of a leak in air chamber 65 . Reference number 72 in FIG. 4 shows the position of seal membrane 70 assumed when air chamber 65 is evacuated under negative air pressure. Position 72 of seal membrane 70 is assumed when blade plate 16 is translating from one position to another, to avoid contact between irregularities, rough surface areas or corrosion extant on blade plate 16 with seal membrane 70 , thereby further prolonging the life of seal membrane 70 .
Inner seal guide 64 and outer seal guide 66 prevent creasing of the fluorelastomer and therefore further prolongs the life of seal membrane 70 . The offset position of bolts 68 a , located on the inner surface of flange 62 , and 68 b , located on the outer surface of flange 62 , with respect to each other force seal membrane 70 to assume its normal (non-evacuated) position even during a loss of air pressure within air chamber 65 .
During the operation of damper 1 , air chamber 65 is evacuated under negative air pressure through air valve 19 and seal membrane 70 is drawn into position 72 against inner and outer seal guides 64 and 66 respectively, to avoid contact with blade plate 16 as blade plate 16 translates into or out of bonnet section 14 . If damper 1 is being closed, blade plate 16 moves into a position juxtaposed with seal cartridge 12 and in between seal cartridge 12 and frame 10 , to occupy space 76 shown in FIG. 5 . As blade 16 is translating into this position, seal membrane 70 is held against seal guides 64 and 66 by negative air pressure within air chamber 65 to prevent contact with blade plate 16 .
Blade guide 60 is preferably welded to flange 62 and serves as a guide for blade plate 16 to ride along, further negating the possibility of contact between blade plate 16 and seal membrane 70 . Preferably, blade guide 60 is composed of a hardened metal or a soft metal having a hardened metallic coating, such that blade guide 60 has a hardness greater than that of blade plate 16 . When fully lowered into lower section 5 , blade plate 16 rests between blade guide 60 and frame 10 of damper 1 . When seal membrane 70 is inflated by the introduction of compressed air into air chamber 65 , seal membrane 70 engages blade plate 16 to form a seal. At this point, blade plate 16 may be not necessarily be in contact with blade guide 60 . Under normal operating conditions, i.e., when damper 1 is opened, air chamber 65 is either pressurized by compressed air within chamber 65 or by neutral air pressure within chamber 65 . In either case, seal membrane 70 should assume its normal, non-evacuated position.
FIG. 14 shows a schematic of a system used to inflate and evacuate air chamber 65 of seal cartridge 12 . Air supply 48 provides pressurized air which is stored in accumulator 50 through check valve 52 . Filter/regulator 46 filters the air of impurities and regulates the pressure. Seal air chamber 65 is inflated when three-way valve 42 is de-energized. To evacuate air chamber 65 , valve 42 is energized and air flow through ejector 44 causes air from air chamber 65 to be withdrawn. Note that the system shown in FIG. 12 is only illustrative of one possible system for manipulating seal membrane 70 ; many other configurations well known in the prior art may also be used.
The illustrations, materials, and dimensions used herein are exemplary in nature only and are not meant to limit the scope of the invention, which is embodied in the claims which follow.
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This invention discloses improvements to a damper of the type used in industrial applications to open and close ducts carrying noxious or corrosive materials, such as combustion by-products. The improvements include a linear rack and wheeled pinion system to raise and lower a damper blade plate and improvements to the seal cartridge to prolong the life of the seal membrane and to prevent galling between the blade plate and the seal cartridge or damper frame.
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This application is a divisional of U.S. patent application Ser. No. 08/845,603, filed Apr. 25, 1997, now U.S. Pat. No. 5,925,384, which is incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to encapsulating electronic elements in a plastic material, and in particular the present invention relates to an apparatus and method for bypassing the molding machine automatic delivery system.
BACKGROUND OF THE INVENTION
The BOSCHMAN automold machine is utilized to encapsulate electronic components such as integrated circuits in a plastic material. Circuit dies are fabricated or die cut from wafer material and then added to a substrate material forming a circuit sub-assembly. The circuit sub-assemblies are run through the BOSCHMAN machine to encapsulate the parts in plastic to protect the circuits dies and leads or wire bonds from damage.
The BOSCHMAN machine operates in a manner where the circuit sub-assemblies are automatically fed into the mold section of the machine with one sub-assembly disposed in each mold cavity. Plastic material is then injected through a sprue into the mold cavities to encapsulate the subassemblies. The encapsulated components are then automatically ejected or unloaded from the machine. The plastic material is initially provided in the form of a pill or pellet and may consist of any number of materials such as a thermoset resin or a melamine compound or the like. The pellets are automatically transported by a pellet boat which individually delivers a pellet to a pot adjacent each mold cavity. The mold section is heated to liquefy the pellets prior to injection of the plastic material into the mold cavities.
The mold cavities and material transport passages of the automold machine must be cleaned periodically to remove excess material and contaminants. The automold machine runs on a continuous cycle or process.
One method of cleaning requires the machine to be shut down long enough for a technician to remove the mold from the machine, replace the mold with a spare, and restart the machine. This process requires significant down time for the machine, which is on the order of 60 minutes for each cleaning cycle. This method requires having a spare mold, which is an added expense. Further, the removed mold must also be cleaned, adding time to the cleaning cycle.
An additional method of cleaning may be performed by running cleaning pellets directly through the machine through the production process path. One problem with this method is that the cleaning pellets are often of a different size than the plastic material pellets. To run a continuous line, the system can only handle one size pellet and therefore the machine must be shut down to convert the system to accept the odd size cleaning pellets. Another problem with this method is that the machine must be completely evacuated of process pellets before loading the cleaning tablets or pellets into the automatic feed system to avoid mixing of materials. The cleaning pellets leave a residue throughout the process path and handling system if run through the machine in this manner. One or more cleaning pellets may even be left in the system when converted over to the process pellets. This causes cleaning material to mix with the plastic material contaminating any parts encapsulated with the mixed materials. The procedure necessary to ready the mold for the cleaning process and production processes are different. If the set-up for the production process is not done perfectly after the cleaning process is complete, the mold must be re-conditioned causing further downtime of the automold machine.
An additional problem with the present machine is that it is difficult and time consuming to do a test or experimental run for materials other than the production pellet material. This is because, again, the machine must be shut down and evacuated of all production pellet material prior to performing the test. Once a test is completed, the machine must again be shut down for conversion back to production material. Because the machine must be shut down, it would be very time inefficient and therefore undesireable to attempt to run a low volume test, such as a single shot test.
For the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an improved apparatus for and method of cleaning a BOSCHMAN automold machine which results in a more reliable production mold process, requires less machine downtime, and is easier to perform than conventional known methods.
SUMMARY OF THE INVENTION
The above-mentioned problems with present automold technology and other problems are addressed by the present invention and which will be understood by reading and studying the following specification. An apparatus and method of bypassing the automatic feeding system of a BOSCHMAN automold machine is described which is useful in the process of encapsulating electronic components and the like with a plastic material which results in a more reliable product while taking less time to perform.
In particular, one embodiment of the present invention describes a manual loader for use in bypassing the automatic pellet feeder of the machine used to encapsulate integrated circuit assemblies in plastic. The loader has a support mounted adjacent the mold section of the machine. The loader also has at least one pellet boat which moves relative to the support into and out of said mold section. The pellet boat includes one or more pellet pots which are adapted to receive and hold a solid pellet of material.
The loader also has a release mechanism which is movable between a blocking position and a release position. The release mechanism retains the pellets in the pellet pots in the blocking position and releases the pellets from the pots when manipulated to the release position for dropping the pellets into a mold of the machine's mold section.
The manual loader may be used to bypass the automatic feeder system to permit cleaning and experimental testing of mold compounds without requiring a total evacuation of production pellet materials from the feeder system. An operator need only momentarily stop the machine's feeder, load cleaning or test pellets into the pellet boat, maneuver the boat into the mold section of the machine, release the pellets into the mold, and remove the boat from the mold section. The operator then need only run the mold through a single cycle to either clean the molds or to produce a single shot of experimental integrated circuit assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a conventional BOSCHMAN automold machine where the front cover panels have been removed to view the internal components of the machine;
FIG. 2 is a perspective view of the automatic feeder system major components of the machine of FIG. 1;
FIG. 3 is an exploded perspective view of an upper and a lower mold section of the machine of FIG. 1 shown with a manual bypass loader constructed in accordance with one embodiment of the invention;
FIG. 4 is a side view in cross section taken along line 4--4 of FIG. 4 of the manual pellet boat;
FIG. 5 is an end view in cross section taken along line 5--5 of FIG. 4 of the manual pellet boat;
FIG. 6 is a top view in cross section taken along line 6--6 of FIG. 5 of the manual pellet boat; and
FIG. 7 is a top view of the release shaft in the release position within the pellet boats of the manual bypass loader of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present inventions. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present inventions is defined only by the appended claims.
Referring now to the drawings, FIG. 1 illustrates a BOSCHMAN automold machine 20 used to encapsulate integrated circuit assemblies with a plastic material as is known in the art. Machine 20 is illustrated in FIG. 1 with the front covers taken off to illustrate the general internal components and sections of the machine. Machine 20 includes a control unit 21 for programming and setting up the machine to control the various steps of the encapsulation process. The control unit 21 may be programmed to accommodate many different applications. The machine also includes a feeder system 22 having a pellet supply 24 for holding a plurality of material pellets therein to be used during the process. Below the pellet supply is a pellet separator 26 for separating out each individual material pellet for delivery to a pellet transport 28. The individual material pellets are fed through the above-described automatic feeder system 22 to the mold section 29 of the machine where a single individual pellet is delivered to each pellet pot as will be described herein.
A mold drive system 34 is driven to bring the two halves of a mold 30 together to encapsulate the integrated circuits held therein. A plunger 32 is driven into mold 30 to transfer material from a pellet pot through sprues (not shown) and in to the individual cavities (FIG. 3). The machine 20 will not be described in any greater detail herein as the machine is well known in the art and the basic process of encapsulating integrated circuits by use of the machine is also known in the art. The invention is directed to a method and apparatus for circumventing or bypassing the automatic feeder system 22 for cleaning the mold section 29 and for easily performing experimental trial molds without having to empty out or clean the automatic feeder system.
Therefore, FIG. 2 illustrates the basic components of the automatic feeder system 22 in greater detail. Pellet supply 24 of the system typically includes a pair of containers 40 which are each filled with a plurality of material pellets 42 so that a continuous supply of pellets may be provided to the system. One container 40 may be removed from the system and refilled while the other one remains attached to the system to continuously supply material pellets. A spiral wall 43 urges pellets 42 within each container 40 toward one end so that they may be dropped down a chute 44 to a rotating cage 46 which separates and properly orients the material pellets 42 therein. The pellets 42 are transported by a small conveying system 48 to the pellet separator 26 where the pellets are individually dropped into a pellet boat 50. The pellet boat 50 transports the pellets to the mold section 29 of the machine for further processing steps.
A lower mold 60 and an upper mold 61 of the mold section is illustrated in FIG. 3. The exemplary lower mold 60 includes two parallel mold cavities therein, each having a plurality of spaced-apart pellet pots 62. A number of circuit cavities 64 are adjacent each pellet pot 62. An integrated circuit assembly (not shown) is held within each circuit cavity 64. The mold is heated so that the pellets within cavities 62 turn to liquid. The liquid is injected by the plunger 32 from the pellet pots 62 through the mold channels 66 to the circuit cavities 64. The mold 60 rests against a bottom heater block 70 for heating the lower mold 60. Similarly, the upper mold 61 having corresponding cavities and a corresponding heater block 76 would mate against lower mold 60 during the encapsulation process.
During standard operation, the pellet boat 50 is automatically manipulated into mold section 29 through upper heater block 76 and further manipulated to drop a material pellet 42 into each pellet cavity 62. The boat 50 is then automatically moved out of the mold section prior to the plunger 32 and mold drive system 34 dropping the upper half of the mold against lower mold 60.
A typical mold of the BOSCHMAN automold machine 20 must typically be cleaned about every 600 to 1,000 shots. A mold is typically cleaned off-line, requiring that each mold be removed from the machine and manually cleaned by one of several known processes using any one of many solvents or compounds. Each time a mold is cleaned, the machine must be shut down or paused while the mold is removed. The machine must either sit idle while the mold is cleaned and replaced or a spare mold must be pre-heated and installed and then the machine must be restarted while the primary mold is cleaned. Either way, the machine is down for a minimum of about sixty minutes to swap molds or longer to clean the only mold. In addition, a qualified technician is required to tear down the mold and then re-install the primary mold.
One problem with the present process is that to maximize the up time of the machine, two molds must be in existence, adding significant cost to a particular application. Also, the machine and the molds suffer wear and tear each time they are removed, cooled, cleaned, re-heated and replaced. Additionally, time and productivity are lost each time the machine is down for cleaning. Further, by constantly removing and replacing the molds, mold alignment is constantly being altered resulting in inconsistent or flawed component production.
An additional problem which exists with the present BOSCHMAN automold machine 20 is that it limits or inhibits experimental runs. It is often necessary to test new compounds for encapsulating integrated circuits, and to do so using the present machine is difficult, time consuming and may damage the machine or production run components after an experimentation run. This is because each time an experimental run is performed, the machine must be shut down, the feeder system and molds must be evacuated of all production pellet material, and then the feeder system must be filled with the experimental compound.
After an experimental run is performed, the machine must again be down to be evacuated of any experimental compound. Significant time is lost when undergoing such a procedure. Also, if the machine is not completely cleared out before and after the experimental run, a mix of materials or compounds may result, either negating the results of an experimental test or producing flawed or damaged production components. Additionally, because of the time it takes to change the machine over, it is inefficient to run a short, very low volume experimental run. It is desirable that there be a means to bypass the automatic feeder system which would permit an experimental run of even a single mold shot.
It is an object of the present invention to provide a manual loader which bypasses the machine's automatic feeding system, permitting the molds to be cleaned while installed in the machine without causing significant production down time. It is also an object of the invention permit experimentation without having to clear out the feeder system of production materials or pellets.
FIG. 3 illustrates a manual bypass loader 100 constructed in accordance with one embodiment of the present invention. Loader 100 is intended to be mounted within mold section 29 of machine 20 adjacent mold 30 (see FIG. 1) so that it may be inserted into the mold section from the opposite side relative to the automatic pellet transport or pellet boat 50. Bypass loader 100 includes a support bracket 102 mounted to a fixed portion of machine 20 such as a cross member 104 within the mold.
Bypass loader 100 includes a pair of manual pellet boats 106 having a plurality of pellet pots or cavities 108 formed therein which are intended to correspond to pots or cavities 62 in the mold 30 as illustrated by lower mold 60. Bypass loader 100 also includes a splined shaft or raceway 110 mounted at one end to a rod mounting bracket 112 supported by an isolation plate 114 adjacent mold 30. The manual pellet boats 106 are carried on a connecting plate or carrier 116 at one end adjacent support bracket 102. Carrier 116 is adapted to be received and slidable along raceway 110 for moving the manual pellet boats into and out of mold section 29 of the machine as will be described herein.
As illustrated in FIGS. 4 and 5, each pellet boat 106 comprises an elongate structure having a plurality of transverse through bores defining pellet pots 108 at one end and arranged longitudinally along the boat 106. As illustrated in FIG. 5, a longitudinal or axial shaft bore 118 is formed along each boat 106 slightly offset from the central axis of each pellet boat. The diameter of shaft bore 118 is intended to slightly impinge into each pellet pot 108. A release shaft 120 (shown in FIG. 7) is received in and extends along the shaft bore and includes a plurality of transverse grooves or clearance cutouts 122 which are each intended to correspond in contour and position with one of pellet pots 108.
When the release shaft 120 is in a release position, each clearance cutout 122 aligns with a corresponding pellet pot 108 to provide an unobstructed passage through pellet boat 106 via each pellet pot. This allows a material pellet 42 held within each pot to pass directly therethrough. The release shaft 120 may be manipulated by either rotational or longitudinal movement to a blocking position such that the clearance cutouts 122 do not correspond or align with pellet pots 108. In this condition, a portion of the diameter of release shaft 120 impedes or impinges upon the perimeter surface of pellet pots 108, thus obstructing passage of material pellets through the pots. If longitudinal movement of the shaft is to be used to block passage through the pots, the clearance cutouts may alternatively be annular rings or grooves formed around the outer diameter of shaft 120.
Each pellet boat 106 includes a raised section 123 corresponding to the end of shaft 120 including the pellet pots 108. The raised section provides a pellet nest 124 above the blocked portion of the pellet pot. Thus, a pellet 42 may be received in pellet pot 108 and retained within each pellet nest 124 when shaft 120 is in the blocking position as described above.
To operate bypass loader 100, each release shaft 120 must be in the blocking position prior to inserting material pellets 42 within the pellet pots 108. Once the material pellets are added, a user will manipulate a handle 130 to slide the bypass loader 100 forward along raceway 110 until all of the pellet pots 108 pass through isolation plate 114 into the mold section 29. A positive stop mechanism or an electronic sensing means such as detect rod 132 may be utilized to sense when bypass loader 100 is fully inserted into the mold section, ensuring that each pellet pot 108 are positioned directly over a corresponding mold cavity or pot 62 in the lower mold 60.
The release shafts 120 must be manipulated to the release position, permitting the material pellets 42 to pass through the pellet pots 108 and boats 106 into the mold cavities 62. The release shafts 120 are spring loaded, and are automatically released when the bypass loader 100 is fully inserted into the mold section. The operator then must manipulate handle 130 to slide the pellet boats back out of the mold section 29 to the rest position. The operator then may run the machine through a mold cycle. During the mold cycle, the lower mold closes and makes contact with the upper mold. Pellets 42 drop into the pots 108, and the plunger forces the melted pellets 42 into the channels 66 to the circuit cavities 64.
The bypass loader 100 of the invention provides two very important aspects not provided by the existing automatic feeder system 22 of the BOSCHMAN automold machine 20. The manual bypass loader 100 permits the machine and its molds 30 to be cleaned without removing the molds from the mold section. Further, this may be done without completely evacuating the automatic feeder system of any production process material pellets. Also, experimental or test runs may be performed using different pellet material compounds for as little as one mold shot. Each test cycle may also include as few as one test pellet or as many material pellets 42 as can be held in the manual pellet boats 106. This again may be done without the necessity of completely evacuating the automatic feeder system of other pellet material compounds. Successive test runs may also be run where each run includes a different material compound.
To clean the molds utilizing the manual bypass loader of the present invention, an operator need only insert cleaning pellets into pellet pots 108 of the pellet boats 106 prior to moving the bypass loader forward into the molds 30 of the machine 20. The cleaning pellets are then dropped into the pellet pots 108 of the upper mold 61. This allows the cleaning material of the pellets to be heated and injected through channel 66 and to the mold cavity 64 to clean them. The cleaning material is then removed from the mold cavity 64, which can occur either manually or automatically. However, since the cleaning material tends to be more fragile, the cleaning material is preferably removed by hand.
To run an experimental test, the automatic feeding system is simply shut off and experimental material pellets are inserted into pellet pots 108 of manual pellet boats 106 and then inserted into the pellet cavities 62 in lower mold 60 as described above. The experimental material will then be heated by the molds, allowing it to flow into circuit cavity 64 to encapsulate integrated circuit assemblies with the experimental compound. The operator then cycles the machine to eject them from the circuit mold cavities and removes them from the machine in a conventional manner. During experiment or cleaning cycles, lead strips without dies are used in the machine 20 for encapsulation, and then are later discarded. To proceed with a production run from either a cleaning or an experimental cycle, the automatic feeding system may simply be turned back on, permitting the production material compound pellets to drop one by one into the production automatic pellet boat feeders 50.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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A manual loader for use in bypassing an automatic pellet feeder for an automold machine used to encapsulate integrated circuit assemblies in plastic. The loader has a support mounted adjacent the mold section of the machine. The loader also has at least one pellet boat which moves relative to the support into and out of said mold section. The pellet boat includes one or more pellet pots which are adapted to receive and hold a solid pellet of material. The loader has a release mechanism which is movable between a blocking position and a release position. The release mechanism retains the pellets in the pellet pots in the blocking position and releases the pellets from the pots when manipulated to the release position for dropping the pellets into a mold of the machine's mold section.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional application of copending application Ser. No. 12/140,676, filed Jun. 17, 2008, which is a divisional application of prior application Ser. No. 11/195,147, filed Aug. 2, 2005, now U.S. Pat. No. 7,399,421. The entire contents and disclosures of patent application Ser. Nos. 12/140,676 and 11/195,147 are hereby incorporated herein by reference in their entireties.
This application is related to application Ser. No. 11/195,150, filed Aug. 2, 2005, for “Injection Molded Microlenses For Optical Interconnects,” now U.S. Pat. No. 7,295,375, issued Nov. 13, 2007, the disclosure of which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a highly efficient wafer-scale microelectronic process for the fabrication of spectral filters, microoptics, optical waveguide arrays and their aligned attachment to optoelectronic semiconductor imaging devices, integrated photonic devices, image displays, optical fiber interconnection, optical backplanes, memory devices, and spectrochemical or biomedical analysis devices.
2. Background Art
Synthetic reconstruction of color images in solid-state analog or digital video cameras is conventionally performed through a combination of an array of optical microlens and spectral filter structures and integrated circuit amplifier automatic gain control operations following a prescribed sequence of calibrations in an algorithm. Fabrication of a planar array of microlenses is conventionally performed by application of a photoresist on a topmost layer of planarized film formed over red, green, blue color filters. By successive processing steps of patterning, developing, etching, followed by thermal reflow, the resist forms approximate plano-convex or hemispherical microlenses. The rheologic properties of the resist will determine the radius of curvature of the microlens elements in the planar array. Coupled with the resist's index of refraction, the resulting microlens array will have a focal length and light-collection properties which may depart from desired optimum performance, including poor control of the fill-factor of the photodiodes in an array comprising the pixel plane. Optical design of the lens shape and refractive index is extremely limited by the necessity to use photoimageable materials with restricted thermal reflow characteristics.
It is difficult to achieve long focal length high radius of curvature and high refractive index microlens arrays in a single array-plane using conventional microlens forming and fabrication processes. U.S. Pat. No. 6,482,669 B1 summarizes a number of the drawbacks of known solutions in the Prior Art. It is further noted and particularly pointed out that the present invention enables high-volume manufacturing of aspheric microlens arrays. In addition to the foregoing description of fabricating semiconductor color imagers for digital cameras, microlens arrays are also widely employed for high-resolution display monitors and for the coupling of optical waveguides in optical backplanes and optical fibers used in optical communications networks. Electrically addressable lens elements made of various liquid crystal materials are also used in lens assemblies with variable focal length and variable depth of field, or to adjust the image position to accommodate different viewing conditions. These active lens elements are on the order of tens of microns in thickness and can be switched at speeds greater than 85 MHz, enabling full spectrum color imaging without noticeable flicker.
FIG. 1A exhibits the Prior Art process 100 for the formation of a microlens array: a planar film of a photoimageable material such as a photoresist is photolithographically patterned such that exposure to actinic radiation and subsequent development of the photoresist forms a two-dimensional array of mesas which can be thermally reflowed (melted) into planoconvex microlenses under surface tension forces. An exploded assembly view is shown in 110 , indicating the relative position and alignment of the microlens array elements to an underlying array of red, green, blue color filters and further underlying array of semiconductor photodetectors. By electronically amplifying and combining the outputs of the red, green and blue signals to comprise a unit of image or a picture element termed a pixel, color image formation is achieved. FIG. 1B is an isometric view showing the detailed semiconductor cross-section of the mesa-patterned photoresist 120 before reflow and the resulting planoconvex lens 130 after reflow. Topographical variations caused by the process of integrating color filters into the semiconductor, as shown in FIG. 1B , are a common problem in the Prior Art and typically require additional processing steps for adding a planarizing layer. The focal length required of the microlens elements is the vertical distance projected down to the photodetector array plane.
As the diameter of the approximately hemispherical microlens is reduced to accommodate increasing imager resolution and pixel density, the precursor photoresist film thickness scales down and the thermal reflow process of the prior art microlens formation process becomes limiting; the radius of curvature and refractive index of the reflowed lens cannot achieve the focal length requirement without significant cross-sectional thinning of the semiconductor device structure. FIG. 1C illustrates the case of collimated incident light 140 collected by planoconvex lens 150 converging a cone of light 170 passing through color filter 160 to focal plane 180 at photodetector 190 . Optically generated cross-talk may result for off-axis incident image light, in spite of measures incorporating metal light shields formed between the color filters, when the optical properties of the microlens are limited by the thermal reflow process of the Prior Art, as demonstrated in FIG. 1D .
SUMMARY OF THE INVENTION
An object of the present invention is to teach an apparatus for high-volume wafer-scale manufacturing by injection molding of microoptic elements and microspectral filtering devices.
The conventional definition of a microlens is a lens with a diameter less than one millimeter. Generalizing this definition to the functional elements of optical systems designs, such as refractive or diffractive lenses, mirror/reflectors, Bragg gratings, interferometric devices like Mach-Zender interferometers, mode transformers for waveguide or fiber-optic couplers, variable or fixed optical attenuators, polarizers, compensators, rotators, splitters, combiners, and other devices, it is in accord with the above-mentioned object of the present invention to teach the extension of injection-molding technology down to the order of a micron.
Another object of the present invention is to provide processes for the wafer-scale fabrication of microoptic devices, which can be integrated into semiconductor structures, such as a color-imaging device for digital cameras. A further object of this invention is to extend this fabrication process to include liquid crystal materials which may be formed into active lens arrays with electronically variable focal length and depth of focus. In accord with another object of the present invention, there is provided a manufacturing method and microelectronic fabrication process sequence which minimizes the number and task-times of the operational unit-process steps required in the reduces of semiconductor arrays for color imaging devices. Production cost minimization is consistent with this latter object of the present invention.
A further object of the present invention is to teach the manufacturing of aspheric microlenses and lensfilter integration that are not possible with Prior Art technologies. A still further object of the present invention is to provide an apparatus and method for the lithographically precise alignment of arrays of microoptic elements to semiconductor structures, such as integrated color filter arrays and photodiode arrays, and, the attachment thereto.
Attachment of semiconductor chips to carriers, modules or packages using controlled collapse chip connection (“C4”) technology has proven to provide superior electrical performance parameters, such as minimizing parasitics, mutual inductance, controlled impedance, and noise reduction. It is an object of the present invention to enable the concurrent use of the injection-molding apparatus for the hybrid use of solders for C4 joining of chips to substrates and for optical polymers or glasses for forming and attaching microoptic elements.
Additional molding features and additional uses for molded microoptic devices are described in U.S. Pat. No. 7,295,375 for “Injection Molded Microlenses For Parallel Optical Interconnects,” issued Nov. 13, 2007, the disclosure of which is hereby incorporated herein by reference in its entirety.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a conventional semiconductor color imager device cross-section.
FIG. 1B depicts the Prior Art thermal reflow process of forming resist into microlenses.
FIG. 1C pictures the light cone for image formation by microlenses onto the photodiodes.
FIG. 1D exhibits the optics for color pixel formation with microlenses and color filters.
FIG. 2 is a simplified process flow chart describing the sequence and principal features of a preferred injection molded microoptics procedure.
FIGS. 3A-3D indicate the process description for mold plate fill.
FIGS. 4A AND 4B are views of the mold plate fill tool scanning injection process.
FIG. 5 depicts the process sequence for alignment, clamp, transfer, and attachment of microlenses.
FIG. 6 provides a side view of the fixture frame for mold to wafer alignment and transfer.
FIG. 7 illustrates the optional post-transfer thermal adjustment of a microlens array.
FIG. 8 indicates the wafer preparation process description for a microlens interface layer.
FIG. 9 is a prior art imager cross-section showing alignment of lens, filter and photodiode.
FIG. 10 shows the integrated red, green and blue color lensfilters of the present invention.
FIG. 11 illustrates an optical assembly for parallel waveguides or fiber-optic interconnects.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention teaches an apparatus and method for the formation of planar arrays of microlenses and/or optical waveguides and photonic devices which may comprise, inter alia, optical bus I/O and memory structures in advanced future computer backplanes, image-formation layers on CMOS or CCD solid-state color imagers, matrix arrays of lenses on flat panel displays, and other fields of applications for microoptic elements.
Unlike conventional art, aspherics, anamorphics, cylindrical lenticular and ellipsoidal microoptic surface designs may be realized with the present invention to provide the long focal lengths required for semiconductor color imaging devices or for VCSEL (vertical cavity surface emitting laser) couplers, particularly those used in parallel optical links including applications such as InfiniBand channels for computers and storage devices. Employment of high refractive index materials, such as polymers, or glasses, or liquid crystal materials, with non-spherical shapes are enabled by the present invention. It is recognized and particularly pointed out that anisotropic etching processes to form cavities in mold plates, including reactive ion etching (RIE) or plasma etching, may be harnessed to create designed microoptics geometries by virtue of differential etch-rates along selected spatial directions, or, by virtue of preferential etching along crystallographic planes. Hence ellipsoidal or aspheric microlens shapes are generated through the controlled ratio of forward to lateral etch-rates in plasma or RIE chambers with defined gas components at specified partial pressures producing designed cavity shapes in a carrier mold plate or template.
Cavities with desired geometry can be created in a glass plate or other suitable carrier mold material such as polyimide to meet the requirement of various applications. Both wet etching and dry etching techniques have been widely used to etch cavities. The resolution of the wet etching technique is relatively poor due to its isotropic etching characteristics and the undercut it generates. In contrast, reactive ion etching (RIE) has the advantage of controlling the directionality and sidewall profile of the etched cavities. RIE offers good selectivity, little undercut, and high throughput. The process starts by first applying a blanket layer of etch mask material on the glass surface, then patterns it to have the mirror image of the device array on the wafer to which it will subsequently be transferred and attached. The etch mask can be a metal mask, polymer or combination of both. The glass plate is loaded in the RIE tool which generally consists of parallel plate electrodes and an rf power supply. The glass plate is placed on the electrode to which rf power is applied. The plasma of ionized gas is generated between the electrodes. A gas inlet introduces reactive gases, and a pumping system is used to maintain a constant pressure in the etching chamber. The pressures used in RIE are 1 to 20 Pa. Suitable etching gases, such as CF4, CF3, C2F6, CHF3, C3F6, CF4+O2, Cl2F2, CCl4, etc. can be selected so as to produce ionic species which react chemically with glass to form volatile products which spontaneously desorb from the etched glass surface and are removed by the vacuum pump system in the RIE tool. The sidewall profile can be controlled and optimized by parameters such as pressure and flow rate, rf power density (W/cm2), electrode design and the chemical nature of the discharge species.
Moldplates can also be fabricated by direct laser etching of the cavities. This process is particularly suitable for polyimides or polyimide-on-glass substrates.
A carrier mold plate with alignment marks and patterned, shaped cavities is designed to generate the microoptic array. Molten polymer or glass is injected to fill the mold plate. A conformal liner of PTFE or other release-film coats the surface of the mold cavities to enable detachment from the mold during transfer and attachment to various devices. Alternatively, plasma etch conditions may be controlled to effect a surface state on the injection mold's cavity walls which is hydrophobic or hydrophilic, thereby aiding the release of the molded microoptic elements. The mold plate coefficient of thermal expansion (CTE) is matched to the target wafer to which the injection molded optical components are bonded. An alternative embodiment employs a layer of polyimide which may either be laser ablated or photoexposed and developed into the array of cavities.
In order to facilitate release of the microlens material from the mold cavities, well known release agents can be used, including waxes and poly(tetrafluoroethylene) (PTFE) coatings. In addition, a class of materials is well known to form dense, highly ordered monolayer films on silica glass surfaces. These self-assembled monolayers, or SAM's, form because of the tendency of trisilanols to form a tight silyl ether network with silanol groups on the glass surface and with silanol groups on neighboring molecules. The self-ordering films come about from the close packing of long chain alkyl groups attached to the trisilanols. For example, when a wet glass surface is dipped into a dilute solution of octadecyltriethoxysilane or octadecyltrichlorosilane, a well ordered monolayer film assembles on the glass surface. Subsequent baking of the film makes a permanent bond of the film to the surface. Because the end group on the long chain alkyl can have a large number of different functional groups, SAM's allow tuning the surface energy of the glass mold to promote release of the microlenses to the wafer to which they are to be transferred. The SAM's are robust and will survive multiple reuses; and, moreover, when fouled they can easily be removed completely by oxygen ashing and a fresh SAM applied.
FIG. 2 provides a process flow-chart description of one embodiment of the present invention. In FIG. 2 , two parallel process sequences are shown, one for the filling and inspection of the cavities in a prepared mold plate, and, a second for the preparation of the wafer to be receiving the transferred elements from the cavities of the mold plate. The details of the apparatus design, alignment, transfer, optional reflow, and mold reuse cleaning processes are described in the set of FIGS. 2 through 7 .
In FIG. 2 , a wafer-scale mold plate 220 with photolithographically formed and etched optical alignment keys 254 and etched cavity array with cavity sidewalls coated with a release layer such as wax, PTFE, a SAM, or other suitable material or plasma process, is injected with a molten lens material 240 . Wafer 210 with etched conjugate optical alignment keys 252 and an optional applied planarizing optical adhesive and refractive index matching layer 230 is brought into alignment by centering alignment key 254 inside key 252 as shown in the aligned state 256 . The alignment process is performed by a conventional photoaligner tool 250 . The microoptic elements formed in the cavities of the mold plate are transferred as shown in 260 to the interface layer 230 . The wafer proceeds to dice, sort and pick 280 for final packaging of the finished device chip, while the mold plate is cleaned and prepared for multiple reuse 270 .
The process flow details for the mold preparation and injection filling sequence are provided in FIG. 3 steps A,B,C,D. As previously described herein, a patterned array of cavities of designed shape are etched into mold plate 300 by one of the isotropic or anisotropic etch processes taught by the present invention. A conformal release layer 310 is applied to the array of cavities, the preferred composition of which may be selected from the group consisting of fluoropolymers such as PTFE (polytetrafluoroethylene), spray release agents based on wax or zinc oxide, a sacrificial laser ablatable layer or thermally decomposable layer using cavity heaters, self-assembled monolayers or SAMs, trichlorosilane, or other antistiction agents. A fill-tool, described in FIG. 4 , injects dispensed liquid from the fill-head crucible into the array of cavities which will be solidified into microoptic or microspectral filter elements.
The preferred liquid materials for microlens arrays may be selected from the group consisting of polymers, photopolymers, glasses, sol-gels, UV-curable epoxies, resins, acrylics, cyclolefins, polycarbonates, PMMA (polymethyl methacrylate), polyimide, glass semiconductors such as Ge x Se 1-x , and, combinations using photoinitiators and/or photoreactive agents. Two optional process sequences may next be followed: a first sequence, illustrated in FIG. 3 step C as transmissive microlenses 320 , or a second sequence shown in FIG. 3 step C as spectrally absorptive microlenses which are defined in the present invention by the new term color filterlenses 330 , or simply filterlenses 330 . The filterlenses 330 are taught in the present invention to be the integration of the microlens array with the appropriate red, green and blue array of color filters. The lensfilter represents the combination of a red, green or blue dye-loaded or other color absorbing filter device into the optical polymer or glass comprising the microlens.
It is recognized and particularly pointed out that extrapolation of the lensfilter concept to other microoptic combinations of image-formation and spectral selection characteristics is subsumed in the present invention, and, that the apparatus and methods taught enable advances in the integration and wafer-scale manufacturing of microoptic products.
The advantage of parallel processing injection mold microoptics in carrier mold plates concurrently with that of other substrates, such as semiconductor device fabrication (e.g., image sensors or VCSEL wafers), is an important distinction from Prior Art. In particular, microoptics for VCSEL applications require unique characteristics which can more easily be fabricated using injection molding; these include fabrication of interconnected lens arrays which compensate for VCSEL array tolerance runout, compensation for the mismatch between a VCSEL divergence angle (typically 15-20 degrees) and the numerical aperture of an optical fiber or waveguide (which can be as low as 6 degrees) without violating international laser eye safety conditions (such as IEC 825). Accurate formation of the microlens surface is crucial, since due to their size, microlens elements cannot be optically polished using conventional means; the injection molding technique greatly facilitates this aspect of microlens fabrication.
A further important distinction is the independent inspection and characterization 340 made possible, as shown in FIG. 3 step D, wherein such spectral measurements as transmission spectrophotometry may be utilized for process and product Quality Control against color filter specifications or microlens focal length. The nature of the transparent glass mold enables blank subtraction of the glass transmission spectrum and optimization of dye-loading, film-thickness, microlens cavity depth and shape, and, determines whether rework is required before the microlens array and/or color filter array is committed to the product wafer. In a similar manner, microlens arrays used for VCSEL applications may enable wafer-scale alignment and test of the microlens/VCSEL combinations, wherein the characterization of VCSEL spectral measurements, optical power, and other features may be utilized for product quality control against the VCSEL specifications. If rework is needed, the mold plate is cleaned and prepared as detailed in the process flow chart provided in FIG. 2 . It is also noteworthy that the mold plates can be prepared, filled and characterized against product engineering specifications to build to stock an inventory of parallel processed components, and, concurrently, wafers may similarly be prepared to stock devices which can be finished in manufacturing in a make-to-order operations management model. Consequently, product engineering changes and upgrades at minimum cost are enabled by the present invention.
FIG. 4 is a schematic representation of the mold plate Fill Tool 400 , comprised of a crucible containing either transmissive molten microlens material 420 for case A, or absorptive color lensfilter material for case B. Either the platen on which the mold plate resides or the dispensing, injection head may be translated relative to the other. Illustrated in FIG. 4 , the Fill-Tool head is selected to be scanned as in 410 relative to the mold plate. A small positive pressure 430 drives fluid flow injection through fill blade 405 to fill a mold plate with cavities 220 ; unfilled cavities 440 ahead of the scan head, and, filled cavities 450 behind the scan head are shown. For the integration of microlens and color filter arrays, lensfilters of green, blue and red are fabricated using fill blade 455 which teaches a configuration for the single-step transfer of lensfilters to a receiving substrate. For CMOS or CCD color imagers the substrate is silicon, and for flat panel displays the substrate may be a glass or polymer plate. For VCSELs, the substrate will be a III-V based semiconductor wafer. The color fill blade 455 is seen to be comprised of a unique configuration of 3 rows, a first blue inject row 460 , a second green inject row 470 , and a third red inject row 480 .
An alternative embodiment employing the standard fill blade 405 is as follows. Dye-loaded photocurable prepolymers are prepared as red, green and blue fluids and placed in separate crucibles. In a first scan of the fill head, all mold plate cavities are filled by dispensing and injecting the green fluid. A map of the red, green and blue color filter positions in a color imager array is used to selectively expose and photocure the corresponding mold plate cavities for green lensfilters. The remaining cavities are emptied and flushed. All green color filter positions remain in the form of green lensfilters. Again using the design map of color imager filter positions, a second scan dispenses and injects blue fluid into all unfilled cavity positions in the mold plate. Selective exposure cross-links and hardens the blue lensfilters in their cavities, and, all remaining uncured cavities are emptied and flushed. A third scan of the fill head dispenses and injects red fluid in the empty cavities and is cured. Spectrophotometric characterization of the filled template at appropriate stages assures in-spec manufacturing of the color lensfilters, unlike Prior Art processes which are testable only when the product has been completed. The color lensfilters are therefore known good lensfilters before committing them to the transfer to a product substrate; lensfilters are transferred to a color image sensor wafer only when the template is perfect. Significant increase in final product yield and cost reduction results.
While the process for injection molding of microlenses and of color filters has been taught for the independent cases of fabricating microlenses or integrating color filters with microlenses, it is recognized and particularly pointed out that the independent fabrication of color filters alone is also enabled by the present invention.
Advantages for molding microlenses include superior shape control, since the microlens elements are shaped by cavities not by surface tension. Laser etching to optical design specifications can be used to augment RIE, plasma or acid wet etched templates. Since the templates are transparent, lenses and spectral filters can be optically characterized in situ in the template. High multiples of reuse of the templates correlate well with lower cost than photolithographic on-wafer processing, resulting in yield improvements by inspection prior to transfer. Single layer arrays of aspheric microlenses provide the equivalence of compound spherical lenses requiring multilayering, with the attendant advantage of a thinner image sensor cross-sectional stack. Thinner image sensors are in turn very desirable for reducing product packaging dimensions. The current industry trend to higher resolution color imagers will similarly benefit from chromatic aberration corrections and color filter compensation for wavelength-dependent index of refraction variations inherent in the red, green, blue color filters of Prior Art.
The transfer process sequence for injection molded microoptics is given in FIG. 5 . An Alignment-Tool using conventional photolithographic alignment keys aligns the filled template to a substrate such as a silicon CMOS color imager, as shown at 500 . The aligned pair is clamped at 510 , the cavity contents transferred, optionally assisted by an ultrasonic or gas pressure agent, and, separated at 530 .
FIG. 6 is a sideview of the mold-to-wafer transfer apparatus 600 . Alignment key 254 on mold plate 220 is centered in alignment key 252 on wafer 210 supported on base 630 and contact points 620 inside fixture frame 610 . Molded microlenses 640 are shown in alignment and in contact with the interface layer 800 shown in FIG. 8 .
After the injection molded microoptic array has been transferred to the receiving device surface, an optional thermal reflow adjustment is shown in FIG. 7 to provide a process for modifying the lens shape and spacing as molded and transferred 700 to a configuration in which the lenses are contiguous 710 , touching at their edges to eliminate gaps. An additional optional step can be added to provide a post-transfer irradiation for index of refraction tuning of the microlenses or an absorbance tuning of the color filters.
FIG. 8 illustrates the wafer preparation for the interface layer 800 which provides planarization, refractive-index matching to minimize interfacial reflection loss, and adhesion of the transferred microoptic array. Also shown is the alignment of color filter layer 820 to photodetector array 830 integrated in the silicon wafer 810 .
A semiconductor color imager cross-section is given in FIG. 9 , depicting the aligned positions of the microlens array elements 900 above the color filters 910 and pn photodiodes. The advanced integration of the color filters and microlenses into the color lensfilters 1000 on interface layer 1010 is taught in the present invention as shown in FIG. 10 .
While one application for microoptic injection molding has been illustrated for solid-state color imaging devices, FIG. 11 exhibits the utility of molding optical assemblies for laser transmitters and receivers in parallel optical interconnects with waveguides or optical fibers, and shows two examples, one for hemicylindrical fibers or waveguides 1110 and square or rectangular fibers or waveguides 1100 .
Most applications for microlenses or other optical coupling elements will also require electrical interconnects as well, if only for connecting power. Procedures are known for the injection molding of solder bumps onto silicon wafers, and it will be advantageous to have a hybrid process to use injection molding for both optical coupling elements as well as solder electrical interconnects. In this process, the microlenses are fabricated on the wafer as already described. Then a second mold is aligned to the wafer. This second mold has two different sets of cavities. The lower set of cavities is slightly larger than the microlenses to allow the mold to be placed in close contact with the wafer without contacting or damaging the microlenses. The second set of cavities is cylindrical through-holes in the glass mold to allow molten solder to be dispensed through the mold onto the wafers. After cooling, the second mold is separated from the wafer; leaving solder interconnects at the appropriate sites for making electrical contacts when the chips are assembled to the packaging substrates.
Additional molding features and additional uses for molded microoptic devices are described in U.S. Pat. No. 7,295,375 for “Injection Molded Microlenses For Parallel Optical Interconnects,” issued Nov. 13, 2007, the disclosure of which is hereby incorporated herein by reference in its entirety.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention.
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A wafer-scale apparatus and method is described for the automation of forming, aligning and attaching two-dimensional arrays of microoptic elements on semiconductor and other image display devices, backplanes, optoelectronic boards, and integrated optical systems. In an ordered fabrication sequence, a mold plate comprised of optically designed cavities is formed by reactive ion etching or alternative processes, optionally coated with a release material layer and filled with optically specified materials by an automated fluid-injection and defect-inspection subsystem. Optical alignment fiducials guide the disclosed transfer and attachment processes to achieve specified tolerances between the microoptic elements and corresponding optoelectronic devices and circuits. The present invention applies to spectral filters, waveguides, fiber-optic mode-transformers, diffraction gratings, refractive lenses, diffractive lens/Fresnel zone plates, reflectors, and to combinations of elements and devices, including microelectromechanical systems (MEMS) and liquid crystal device (LCD) matrices for adaptive, tunable elements. Preparation of interfacial layer properties and attachment process embodiments are taught.
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RELATED APPLICATIONS
Applicants claim, under 35 U.S.C. §119, the benefit of priority of the filing date of May 31, 2011 of a German patent application, copy attached, Serial Number 10 2011 103 739.3, filed on the aforementioned date, the entire contents of which is incorporated herein by reference.
BACKGROUND
1. Technical Field
The present invention relates to a method for installing a measuring tape of an angle measuring device, and to an apparatus for performing the method.
The present invention further relates to a structural unit including a measuring tape and an apparatus for installing this measuring tape in accordance with the present invention.
2. Background Information
In angle measuring devices, increasingly there is a need to position a rotating object of relatively large diameter exactly. One example of such an application is large round tables in processing machine, but also telescopes. To enable the most exact possible angular positioning of the round table or telescope, it is known to make a circumferential surface available on the object to be measured and to install a measuring tape with a measurement graduation along the circumference. One simple known way to do this installation is to clamp the measuring tape over the circumference. The measuring tape is firmly restrained on one end, and the remainder of the measuring tape is wrapped around the convex circumferential surface of the object to be measured. By static friction between the circumferential surface and the measuring tape, locally different tension ratios develop in the measuring tape over the circumference. The deviation in the measurement graduation applied to the measuring tape varies along the measuring tape in a manner equivalent to the locally varying tension, which in particular leads to short-period errors in the angle measurement.
In German Patent DE 197 51 019 C2, an installation method and an apparatus are known with which the same tensioning force is introduced at both ends of the measuring tape that attains a reduction in angle error. However, when compared to systems in which only one end of the measuring tape is firmly joined to its underlay, and in the installation operation a tensioning force is exerted on the second end, the tension ratios over the entire circumference, especially with large diameters, are as before still inadequate for precise angle measurements.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is therefore to disclose a method for installing a measuring tape with which the measuring tape can be installed on a circumferential surface of an object to be measured in such a way that an exact angle measurement over this circumference is made possible.
This object is attained according to the present invention by a method for installing a measuring tape on a circumferential surface of a holder. The method including wrapping the circumferential surface of the holder with the measuring tape and bracing the measuring tape such that the measuring tape extends spaced apart from the circumference of the holder. When the measuring tape extends spaced from the circumference of the holder due to the bracing, exerting a tensioning force on the measuring tape so that the measuring tape is held with low friction above the circumference, wherein the tensioning force is distributed at least nearly uniformly over the circumference. The method includes undoing the bracing of the measuring tape beginning at a fixation point at which a portion of the measuring tape is affixed to the circumferential surface. The method also includes applying the measuring tape to the circumferential surface of the holder while maintaining the tensioning force.
For installing a measuring tape on a circumferential surface of a holder, the following method step is performed first:
wrapping the circumferential surface of the holder with the measuring tape and bracing the measuring tape such that it extends spaced apart from the circumferential surface of the holder, and exerting a tensioning force on the measuring tape in this state of the measuring tape in which it is held with low friction above the circumference, the tensioning force being distributed at least nearly uniformly over the circumference.
Keeping the measuring tape spaced apart from the circumferential surface of the holder in as friction-free a manner as possible is preferably effected by braces spaced apart from one another in the circumferential direction.
The braces can be positioned on the holder before the measuring tape is wrapped around the circumferential surface. Alternatively, the braces and the measuring tape can be placed around the holder simultaneously. As another possibility, the measuring tape is wrapped around the circumferential surface first and only after that is the friction-free state of the measuring tape created, by lifting it from the circumferential surface.
Once a uniform distribution of tension over the entire length of the measuring tape and, thus, over the wrapped circumference has been attained, the bracing of the measuring tape is undone beginning at a fixation point so that the measuring tape presses against the circumferential surface of the holder while the tensioning force is maintained. This pressing of the measuring tape against the circumferential surface is effected progressively in the circumferential direction.
The fixation point can be formed by fixing the measuring tape on the holder, for instance by one of its ends, and then the tensioning force is applied to the other end of the measuring tape.
Alternatively, a tensioning force can be introduced simultaneously at both ends of the measuring tape, as shown for example in DE 197 51 019 C2. In that case, the fixation point develops in the middle of the circumference wrapped by the measuring tape, and from there, the bracing of the measuring tape must be undone, and the measuring tape is pressed continuously against the circumferential surface.
The tensioning force is a tensile force on the measuring tape, which can be introduced by a weight or a spring.
For creating the spacing of the low-friction support of the measuring tape, the braces advantageously have rollers in the form of guide rollers. Thus, during the tension compensation, only the relatively slight rolling friction of the rollers, against which the measuring tape presses, occurs between the holder and the measuring tape.
So that the tensioning force introduced can be distributed uniformly over the entire length of the measuring tape during the installation, a state is created in which there is low-friction support of the measuring tape relative to the holder. By the provisions according to the present invention, a homogeneous tension state is achieved over the circumference of the measuring tape. Partial slipping of the measuring tape in the circumferential direction (stick-slip effect) during the measurement operation is, thus, largely avoided.
The circumferential surface of the holder on which the measuring tape is installed can extend over 360°, and, thus, over one complete revolution, or over a sector of less than 360°.
Another object of the present invention is to disclose an easily manipulated apparatus for installing a measuring tape on a circumferential surface of a holder. The apparatus includes a means for bracing the measuring tape so that the measuring tape extends spaced apart from the circumferential surface of the holder. The apparatus includes a means for exerting a tensioning force on the measuring tape while the measuring tape extends spaced apart from the circumferential surface of the holder, and wherein the tensioning force is distributed at least nearly uniformly over a circumference of the holder. The apparatus further includes a means for undoing said bracing of the measuring tape so that the measuring tape, beginning at a fixation point, is pressed against the circumferential surface of the holder while the tensioning force is being maintained.
The braces can be a plurality of braces that are shiftable independently of one another, for instance in the form of carriages that are movable in the circumferential direction.
A plurality of braces spaced apart in the circumferential direction can also be coupled to one another by a connection body and can be shifted jointly in the circumferential direction.
The braces can have casters, by which they are guided shiftably in the circumferential direction on the holder, in particular in a slot in the holder.
At least one of the braces can have a magnet. This magnet can be used for maintaining the bracing of the holder by magnetic force. The magnetic maintaining force can be designed to be variable, instance by making the spacing of the magnets from the holder variable.
At least one of the braces can be embodied for varying the spacing between the circumferential surface and the measuring tape. To that end, the brace, for instance, has a pivotable mounting, which on its end has a guide roller that guides the measuring tape.
A structural unit according to the present invention includes a measuring tape to be installed on a circumferential surface of a holder and an apparatus for installing said measuring tape. The apparatus includes a means for bracing the measuring tape so that the measuring tape extends spaced apart from the circumferential surface of the holder. The apparatus includes a means for exerting a tensioning force on the measuring tape while the measuring tape extends spaced apart from the circumferential surface of the holder, and wherein the tensioning force is distributed at least nearly uniformly over a circumference of the holder. The apparatus further includes a means for undoing said bracing of the measuring tape so that the measuring tape, beginning at a fixation point, is pressed against the circumferential surface of the holder while the tensioning force is being maintained.
Further advantages and details of the present invention will become apparent from the ensuing description of exemplary embodiments in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a possible first method step for a possible process for installing a measuring tape on a circumferential surface in accordance with the present invention;
FIG. 2 shows a possible second method step for the possible process of FIG. 1 in accordance with the present invention;
FIG. 3 shows a possible state during the possible process of FIGS. 1-2 ;
FIG. 4 shows an embodiment of a carriage as a brace to be used with the possible process of FIGS. 1-2 in accordance with the present invention;
FIG. 5 shows a possible third method step for the process of FIGS. 1-2 with a first position of the carriage of FIG. 4 in accordance with the present invention;
FIG. 6 shows a possible fourth method step for the process of FIGS. 1-2 and 5 with a second position of the carriage of FIG. 4 in accordance with the present invention.
FIG. 7 shows a possible fifth method step for the process of FIGS. 1-2 and 5 - 6 in accordance with the present invention;
FIG. 8 shows a possible sixth method step for the process of FIGS. 1-2 and 5 - 7 in accordance with the present invention;
FIG. 9 shows a possible seventh method step for the process of FIGS. 1-2 and 5 - 8 in accordance with the present invention;
FIG. 10 shows a possible eighth method step for the process of FIGS. 1-2 and 5 - 9 in accordance with the present invention;
FIG. 11 shows the measuring tape completely installed on the holder using the method of FIGS. 1-2 and 5 - 9 and the carriage of FIG. 4 in accordance with the present invention;
FIG. 12 shows a second exemplary embodiment for installing a measuring tape on a circular arc in accordance with the present invention;
FIG. 13 shows a third exemplary embodiment for installing a measuring tape on a circumferential surface of a holder using braces in accordance with the present invention;
FIG. 14 shows a possible method step for a possible second process for installing a measuring tape with braces of FIG. 13 in accordance with the present invention;
FIG. 15 shows a further possible method step for a possible process for installing a measuring tape with braces of FIG. 13 in accordance with the present invention; and
FIG. 16 shows a second embodiment of the braces of FIG. 13 in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-11 show a first example of a process for installing a measuring tape 1 on a circumferential surface 11 of a holder 10 , which in the exemplary embodiment is a telescope ring structure. The circumferential surface 11 in this example is formed by the bottom of a slot 12 which is made in the holder 10 and extends over a full 360°. The diameter of such a telescope ring structure can amount to several meters.
The measuring tape 1 is a flexible but lengthwise largely stable band, in particular a steel band. On its top side, the measuring tape 1 has a measurement graduation 2 , which can be scanned optically. Instead of the optically scannable measurement graduation 2 , a measurement graduation that can be scanned magnetically, capacitively, or inductively can also be provided. The measurement graduation can be designed incrementally for relative measurement of an angle position or in encoded form for absolute angle measurement. The measurement graduation can be a single-track or multiple-track measurement graduation.
For installing the measuring tape 1 on the holder 10 , in a first step shown in FIG. 1 the measuring tape 1 is wrapped around the circumferential surface 11 of the holder 10 . The first end of the measuring tape 1 is connected to a first part 21 of a turnbuckle. This first part 21 of the turnbuckle is inserted into a recess 13 in the holder 10 . After that, the measuring tape 1 is placed in the slot 12 over the outer circumference of the holder 10 . The first end of the measuring tape 1 is also fixed to the holder 10 . This fixation is effected in the example shown in the vicinity of the recess 13 by a clamping piece 14 . In a manner not shown, the clamping piece 14 can be omitted if the fixation of the measuring tape 1 to the holder 10 is effected by the first part 21 of the turnbuckle itself, on which the first end of the measuring tape 1 is fastened.
In a second step of the method, a tensioning force F is exerted on the measuring tape 1 , as shown in FIG. 2 . The tensioning force F is introduced, for example, by attaching a weight via a deflection roller 23 , as schematically shown in FIG. 2 . The tensioning force F is introduced at the second end of the measuring tape 1 , for instance at a second part 22 of the turnbuckle that is fastened to the second end of the measuring tape 1 . The measuring tape 1 rests on the circumferential surface 11 of the slot 12 of the holder 10 . By static friction between the measuring tape 1 and the circumferential surface 11 , the tension of the measuring tape 1 is reduced, beginning at the point of introduction over the circumference, and, thus, extends nonhomogeneously over the circumference. A nonhomogeneous distribution of the tension over the wrapped region of the measuring tape can also occur as the result of different coefficients of friction between the circumferential surface 11 and the measuring tape 1 .
According to the present invention, a homogeneous tension of the measuring tape 1 is now achieved by supporting the measuring tape 1 with as little friction as possible over the circumference during the installation process. This is achieved by undoing a frictional contact between the measuring tape 1 and the circumferential surface 11 , so that the introduced tensioning force F can be distributed uniformly over the circumference, or, in other words, over the entire length of the measuring tape. To that end, in the prestressed state, braces 30 are put in place between the circumferential surface 11 and the measuring tape 1 in such a way that beginning at its first end that is fixed to the holder 10 , the measuring tape 1 extends with uniform spacing from the circumferential surface 11 over the entire circumference. This state is shown in FIG. 3 .
The braces in the first exemplary embodiment are carriages 30 , a plurality of which can be inserted between the circumferential surface 11 of the holder 10 and the tensioned measuring tape 1 and which as a result lift the measuring tape 1 away from the circumferential surface 11 . The carriages 30 are designed such that they are guided in the circumferential direction in the slot 12 . The construction of such a carriage 30 is shown as an example in FIG. 4 . Each carriage 30 accordingly includes two ball-bearing-supported casters 31 , which roll in the slot 12 in the holder 10 and are guided there. A further ball-bearing-supported roller serves as a guide roller 32 for guiding the measuring tape 1 , which for that purpose has a slot 33 on its outer circumference. The guide roller 32 can be fastened to a pivotable mounting 34 , and, as a result, the height of the carriage 30 and, thus, the desired spacing between the circumferential surface 11 of the holder 10 and the measuring tape 1 can be adjusted.
How the state of the measuring tape 1 shown in FIG. 3 is attained will now be described. As shown in FIG. 5 , a first carriage 30 is inserted into the slot 12 of the holder 10 and moved in the circumferential direction. If the guide roller 32 of the carriage 30 comes into contact with the measuring tape 1 , the latter lifts radially away from the circumferential surface 11 . The carriage 30 is then displaced onward in the tangential direction along the circumference, in the direction of the clamping piece 14 fastened to the holder 10 , so that the portion of the measuring tape 1 between the fixation point P and the carriage 30 no longer has any contact with the circumferential surface 11 . Once this first carriage has reached this terminal position, it is restrained nondisplaceably in this terminal position. This restraint can be done by clamping the casters 31 , for which purpose a clamping mechanism is integrated with the carriage 30 . The state thus reached is shown in FIG. 6 .
After that, the further carriages 30 are inserted between the circumferential surface 11 and the measuring tape 1 , until the state shown in FIG. 3 is reached and the measuring tape 1 , beginning at the clamping piece 14 , is spaced apart from the circumferential surface 11 over the entire circumference. The spacing of the carriages 30 from one another (viewed in the circumferential direction) should be selected such that each portion of the measuring tape 1 located between two carriages 30 is completely lifted up or in other words spaced apart from the circumferential surface 11 . The number of carriages 30 required depends on the diameter of the holder 10 and on the circumferential surface 11 . As a result of the lifting of the measuring tape 1 from the circumferential surface 11 , the introduced tensioning force F now, over the entire circumference, counteracts only the very slight rolling friction of the guide rollers 32 of the carriages 30 . Thus the introduced tensioning force F can be distributed largely uniformly over the entire length of the measuring tape 1 from the clamping piece 14 , or, in other words, the fixation point P, to the second end.
Once all the carriages 30 have been introduced and the tensioning force F has been distributed uniformly over the entire circumference, the process of removing the braces, in this example the carriages 30 , can be begun. To that end, the first carriage 30 is displaced in the direction of the second carriage 30 , until shortly before reaching the second carriage 30 , as shown in FIG. 7 . During this displacement of the first carriage 30 in the direction of the second carriage 30 , the measuring tape 1 in the tensioned state is pressed tangentially against the circumferential surface 11 of the slot 12 .
Next, the pivotable mounting 34 of the second carriage 30 is shifted in the direction of the circumferential surface 11 by swiveling it down. By this provision, the contact of the guide roller 32 with the measuring tape 1 is undone, and the second carriage 30 can be removed from the slot 12 of the holder 10 . The state in which the guide roller 32 of the second carriage 30 has been swiveled closed is shown in FIG. 8 .
An alternative to the mounting 34 that can be swiveled closed is to embody the first carriage 30 with a larger guide roller, such that the diameter of this guide roller is greater than the diameter of the guide rollers of the other carriages 30 . The result, in the displacement of the first carriage 30 in the direction of the second carriage 30 , is again that the measuring tape 1 is lifted away from the guide roller of the second carriage 30 . When the first carriage 30 has been displaced far enough in the direction of the second carriage 30 , the contact of the guide roller of the second carriage 30 with the measuring tape 1 is undone, and the second carriage 30 can be removed from the slot 12 of the holder 10 .
This procedure is now done repeatedly between the first carriage 30 and the further carriages 30 . Thus, the first carriage 30 is now displaced in the direction of the third carriage 30 , and the guide roller 32 by pivoting of the lever 34 the contact of the guide roller 32 of the third carriage 30 with the measuring tape 1 is undone. In this state, the third carriage 30 can now be removed from the slot 12 of the holder 10 . This removal procedure is repeated until the first carriage 30 has reached the second end of the measuring tape 1 and can be completely removed from the slot 12 .
So that the introduced tensioning force F is preserved in the region of the measuring tape 1 that has already been brought into contact with the circumferential surface 11 , the measuring tape 1 is fixed in the vicinity of its second end to the holder 10 , in this example by a clamping piece 15 . This state is shown in FIG. 9 .
Now, the device for introducing the tensioning force F is removed so that the second part 22 of the turnbuckle can be placed in the recess 13 in the holder 10 and screwed to the first part 21 of the turnbuckle, as shown in FIG. 10 . By this screwing procedure, the still-absent prestressing is introduced into the measuring tape 1 in the region of the turnbuckle 21 , 22 between the first clamping piece 14 and the second clamping piece 15 . After that, the fixation of the measuring tape 1 to the holder is released, by removing the first clamping piece 14 and the second clamping piece 15 . The measuring tape 1 completely installed on the holder 10 is shown in FIG. 11 . In this state, the measuring tape 1 rests in tensioned fashion on the entire circumferential surface 11 . In this example, the two ends of the measuring tape 1 are connected to one another by the use of the turnbuckle 21 , 22 ; alternatively, still other connectors are conceivable as well, such as welding the two ends together.
After the two ends of the measuring tape have been connected, the measuring tape 1 cannot be fixed to the holder 10 at any point in the measuring mode of operation. Alternatively, to form a reference point, the measuring tape can be fixed to the holder at one point or in one region, for example by clamping or gluing.
The introduced tensioning force F is selected to be so great that even in the event of a difference in thermal expansion between the holder 10 and the measuring tape 1 , secure contact of the measuring tape 1 with the holder 10 in the measurement mode of operation is ensured.
The method described in conjunction with FIGS. 1-11 can also be performed with or without the two clamping pieces 14 , 15 , if the first part 21 of the turnbuckle takes on the function of the first clamping piece 14 and the second part 22 of the turnbuckle takes on the function of the second clamping piece 15 .
In addition to the installation of the measuring tape 1 over 360°, installation on a circular arc forming the circumferential surface 11 . 1 , such as a segmental holder 10 . 1 , with a circumferential surface 11 . 1 of less than 360° is also possible. The method steps proceed analogously to the method described first above, and the apparatus for performing the method has a comparable construction, and therefore only a brief explanation of FIG. 12 will be provided. Once again, a holder 10 . 1 is made available, in which a slot 12 . 1 extending all the way around the holder is made for receiving the measuring tape 1 . 1 . The holder 10 . 1 is designed in arc like fashion. The measuring tape 1 . 1 is again fixed by its first end to the holder 10 . 1 at the fixation point P, for instance by being screwed to the holder. Via a device that has a deflection roller 23 . 1 , a tensioning force F is exerted on the measuring tape 1 . 1 , and once again braces in the form of carriages 30 . 1 are introduced between the circumferential surface 11 . 1 and the measuring tape 1 . 1 , to establish a spacing between the circumferential surface 11 . 1 and the measuring tape 1 . 1 . Once the compensation for the tensioning force F of the measuring tape 1 . 1 has been done over the entire segmental holder 10 . 1 , that is, over the entire length of the measuring tape 1 . 1 beginning at the fixation point P, the carriages 30 . 1 are again removed in succession until the last carriage 30 . 1 has also been removed from the slit 12 . 1 . Because of the incremental removal of all the carriages 30 , the measuring tape 1 . 1 in the tensioned state is pressed progressively and tangentially against the circumferential surface 11 . 1 . Once the last carriage 30 . 1 has been removed, the second end of the measuring tape 1 . 1 is fixed to the holder 10 . 1 , for instance by clamping with a clamping piece or by being screwed to the holder. The embodiment of the carriages 30 . 1 is equivalent to that of the carriages in the first exemplary embodiment, so that by the carriages 30 . 1 , the static friction between the circumferential surface 11 . 1 and the measuring tape 1 . 1 is undone, and during the state in which the tensioning force F is compensated for over the entire wrap angle, only the extremely slight rolling friction of the guide rollers 32 . 1 supported in the carriages 30 . 1 is exerted on the measuring tape 1 . 1 and counteracts the homogeneous compensation.
In conjunction with FIGS. 13-16 , a third exemplary embodiment will now be described in detail. The difference from the exemplary embodiments described so far is that the individually actuatable bracing elements, in those examples embodied as carriages 30 , 30 . 1 , are now connected to one another and form a kind of chain. The carriages 30 . 2 can then be introduced jointly, in a state in which they are connected to one another, and once the tensioning force F of the measuring tape 1 . 2 has been compensated for, they can be removed, again jointly. The principle of this arrangement is illustrated in FIG. 13 . Each of the carriages 30 . 2 again includes one guide roller 32 . 2 for lifting the measuring tape 1 . 2 in a guided manner and casters 31 . 2 for guiding the carriages 30 . 2 in the circumferential direction of the holder 10 . 2 . The carriages 30 . 2 are connected to one another by a flexible connection body 35 . The connection body 35 can be a steel band, for example.
The circumferential surface 11 . 2 of the holder 10 . 2 is again wrapped with the measuring tape 1 . 2 , and a tensioning force F is exerted on at least one end of the measuring tape. The measuring tape 1 . 2 can again rest in a slot 12 . 2 of the holder 10 . 2 , and the circumferential surface 11 . 2 is then formed by the bottom of the slot 12 . 2 . In this state, the joined-together carriages 30 . 2 are inserted between the holder 10 . 2 and the measuring tape 1 . 2 , as shown in FIG. 14 . The disposition of the braces in the form of joined-together carriages 30 . 2 is designed such that in the inserted state, the measuring tape 1 . 2 is lifted, beginning at the first end fixed to the holder, from the circumferential surface 11 . 2 over the entire circumference (wrap angle) and, thus, is supported with as little friction as possible, and the applied tensioning force F is distributed over the entire length of the measuring tape. This state is shown in FIG. 15 .
Once the tension has been compensated for, the joined-together carriages 30 . 2 are removed, and, thus, beginning at the fixation point P the bracing of the measuring tape 1 . 2 is undone, so that beginning at the first fixed end of the measuring tape 1 . 2 , that is, the tensioning point P, the measuring tape 1 . 2 is pressed tangentially against the circumferential surface 11 . 2 . The fixation point P is preserved.
In the event of large measuring tape lengths, the bracing of the measuring tape 1 . 2 can also include a plurality of chains, each chain having a plurality of carriages 30 . 2 joined together each via a respective connection body. In that case, these chains each include a plurality of carriages 30 . 2 that are inserted in succession between the circumferential surface 11 . 2 and the measuring tape 1 . 2 .
As shown schematically in FIG. 16 , the carriages 30 . 2 can have magnets 36 , which ensure that the carriages 30 . 2 rest well on the circumferential surface 11 . 2 without falling out. To that end, the magnets 36 are opposite the circumferential surface 11 . 2 of the holder 202 and spaced slightly apart from the holder. In this case, the holder 10 . 2 must accordingly either include a ferromagnetic material or at least have a ferromagnetic material in the vicinity of the magnets 36 .
In all the exemplary embodiments, the braces, or at least one of the braces, can be provided with a kind of brake, in order to fix the brace to the holder at a desired position on the circumference. This kind of brake can be implemented, for instance, by making the braces capable of being clamped locally to the holder, for which purpose a clamping mechanism is provided for the clamping.
In the examples of the methods described thus far, the first step is wrapping the holder 10 , 10 . 1 , 10 . 2 with the measuring tape 1 , 1 . 1 , 1 . 2 , and only after that are the braces introduced, for instance in the form of the carriages 30 , 30 . 1 , 30 . 2 . It is alternatively possible first to dispose the braces and only then in a subsequent step to place the measuring tape on the braces and after that to exert the tensioning force F on the measuring tape. The measuring tape and the braces can also be applied jointly, or, in other words, installed simultaneously.
Instead of the carriages 30 , 30 . 1 , 30 . 2 that are displaceable over the circumference of the holder 10 , 10 . 1 , 102 , elements can also be attached that are fastened to the holder 10 , 10 . 1 , 10 . 2 and that allow localized lifting up of the measuring tape 1 , 1 . 1 , 1 . 2 for the period of time of the homogeneous compensation for the tensioning force F of the measuring tape 1 , 1 . 1 , 1 . 2 .
The foregoing description is provided to illustrate the present invention, and is not to be construed as a limitation. Numerous additions, substitutions and other changes can be made to the present invention without departing from its scope as set forth in the appended claims.
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A method for installing a measuring tape on a circumferential surface of a holder. The method including wrapping the circumferential surface of the holder with the measuring tape and bracing the measuring tape such that the measuring tape extends spaced apart from the circumference of the holder. When the measuring tape extends spaced from the circumference of the holder due to the bracing, exerting a tensioning force on the measuring tape so that the measuring tape is held with low friction above the circumference, wherein the tensioning force is distributed at least nearly uniformly over the circumference. The method includes undoing the bracing of the measuring tape beginning at a fixation point at which a portion of the measuring tape is affixed to the circumferential surface. The method also includes applying the measuring tape to the circumferential surface of the holder while maintaining the tensioning force.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/239,048 filed on Sep. 1, 2009, the entire contents of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to mechanical igniters, and more particularly to compact, low-volume, reliable and easy to manufacture mechanical igniters and ignition systems for thermal batteries and the like.
[0004] 2. Prior Art
[0005] Thermal batteries represent a class of reserve batteries that operate at high temperature. Unlike liquid reserve batteries, in thermal batteries the electrolyte is already in the cells and therefore does not require a distribution mechanism such as spinning. The electrolyte is dry, solid and non-conductive, thereby leaving the battery in a non-operational and inert condition. These batteries incorporate pyrotechnic heat sources to melt the electrolyte just prior to use in order to make them electrically conductive and thereby making the battery active. The most common internal pyrotechnic is a blend of Fe and KClO 4 . Thermal batteries utilize a molten salt to serve as the electrolyte upon activation. The electrolytes are usually mixtures of alkali-halide salts and are used with the Li(Si)/FeS 2 or Li(Si)/CoS 2 couples. Some batteries also employ anodes of Li(Al) in place of the Li(Si) anodes. Insulation and internal heat sinks are used to maintain the electrolyte in its molten and conductive condition during the time of use. Reserve batteries are inactive and inert when manufactured and become active and begin to produce power only when they are activated.
[0006] Thermal batteries have long been used in munitions and other similar applications to provide a relatively large amount of power during a relatively short period of time, mainly during the munitions flight. Thermal batteries have high power density and can provide a large amount of power as long as the electrolyte of the thermal battery stays liquid, thereby conductive. The process of manufacturing thermal batteries is highly labor intensive and requires relatively expensive facilities. Fabrication usually involves costly batch processes, including pressing electrodes and electrolytes into rigid wafers, and assembling batteries by hand. The batteries are encased in a hermetically-sealed metal container that is usually cylindrical in shape. Thermal batteries, however, have the advantage of very long shelf life of up to 20 years that is required for munitions applications.
[0007] Thermal batteries generally use some type of igniter to provide a controlled pyrotechnic reaction to produce output gas, flame or hot particles to ignite the heating elements of the thermal battery. There are currently two distinct classes of igniters that are available for use in thermal batteries. The first class of igniter operates based on electrical energy. Such electrical igniters, however, require electrical energy, thereby requiring an onboard battery or other power sources with related shelf life and/or complexity and volume requirements to operate and initiate the thermal battery. The second class of igniters, commonly called “inertial igniters”, operates based on the firing acceleration. The inertial igniters do not require onboard batteries for their operation and are thereby often used in high-G munitions applications such as in gun-fired munitions and mortars.
[0008] In general, the inertial igniters, particularly those that are designed to operate at relatively low impact levels, have to be provided with the means for distinguishing events such as accidental drops or explosions in their vicinity from the firing acceleration levels above which they are designed to be activated. This means that safety in terms of prevention of accidental ignition is one of the main concerns in inertial igniters.
[0009] In recent years, new improved chemistries and manufacturing processes have been developed that promise the development of lower cost and higher performance thermal batteries that could be produced in various shapes and sizes, including their small and miniaturized versions. However, the existing inertial igniters are relatively large and not suitable for small and low power thermal batteries, particularly those that are being developed for use in miniaturized fuzing, future smart munitions, and other similar applications.
[0010] The need to differentiate accidental and initiation accelerations by the resulting impulse level of the event necessitates the employment of a safety system which is capable of allowing initiation of the igniter only during high total impulse levels. The safety mechanism can be thought of as a mechanical delay mechanism, after which a separate initiation system is actuated or released to provide ignition of the pyrotechnics. An inertial igniter that combines such a safety system with an impact based initiation system and its alternative embodiments are described herein together with alternative methods of initiation pyrotechnics.
[0011] Inertia-based igniters must therefore comprise two components so that together they provide the aforementioned mechanical safety (delay mechanism) and to provide the required striking action to achieve ignition of the pyrotechnic elements. The function of the safety system is to fix the striker in position until a specified acceleration time profile actuates the safety system and releases the striker, allowing it to accelerate toward its target under the influence of the remaining portion of the specified acceleration time profile. The ignition itself may take place as a result of striker impact, or simply contact or proximity. For example, the striker may be akin to a firing pin and the target akin to a standard percussion cap primer. Alternately, the striker-target pair may bring together one or more chemical compounds whose combination with or without impact will set off a reaction resulting in the desired ignition.
[0012] In addition to having a required acceleration time profile which will actuate the device, requirements also commonly exist for non-actuation and survivability. For example, the design requirements for actuation for one application are summarized as:
[0013] 1. The device must fire when given a [square] pulse acceleration of 900 G±150 G for 15 ms in the setback direction.
[0014] 2. The device must not fire when given a [square] pulse acceleration of 2000 G for 0.5 ms in any direction.
[0015] 3. The device must not actuate when given a ½-sine pulse acceleration of 490 G (peak) with a maximum duration of 4 ms.
[0016] 4. The device must be able to survive an acceleration of 16,000 G, and preferably be able to survive an acceleration of 50,000 G.
[0017] A schematic of a cross-section of a conventional thermal battery and inertial igniter assembly is shown in FIG. 1 . In thermal battery applications, the inertial igniter 10 (as assembled in a housing) is generally positioned above the thermal battery housing 11 as shown in FIG. 1 . Upon ignition, the igniter initiates the thermal battery pyrotechnics positioned inside the thermal battery through a provided access 12 . The total volume that the thermal battery assembly 16 occupies within munitions is determined by the diameter 17 of the thermal battery housing 11 (assuming it is cylindrical) and the total height 15 of the thermal battery assembly 16 . The height 14 of the thermal battery for a given battery diameter 17 is generally determined by the amount of energy that it has to produce over the required period of time. For a given thermal battery height 14 , the height 13 of the inertial igniter 10 would therefore determine the total height 15 of the thermal battery assembly 16 . To reduce the total volume that the thermal battery assembly 16 occupies within a munitions housing, it is therefore important to reduce the height of the inertial igniter 10 . This is particularly important for small thermal batteries since in such cases the inertial igniter height with currently available inertial igniters can be almost the same order of magnitude as the thermal battery height.
[0018] With currently available inertial igniters, a schematic of which is shown in FIG. 2 , the inertial igniter 20 may have to be positioned within a housing 21 as shown in FIG. 3 , particularly for relatively small igniters. The housing 21 and the thermal battery housing 11 may share a common cap 22 , with the opening 25 to allow the ignition fire to reach the pyrotechnic material 24 within the thermal battery housing. As the inertial igniter is initiated, the sparks can ignite intermediate materials 23 , which can be in the form of thin sheets to allow for easy ignition, which would in turn ignite the pyrotechnic materials 24 within the thermal battery through the access hole 25 .
[0019] A schematic of a cross-section of a currently available inertial igniter 20 is shown in FIG. 2 in which the acceleration is in the upward direction (i.e., towards the top of the paper). The igniter has side holes 26 to allow the ignition fire to reach the intermediate materials 23 as shown in FIG. 3 , which necessitate the need for its packaging in a separate housing, such as in the housing 21 . The currently available inertial igniter 20 is constructed with an igniter body 60 . Attached to the base 61 of the housing 60 is a cup 62 , which contains one part of a two-part pyrotechnic compound 63 (e.g., potassium chlorate). The housing 60 is provided with the side holes 26 to allow the ignition fire to reach the intermediate materials 23 as shown in FIG. 3 . A cylindrical shaped part 64 , which is free to translate along the length of the housing 60 , is positioned inside the housing 60 and is biased to stay in the top portion of the housing as shown in FIG. 2 by the compressively preloaded helical spring 65 (shown schematically as a heavy line). A turned part 71 is firmly attached to the lower portion of the cylindrical part 64 . The tip 72 of the turned part 71 is provided with cut rings 72 a , over which is covered with the second part of the two-part pyrotechnic compound 73 (e.g., red phosphorous).
[0020] A safety component 66 , which is biased to stay in its upper most position as shown in FIG. 2 by the safety spring 67 (shown schematically as a heavy line), is positioned inside the cylinder 64 , and is free to move up and down (axially) in the cylinder 64 . As can be observed in FIG. 2 , the cylindrical part 64 is locked to the housing 60 by setback locking balls 68 . The setback locking balls 68 lock the cylindrical part 64 to the housing 60 through holes 69 a provided on the cylindrical part 64 and the housing 60 and corresponding holes 69 b on the housing 60 . In the illustrated configuration, the safety component 66 is pressing the locking balls 68 against the cylindrical part 64 via the preloaded safety spring 67 , and the flat portion 70 of the safety component 66 prevents the locking balls 68 from moving away from their aforementioned locking position. The flat portion 70 of the safety component 66 allows a certain amount of downward movement of the safety component 66 without releasing the locking balls 68 and thereby allowing downward movement of the cylindrical part 64 . For relatively low axial acceleration levels or higher acceleration levels that last a very short amount of time, corresponding to accidental drops and other similar situations that cause safety concerns, the safety component 66 travels up and down without releasing the cylindrical part 64 . However, once the firing acceleration profiles are experienced, the safety component 66 travels downward enough to release balls 68 from the holes 69 b and thereby release the cylindrical part 64 . Upon the release of the safety component 66 and appropriate level of acceleration for the cylindrical part 64 and all other components that ride with it to overcome the resisting force of the spring 65 and attain enough momentum, then it will cause impact between the two components 63 and 73 of the two-part pyrotechnic compound with enough strength to cause ignition of the pyrotechnic compound.
[0021] The aforementioned currently available inertial igniters have a number of shortcomings for use in thermal batteries, specifically, they are not useful for relatively small thermal batteries for munitions with the aim of occupying relatively small volumes, i.e., to achieve relatively small height total igniter compartment height 13 , FIG. 1 . Firstly, the currently available inertial igniters, such as that shown in FIG. 2 , are relatively long thereby resulting in relatively long total igniter heights 13 . Secondly, since the currently available igniters are not sealed and exhaust the ignition fire out from the sides, they have to be packaged in a housing 21 , usually with other ignition material 23 , thereby increasing the height 13 over the length of the igniter 20 (see FIG. 3 ). In addition, since the pyrotechnic materials of the currently available igniters 20 are not sealed inside the igniter, they are prone to damage by the elements and cannot usually be stored for long periods of time before assembly into the thermal batteries unless they are stored in a controlled environment.
SUMMARY OF THE INVENTION
[0022] A need therefore exists for novel miniature inertial igniters for thermal batteries used in gun fired munitions, particularly for small and low power thermal batteries that could be used in fuzing and other similar applications, thereby eliminating the need for external power sources. The innovative inertial igniters can be scalable to thermal batteries of various sizes, in particular to miniaturized igniters for small size thermal batteries. Such inertial igniters must be safe and in general and in particular they should not initiate if dropped, e.g., from up to 7 feet onto a concrete floor for certain applications; should withstand high firing accelerations, for example up to 20-50,000 Gs; and should be able to be designed to ignite at specified acceleration levels when subjected to such accelerations for a specified amount of time to match the firing acceleration experienced in a gun barrel as compared to high G accelerations experienced during accidental falls which last over very short periods of time, for example accelerations of the order of 1000 Gs when applied for 5 msec as experienced in a gun as compared to for example 2000 G acceleration levels experienced during accidental fall over a concrete floor but which may last only 0.5 msec. Reliability is also of much concern since the rounds should have a shelf life of up to 20 years and could generally be stored at temperatures of sometimes in the range of −65 to 165 degrees F. This requirement is usually satisfied best if the igniter pyrotechnic is in a sealed compartment. The inertial igniters must also consider the manufacturing costs and simplicity in design to make them cost effective for munitions applications.
[0023] To ensure safety and reliability, inertial igniters should not initiate during acceleration events which may occur during manufacture, assembly, handling, transport, accidental drops, etc. Additionally, once under the influence of an acceleration profile particular to the firing of ordinance from a gun, the device should initiate with high reliability. In many applications, these two requirements often compete with respect to acceleration magnitude, but differ greatly in impulse. For example, an accidental drop may well cause very high acceleration levels—even in some cases higher than the firing of a shell from a gun. However, the duration of this accidental acceleration will be short, thereby subjecting the inertial igniter to significantly lower resulting impulse levels. It is also conceivable that the igniter will experience incidental low but long-duration accelerations, whether accidental or as part of normal handling, which must be guarded against initiation. Again, the impulse given to the miniature inertial igniter will have a great disparity with that given by the initiation acceleration profile because the magnitude of the incidental long-duration acceleration will be quite low.
[0024] Those skilled in the art will appreciate that the inertial igniters disclosed herein may provide one or more of the following advantages over prior art inertial igniters:
[0025] provide inertial igniters that are significantly shorter and smaller in volume than currently available inertial igniters for thermal batteries or the like, particularly relatively small thermal batteries to be used in munitions without occupying very large volumes;
[0026] provide inertial igniters that can be mounted directly onto the thermal batteries without a housing (such as housing 21 shown in FIG. 3 ), thereby allowing even a smaller total height and volume for the inertial igniter assembly;
[0027] provide inertial igniters that can directly initiate the pyrotechnics materials inside the thermal battery without the need for intermediate ignition material (such as the additional material 23 shown in FIG. 3 ) or a booster;
[0028] provide inertia igniters that could be constructed to guide the pyrotechnic flame essentially downward (in the direction opposite to the direction of the firing acceleration—usually for mounting on the top of the thermal battery as shown in FIG. 3 ), or essentially upward (in the direction opposite of the firing acceleration—usually for mounting at the bottom of the thermal battery), or essentially sidewise (lateral to the direction of the firing);
[0029] provide inertial igniters that allow the use of standard off-the-shelf percussion cap primers instead of specially designed pyrotechnic components; and
[0030] provide inertial igniters that can be sealed to simplify storage and increase their shelf life.
[0031] Accordingly, inertial igniters and ignition systems for use with thermal batteries for producing power upon acceleration are provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] These and other features, aspects, and advantages of the apparatus of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0033] FIG. 1 illustrates a schematic of a cross-section of a thermal battery and inertial igniter assembly.
[0034] FIG. 2 illustrates a schematic of a cross-section of a conventional inertial igniter assembly known in the art.
[0035] FIG. 3 illustrates a schematic of a cross-section of a conventional inertial igniter assembly known in the art positioned within a housing and having intermediate materials for ignition.
[0036] FIG. 4 illustrates a schematic of a cross-section of a first embodiment of an inertial igniter in a locked position.
[0037] FIG. 5 a illustrates a schematic of the isometric drawing of a first embodiment of an inertial igniter together with the top cap of a thermal battery to which it is attached.
[0038] FIG. 5 b illustrates a second view of the isometric drawing of the first embodiment of the inertial igniter of FIG. 5 a showing the openings that are provided to exit the ignition sparks and flames into the thermal battery.
[0039] FIG. 5 c illustrates a schematic of the isometric drawing of a first embodiment of an inertial igniter of FIG. 5 a without the outer housing (side wall and top cap) of the inertial igniter.
[0040] FIG. 6 illustrates the inertial igniter of FIG. 4 upon a non-firing accidental acceleration.
[0041] FIG. 7 illustrates the inertial igniter of FIG. 4 upon a firing acceleration.
[0042] FIG. 8 illustrates the inertial igniter of FIG. 4 upon the striker mass impacting base, causing the initiation of ignition of the two-part pyrotechnic compound.
[0043] FIG. 9 illustrates a schematic of a cross-section of a second embodiment of an inertial igniter in a locked position.
[0044] FIG. 10 illustrates a schematic of a cross-section of a third embodiment of an inertial igniter in initiation position.
[0045] FIGS. 11 a and 11 b illustrate an isometric and a schematic of a cross-section, respectively, of a fourth embodiment of an inertial igniter in initiation position.
[0046] FIG. 12 illustrates a schematic of a cross-section of a fifth embodiment of an inertial igniter in a locked position.
[0047] FIG. 13 illustrates an isometric cut away view of a sixth embodiment of an inertial igniter.
[0048] FIG. 14 illustrates a full isometric view of the inertial igniter of FIG. 13 .
[0049] FIGS. 15 a and 15 b illustrate first and second variations of thermal battery and inertial igniter assemblies.
[0050] FIG. 16 illustrates a first variation of the inertial igniter of FIG. 13 .
[0051] FIG. 17 illustrates a second variation of the inertial igniter of FIG. 13 .
[0052] FIG. 18 illustrates a third variation of the inertial igniter of FIG. 13 .
[0053] FIG. 19 illustrates a thermal battery/inertial igniter assembly in which more than one inertial igniter is used.
[0054] FIG. 20 a illustrates a top view and FIG. 20 b illustrates an isometric view of a bottom plate and posts for a gang of three inertial igniters.
[0055] FIG. 21 a illustrates a top view and FIG. 21 b illustrates an isometric view of a bottom plate and posts for a variation of the gang of three inertial igniters of FIGS. 20 a and 20 b.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0056] A schematic of a cross-section of a first embodiment of an inertia igniter is shown in FIG. 4 , referred to generally with reference numeral 30 . The inertial igniter 30 is constructed with igniter body 31 , consisting of a base 32 and at least two posts 33 , and a housing wall 34 . The base 32 and two posts 33 , which may be integral or may have been constructed as separate pieces and joined together, for example by welding of press fitting or other methods commonly used in the art. In the schematic of FIG. 4 , the igniter body 31 and the housing wall 34 are shown to be joined together at the base 32 ; however, the two components may be integrated as one piece and a separate top cap 35 may then be provided, which is then joined to the top surface of the housing 34 following assembly of the igniter (in the schematic of FIG. 4 the top cap 35 is shown as an integral part of the housing 34 ). In addition, the base of the housing 32 may be extended to form the cap 36 of the thermal battery 37 , the top portion of which is shown with dashed lines in FIG. 4 .
[0057] The inertial igniter 30 with the thermal battery top cap 36 is shown in the isometric drawings of FIGS. 5 a and 5 b . The inertial igniter without its housing 34 and top cap 35 is shown in the isometric drawing of FIG. 5 c . The base of the housing 32 is also provided with at least one opening 38 (with corresponding openings in the thermal battery top cap 36 ) to allow the ignited sparks and fire to exit the inertial igniter into the thermal battery 37 upon initiation of the inertial igniter pyrotechnics 46 and 47 , FIG. 4 , or percussion cap primer when used in place of the pyrotechnics 46 and 47 (not shown).
[0058] A striker mass 39 is shown in its locked position in FIGS. 4 and 5 c . The striker mass 39 is provided with vertical recesses 40 that are used to engage the posts 33 and serve as guides to allow the striker mass 39 to ride down along the length of the posts 33 without rotation with an essentially pure up and down translational motion. In its illustrated position in FIGS. 4 and 5 c , the striker mass 39 is locked in its axial position to the posts 33 by at least one setback locking ball 42 . The setback locking ball 42 locks the striker mass 39 to the posts 33 of the inertial igniter body 31 through the holes 41 provided in the posts 33 and a concave portion such as a dimple (or groove) 43 on the striker mass 39 as shown in FIG. 4 . A setback spring 44 with essentially dead coil section 45 , which is preferably in compression, is also provided around but close to the posts as shown in FIGS. 4 and 5 c . In the configuration shown in FIG. 4 , the locking balls 42 are prevented from moving away from their aforementioned locking position by the dead coil section 45 of the setback spring 44 . The dead coil section 45 can ride up and down beyond the posts 33 as shown in FIGS. 4 and 5 c , but is biased to stay in its upper most position as shown in the schematic of FIG. 4 by the setback spring 44 .
[0059] In this embodiment, a two-part pyrotechnics compound is shown to be used, FIG. 4 . One part of the two-part pyrotechnics compound 47 (e.g., potassium chlorate) is provided on the interior side of the base 32 , preferably in a provided recess (not shown) over the exit holes 38 . The second part of the pyrotechnics compound (e.g., red phosphorous) 46 is provided on the lower surface of the striker mass surface 39 facing the first part of the pyrotechnics compound 47 as shown in FIG. 4 . The surfaces to which the pyrotechnic parts 46 and 47 are attached are roughened and/or provided with surface cuts, recesses, or the like as commonly used in the art (not shown) to ensure secure attachment of the pyrotechnics materials to the applied surfaces.
[0060] In general, various combinations of pyrotechnic materials may be used for this purpose. One commonly used pyrotechnic material consists of red phosphorous or nano-aluminum, indicated as element 46 in FIG. 4 , and is used with an appropriate binder (such as vinyl alcohol acetate resin or nitrocellulose) to firmly adhere to the bottom surface of the striker mass 39 . The second component can be potassium chlorate, potassium nitrate, or potassium perchlorate, indicated as element 47 in FIG. 4 , and is used with a binder (preferably but not limited to with such as vinyl alcohol acetate resin or nitrocellulose) to firmly attach the compound to the surface of the base 32 (preferably inside of a recess provided in the base 32 —not shown) as shown in FIG. 4 .
[0061] The basic operation of the disclosed inertial igniter 30 will now be described with reference to FIGS. 4-8 . Any non-trivial acceleration in the axial direction 48 which can cause dead coil section 45 to overcome the resisting force of the setback spring 44 will initiate and sustain some downward motion of only the dead coil section 45 . The force due to the acceleration on the striker mass 39 is supported at the dimples 43 by the locking balls 42 which are constrained inside the holes 41 in the posts 33 . If an acceleration time in the axial direction 48 imparts a sufficient impulse to the dead coil section 45 (i.e., if an acceleration time profile is greater than a predetermined threshold), it will translate down along the axis of the assembly until the setback locking balls 42 are no longer constrained to engage the striker mass 39 to the posts 33 of the housing 31 . If the acceleration event is not sufficient to provide this motion (i.e., the acceleration time profile provides less impulse than the predetermined threshold), the dead coil section 45 will return to its start (top) position under the force of the setback spring 44 . The schematic of the inertial igniter 30 with the dead coil section 45 moved down certain distance d 1 as a result of an acceleration event, which is not sufficient to unlock the striker mass 39 from the posts 33 of the housing 31 , is shown in FIG. 6 .
[0062] Assuming that the acceleration time profile was at or above the specified “all-fire” profile, the dead coil section 45 will have translated down full-stroke d 2 , allowing the striker mass 39 to accelerate down towards the base 32 . In such a situation, since the locking balls 42 are no longer constrained by the dead coil section 45 , the downward force that the striker mass 39 has been exerting on the locking balls 42 will force the locking balls 42 to move outward in the radial direction. Once the locking balls 42 are out of the way of the dimples 43 , the downward motion of the striker mass 39 is impeded only by the elastic force of the setback spring 44 , which is easily overcome by the impulse provided to the striker mass 39 . As a result, the striker mass 39 moves downward, causing the parts 46 and 47 of the two-part pyrotechnic compound to strike with the requisite energy to initiate ignition. The configuration of the inertial igniter 30 when the balls 42 are free to move outward in the radial direction, thereby releasing the striker mass 39 is shown in the schematic of FIG. 7 . The configuration of the inertial igniter 30 when the part 46 of the two-part pyrotechnic compound is striking the part 47 is shown in the schematic of FIG. 8 .
[0063] In another embodiment, the dead coil section 45 may be constructed as a separate collar and positioned similarly over the setback spring 44 . The collar replacing the dead coil section 45 may also be attached to the top coil of the setback spring 44 , e.g., by welding, brazing, or adhesives such as epoxy, or the like. The advantage of attaching the collar to the top of the setback spring 44 is that it would help prevent it to get struck over the posts 33 as it is being pushed down by the applied acceleration in the direction of the arrow 48 , FIGS. 6-8 .
[0064] Alternatively, the dead coil section 45 and the setback spring 44 may be integral, made out of, for example, a cylindrical section with spiral or other type shaped cuts over its lower section to provide the required axial flexibility to serve the function of the setback spring 44 . The upper portion of this cylinder is preferably left intact to serve the function of the dead coil section 45 , FIGS. 6-8 .
[0065] It is appreciated by those skilled in the art that by varying the mass of the striker 39 , the mass of the dead coil section 45 , the spring rate of the setback spring 44 , the distance that the dead coil section 45 has to travel downward to release the locking balls 42 and thereby release the striker mass 39 , and the distance between the parts 46 and 47 of the two-part pyrotechnic compound, the designer of the disclosed inertial igniter 30 can match the fire and no-fire impulse level requirements for various applications as well as the safety (delay or dwell action) protection against accidental dropping of the inertial igniter and/or the munitions or the like within which it is assembled.
[0066] Briefly, the safety system parameters, i.e., the mass of the dead coil section 45 , the spring rate of the setback spring 44 and the dwell stroke (the distance that the dead coil section 44 has to travel downward to release the locking balls 42 and thereby release the striker mass 39 ) must be tuned to provide the required actuation performance characteristics. Similarly, to provide the requisite impact energy, the mass of the striker 39 and the separation distance between the parts 46 and 47 of the two-part pyrotechnic compound must work together to provide the specified impact energy to initiate the pyrotechnic compound when subjected to the remaining portion of the prescribed initiation acceleration profile after the safety system has been actuated.
[0067] In addition, since the safety and striker systems each require a certain actuation distance to achieve the necessary performance, the most axially compact design is realized by nesting the two systems in parallel as it is done in the embodiment of FIG. 4 . It is this nesting of the two safety and striker systems that allows the height of the disclosed inertial igniter to be significantly shorter than the currently available inertial igniter design (as shown in FIG. 2 ), in which the safety and striker systems are configured in series. In fact, an initial prototype of the disclosed inertial igniter 30 has been designed to the fire and no-fire and safety specifications of the currently available inertial igniter shown in FIG. 2 and has achieved height and volume reductions of over 60 percent. It is noted that by optimizing the parameters of the disclosed inertial igniter, both height and volume can be further reduced.
[0068] In another embodiment, the two-part pyrotechnics 46 and 47 , FIG. 4 , are replaced by a percussion cap primer 49 attached to the base 32 of the inertial igniter 60 and a striker tip 50 as shown in the schematic of a cross-section of FIG. 9 . In this illustration, all components are the same as those shown in FIG. 4 with the exception of replacing the percussion cap primer 49 and the striker tip 50 with striker assembly. The striker tip 50 is firmly attached to the striker mass 39 .
[0069] The striker mass 39 and striker tip 50 may be a monolithic design with the striking tip 50 being a machined boss protruding from the striker mass, or the striker tip 50 may be a separate piece pressed or otherwise permanently fixed to the striker mass. A two-piece design would be favorable to the need for a striker whose density is different than steel, but whose tip would remain hard and tough by attaching a steel ball, hemisphere, or other shape to the striker mass. A monolithic design, however, would be generally favorable to manufacturing because of the reduction of part quantity and assembly operations.
[0070] An advantage of using the two component pyrotechnic materials as shown in FIG. 4 is that these materials can be selected such that ignition is provided at significantly lower impact forces than are required for commonly used percussion cap primers. As a result, the amount of distance that the striker mass 39 has to travel and its required mass is thereby reduced, resulting in a smaller total height (shown as 15 in FIG. 1 ) of the thermal battery assembly. This choice, however, has the disadvantage of not using standard and off-the-shelf percussion cap primers, thereby increasing the component and assembly cost of the inertial igniter.
[0071] The disclosed inertial igniters are seen to discharge the ignition fire and sparks directly into the thermal battery, FIGS. 4-9 , to ignite the pyrotechnic materials 24 within the thermal battery 11 ( FIG. 3 ). As a result, the additional housing 21 and ignition material 23 shown in FIG. 3 can be eliminated, greatly simplifying the resulting thermal battery design and manufacture. In addition, the total height 13 and volume of the inertial igniter assembly 10 and the total height 15 of the complete thermal battery assembly 16 are reduced, thereby reducing the total volume that has to be allocated in munitions or the like to house the thermal battery.
[0072] The disclosed inertial igniters are shown sealed within their housing, thereby simplifying their storage and increase their shelf life.
[0073] FIG. 10 shows the schematic of a cross-section of another embodiment 80 . This embodiment is similar to the embodiment shown in FIGS. 4-8 , with the difference that the striker mass 39 ( FIGS. 4-8 ) is replaced with a striker mass 82 , with at least one opening passage 81 to guide the ignition flame up through the igniter 80 to allow the pyrotechnic materials (or the like) of a thermal battery (or the like) positioned above the igniter 80 (not shown) to be initiated. In addition, the top cap 35 ( FIG. 4-8 ) is preferably eliminated or replaced by a cap 83 with appropriately positioned openings to allow the flames to enter the thermal battery and initiate its pyrotechnic materials. The openings 38 ( FIG. 5 b ) are obviously no longer necessary.
[0074] FIG. 11 b shows the schematic of a cross-section of another embodiment 90 . This embodiment is similar to the embodiment shown in FIGS. 4-8 , with the difference that the openings 38 ( FIG. 5 b ) for the flame to exit the igniter 30 is replaced with side openings 91 , FIG. 11 a , to allow the flame to exit from the side of the igniter to initiate the pyrotechnic materials (or the like) of a thermal battery or the like (not shown) that is positioned around the body of the igniter 90 . Alternatively, the igniter housing 92 may be eliminated, thereby allowing the generated ignition flames to directly flow to the sides of the igniter 90 and initiate the pyrotechnic materials of the thermal battery or the like.
[0075] FIG. 12 shows the schematic of a cross-section of another embodiment 100 . This embodiment is similar to the embodiment shown in FIGS. 4-8 , with the difference that the dead coil section 45 ( FIGS. 4-5 ) is replaced with a solid, preferably relatively very rigid, cylindrical section 101 . The advantage of using a rigid cylindrical section 101 is that the balls 42 ( FIGS. 4-5 ) would not tend to cause the individual coils of the dead coil section 45 to move away from their cylindrically positioned configuration, thereby increasing the probability that the dead coil section could get stuck by the friction forces due to the pressure exerted by the balls 42 to the interior of the housing 34 ( FIG. 4 ) or other similar possible scenarios.
[0076] In certain applications, the required reliability levels for initiation of inertial igniters are extremely high. In certain cases, the igniters should be designed and manufactured to perform their function with extremely high reliability of nearly 100 percent. Some cases may even require the use of multiple and redundant inertial igniters to obtain nearly 100 percent reliability.
[0077] The cost issue is also another important consideration since in small thermal batteries that have to be initiated by inertial igniters, the cost of inertial igniters may easily be a significant portion of the total cost. However, to significantly reduce the cost, inertial igniters have to be designed with fewer and easy to manufacture parts and be easy to assemble. In addition, the inertial igniters must use mass produced and commercially available parts.
[0078] The embodiments of the inertial igniters disclosed below are to provide the aforementioned advantages of the embodiments shown in FIGS. 4-12 and in addition: (1) provide inertial igniters that are significantly more reliable and easy to manufacture than currently available inertial igniters for thermal batteries or the like, particularly for relatively small thermal batteries that are used in munitions; (2) provide highly reliable and at the same time very small inertial igniters that do not occupy a significant volumes of small thermal batteries; (3) provide inertial igniters that are easy to manufacture and assemble into thermal batteries; and (4) provide inertial igniters that are readily modified to satisfy a wide range of no-fire and all-fire requirements without requiring costly engineering development and manufacturing equipment changes.
[0079] A need exists for novel miniature inertial igniters for thermal batteries used in gun fired munitions, that are extremely reliable, low cost (such as having fewer easy to manufacture parts that are not required to be fabricated to very low tolerances), easy to manufacture and assemble, and easy to assemble into a thermal battery (such as simply “drop-in” component during thermal battery assembly). Such inertial igniters can also be adaptable to a wide range of all-fire and no-fire requirements without requiring a significant amount of engineering development and testing. Such inertial igniters can also be capable of allowing multiple inertial igniters to be readily packed into thermal batteries as redundant initiators to further increase initiation reliability when such extremely high initiation reliability are warranted. Such inertial igniters are particularly needed for small and low power thermal batteries that could be used in fuzing and other similar applications. Such inertial igniters must be safe and in general and in particular they should not initiate if dropped, e.g., from up to 5-7 feet onto a concrete floor for certain applications; should withstand high firing accelerations and do not cause damage to the thermal battery, for example up to 20-50,000 Gs or even more; and should be able to be designed to ignite at specified acceleration levels when subjected to such accelerations for a specified amount of time to match the firing acceleration experienced in a gun barrel as compared to high G accelerations experienced during accidental falls which last for very short periods of time, for example accelerations of the order of 1000 Gs when applied for over 5 msec as experienced in a gun as compared to, for example 2000 G acceleration levels experienced during accidental fall over a concrete floor but which may last only 0.5 msec. Reliability is also of much concern since the rounds should have a shelf life of up to 20 years and could generally be stored at temperatures of sometimes in the range of −65 to 165 degrees F. This requirement is usually satisfied best if the igniter pyrotechnic is in a sealed compartment.
[0080] An isometric cross-sectional view of a sixth embodiment of an inertia igniter is shown in FIG. 13 , referred to generally with reference numeral 200 . The full isometric view of the inertial igniter 200 is shown in FIG. 14 . The inertial igniter 200 is constructed with igniter body 201 , consisting of a base 202 and at least three posts 203 . The base 202 and the at least three posts 203 , can be integrally formed as a single piece but may also be constructed as separate pieces and joined together, for example by welding or press fitting or other methods commonly used in the art. The base 202 of the housing can also be provided with at least one opening 204 (with a corresponding opening(s) in the thermal battery—not shown) to allow ignited sparks and fire to exit the inertial igniter and enter into the thermal battery positioned under the inertial igniter 200 upon initiation of the inertial igniter pyrotechnics 215 , or percussion cap primer when used in place of the pyrotechnics, similar to the primer 49 in the embodiment 60 shown in FIG. 9 . Although illustrated with the opening 204 in the base, the opening (or openings) can alternatively be formed in a side wall as is shown in FIG. 11 a or in the striker mass as is shown in FIG. 10 .
[0081] The base 202 of the housing may be extended to form a cap for the thermal battery, similar to the cap 36 of the thermal battery 37 shown for the embodiment 30 in FIGS. 4 and 5 .
[0082] A striker mass 205 is shown in its locked position in FIG. 13 . The striker mass 205 is provided with guides for the posts 203 , such as vertical surfaces 206 (which may be recessed as shown in the embodiment 30 in FIGS. 4 and 5 ), that are used to engage the corresponding (inner) surfaces of the posts 203 and serve as guides to allow the striker mass 205 to ride down along the length of the posts 203 without rotation with an essentially pure up and down translational motion. However, the surfaces 206 minimize the chances of the striker mass 205 jamming as compared to the recesses 40 . Further, manufacturing precision is reduced (for both the posts 203 and the striker mass 205 ) when the surfaces 206 are used in place of the recesses 40 . Consequently, both the striker mass 205 and the inertial igniter structure (which includes the posts 203 ) is easier to produce and less costly when the surfaces 206 are used in place of the recesses 40 .
[0083] In its illustrated position in FIGS. 13 and 14 , the striker mass 205 is locked in its axial position to the posts 203 by at least one setback locking ball 207 . The setback locking ball 207 locks the striker mass 205 to the posts 203 of the inertial igniter body 201 through the holes 208 provided in the posts 203 and a concave portion such as a dimple (or groove) 209 on the striker mass 205 as shown in FIG. 13 . A setback spring 210 , which is preferably in compression, is also provided around but close to the posts 203 as shown in FIGS. 13 and 14 . In the configuration shown in FIG. 13 , the locking balls 207 are prevented from moving away from their aforementioned locking position by the collar 211 . The setback spring 210 can be a wave spring with rectangular cross-section. The rectangular cross-section eliminates the need to fix or otherwise retain the striker spring 210 to the collar 211 , which is an expensive process; the flat coil spring surfaces minimizes the chances of coils slipping laterally (perpendicular to the direction of acceleration 218 ), which can cause jamming and prevent the release of the striker mass 205 (preventing the collar to move down enough to release the locking balls). Furthermore, wave springs generate friction between the waves at contact points along the spring wire, thereby reducing the chances for the collar 211 to rapidly bounce back up and preventing the striker mass 205 from being released.
[0084] The collar 211 is preferably provided with partial guide 212 (“pocket”), which are open on the top as indicated by the numeral 213 . The guide 212 may be provided only at the location of the locking balls 207 as shown in FIGS. 13 and 14 , or may be provided as an internal surface over the entire inner surface of the collar 211 (not shown). The advantage of providing local guides 212 is that it results in a significantly larger surface contact between the collar 211 and the outer surfaces of the posts 203 , thereby allowing for smoother movement of the collar 211 up and down along the length of the posts 203 . In addition, they prevent the collar 211 from rotating relative to the inertial igniter body 201 and makes the collar stronger and more massive. The advantage of providing a continuous inner recess guiding surface for the locking balls 207 is that it would require fewer machining processes during the collar manufacture. Although only one locking ball 207 is illustrated in FIG. 13 , more than one can be provided, such as a locking ball 207 associated with each post 203 . More than one locking ball 207 can also be associated with each post 203 .
[0085] The collar 211 rides up and down on the posts 203 as can be seen in FIGS. 13 and 14 , but is biased to stay in its upper most position as shown in FIGS. 13 and 14 by the setback spring 210 . The guides 212 are provided with bottom ends 214 , so that when the inertial igniter is assembled as shown in FIGS. 13 and 14 , the setback spring 210 which is biased (preloaded) to push the collar 211 upward away from the igniter base 201 , would “lock” the collar 211 in its uppermost position against the locking balls 207 . As a result, the assembled inertial igniter 200 stays in its assembled state and would not require a top can (similar to the top cap 35 in the embodiment 30 of FIG. 4 ) to prevent the collar 211 from being pushed up and allowing the locking balls 207 from moving out and releasing the striker mass 205 .
[0086] In the sixth embodiment, a one part pyrotechnics compound 215 (such as lead styphnate or other similar compound) can be used as shown in FIG. 13 . The surfaces to which the pyrotechnic compound 215 is attached can be roughened and/or provided with surface cuts, recesses, projections, or the like and/or treated chemically as commonly done in the art (not shown) to ensure secure attachment of the pyrotechnics material to the applied surfaces. The use of one part pyrotechnics compound makes the manufacturing and assembly process much simpler and thereby leads to lower inertial igniter cost. The striker mass can be provided with a relatively sharp tip 216 and the igniter base surface 202 is provided with a protruding tip 217 which is covered with the pyrotechnics compound 215 , such that as the striker mass is released during an all-fire event and is accelerated down (opposite to the arrow 218 illustrated in FIG. 13 ), impact occurs mostly between the surfaces of the tips 216 and 217 , thereby pinching the pyrotechnics compound 215 , thereby providing the means to obtain a reliable initiation of the pyrotechnics compound 215 .
[0087] Alternatively, a two-part pyrotechnics compound as shown and described for the embodiment 30 of FIG. 4 can be used. One part of the two-part pyrotechnics compound 47 ( FIG. 4 ), e.g., potassium chlorate, can be provided on the interior side of the base 32 , such as in a provided recess (not shown) over the exit holes 38 . The second part of the pyrotechnics compound (e.g., red phosphorous) 46 can be provided on the lower surface of the striker mass surface 39 facing the first part of the pyrotechnics compound 47 , as shown in FIG. 4 . In general, various combinations of pyrotechnic materials can be used for this purpose. One commonly used pyrotechnic material consists of red phosphorous or nano-aluminum, indicated as element 46 in FIG. 4 , and is used with an appropriate binder (such as vinyl alcohol acetate resin or nitrocellulose) to firmly adhere to the bottom surface of the striker mass 39 . The second component can be potassium chlorate, potassium nitrate, or potassium perchlorate, indicated as element 47 in FIG. 4 , and is used with a binder (such as, but not limited to vinyl alcohol acetate resin or nitrocellulose) to firmly attach the compound to the surface of the base 32 (such as inside of a recess provided in the base 32 —not shown) as shown in FIG. 4 .
[0088] Alternatively, instead of using the pyrotechnics compound 215 , FIG. 13 , a percussion cap primer or the like (similar to the percussion cap primer 49 used in the embodiment 60 of FIG. 9 ) can be used. A striker tip (similar to the striker tip 50 shown in FIG. 9 for the embodiment 60 ) can be provided at the tip 216 of the striker mass 205 (not shown) to facilitate initiation upon impact.
[0089] The basic operation of the embodiment 200 of the inertial igniter of FIGS. 13 and 14 is similar to that of embodiment 30 ( FIGS. 4-8 ) as previously described. Here again, any non-trivial acceleration in the axial direction 218 which can cause the collar 211 to overcome the resisting force of the setback spring 210 will initiate and sustain some downward motion of the collar 211 . The force due to the acceleration on the striker mass 205 is supported at the dimples 209 by the locking balls 207 which are constrained inside the holes 208 in the posts 203 . If an acceleration time in the axial direction 218 imparts a sufficient impulse to the collar 211 (i.e., if an acceleration time profile is greater than a predetermined threshold), it will translate down along the axis of the assembly until the setback locking balls 205 are no longer constrained to engage the striker mass 205 to the posts 203 . If the acceleration event is not sufficient to provide this motion (i.e., the acceleration time profile provides less impulse than the predetermined threshold), the collar 211 will return to its start (top) position under the force of the setback spring 210 .
[0090] Assuming that the acceleration time profile was at or above the specified “all-fire” profile, the collar 211 will have translated down past the locking balls 207 , allowing the striker mass 205 to accelerate down towards the base 202 . In such a situation, since the locking balls 207 are no longer constrained by the collar 211 , the downward force that the striker mass 205 has been exerting on the locking balls 207 will force the locking balls 207 to move outward in the radial direction. Once the locking balls 207 are out of the way of the dimples 209 , the downward motion of the striker mass 205 is impeded only by the elastic force of the setback spring 210 , which is easily overcome by the impulse provided to the striker mass 205 . As a result, the striker mass 205 moves downward, causing the tip 216 of the striker mass 205 to strike the pyrotechnic compound 215 on the surface of the protrusion 217 with the requisite energy to initiate ignition (similar to the configuration shown for the embodiment 30 in FIG. 8 ).
[0091] In the embodiment 200 of the inertial igniter shown in FIGS. 13 and 14 , the setback spring 210 is illustrated as a helical wave spring type fabricated with rectangular cross-sectional wires (such as the ones manufactured by Smalley Steel Ring Company of Lake Zurich, Ill.). This is in contrast with the helical springs with circular wire cross-sections used in the embodiments of FIGS. 4-12 . The use of the aforementioned rectangular cross-section wave springs or the like has the following significant advantages over helical springs that are constructed with wires with circular cross-sections. Firstly and most importantly, as the spring is compressed and nears its “solid” length, the flat surfaces of the rectangular cross-section wires come in contact and generate minimal lateral forces that would otherwise tend to force one coil to move laterally relative to the other coils as is usually the case when the wires are circular in cross-section. Lateral movement of the coils can, in general, interfere with the proper operation of the inertial igniter since it could, for example jam a coil to the outer housing of the inertial igniter (not shown in FIGS. 13 and 14 ), which is usually desired to house the igniter 200 or the like with minimal clearance to minimize the total volume of the inertial igniter. In addition, the laterally moving coils could also jam against the posts 203 thereby further interfering with the proper operation of the inertial igniter. The use of the present wave springs with rectangular cross-section eliminates such lateral movement and therefore significantly increases the reliability of the inertial igniter and also significantly increases the repeatability of the initiation for a specified all-fire condition. The second advantage of the use of the aforementioned wave springs with rectangular cross-section, particularly since the wires can and are usually made thin in thickness and relatively wide, the solid length of the resulting wave spring can be made to be significantly less than an equivalent regular helical spring with circular cross-section. As a result, the total height of the resulting inertial igniter can be reduced. Thirdly, since the coil waves are in contact with each other at certain points along their lengths and as the spring is compressed, the length of each wave is slightly increased, therefore during the spring compression the friction forces at these contact points do a certain amount of work and thereby absorb a certain amount of energy. The presence of such friction forces ensures that the firing acceleration and very rapid compression of the spring would to a lesser amount tend to “bounce” the collar 211 back up and thereby increasing the possibility that it would interfere with the exit of the locking balls from the dimples 209 of the striker mass 205 and the release of the striker mass 205 . The above characteristic of the wave springs with rectangular cross-section therefore also significantly enhances the performance and reliability of the inertial igniter 200 while at the same time allowing its height (and total volume) to be reduced.
[0092] It is appreciated by those skilled in the art that by varying the mass of the striker 205 , the mass of the collar 211 , the spring rate of the setback spring 210 , the distance that the collar 211 has to travel downward to release the locking balls 207 and thereby release the striker mass 205 , and the distance between the tip 216 of the striker mass 205 and the pyrotechnic compound 215 (and the tip of the protrusion 217 ), the designer of the disclosed inertial igniter 200 can match the all-fire and no-fire impulse level requirements for various applications as well as the safety (delay or dwell action) protection against accidental dropping of the inertial igniter and/or the munitions or the like within which it is assembled.
[0093] Briefly, the safety system parameters, i.e., the mass of the collar 211 , the spring rate of the setback spring 210 and the dwell stroke (the distance that the collar 210 has to travel downward to release the locking balls 207 and thereby release the striker mass 205 ) must be tuned to provide the required actuation performance characteristics. Similarly, to provide the requisite impact energy, the mass of the striker 205 and the aforementioned separation distance between the tip 216 of the striker mass and the pyrotechnic compound 215 (and the tip of the protrusion 217 ) must work together to provide the specified impact energy to initiate the pyrotechnic compound when subjected to the remaining portion of the prescribed initiation acceleration profile after the safety system has been actuated.
[0094] The striker mass 205 and striker tip 216 may be a monolithic design with the striking tip 216 being formed, as shown in FIG. 13 , or as a boss protruding from the striker mass, or the striker tip 216 may be a separate piece, possibly fabricated from a material that is significantly harder than the striker mass material, and pressed or otherwise permanently fixed to the striker mass. A two-piece design would be favorable to the need for a striker whose density is different than steel, but whose tip would remain hard and tough by attaching a steel ball, hemisphere, or other shape to the striker mass. A monolithic design, however, would be generally favorable to manufacturing because of the reduction of part quantity and assembly operations.
[0095] The use of three or more posts 203 in the embodiment 200 of FIGS. 13 and 14 has several significant advantages over the two post designs of the embodiments of FIGS. 4-5 . namely, unlike the embodiment 30 of FIGS. 4 and 5 in which the striker mass 39 is provided with vertical recesses 40 that are used to engage the posts 33 and serve as guides to allow the striker mass 39 to ride down along the length of the posts 33 without rotation, the use of at least three posts 203 in the embodiment 200 of FIGS. 13 and 14 eliminates the need for the aforementioned vertical recesses in the striker mass 205 . As a result, the chances that the striker mass 203 gets jammed at the interface between the aforementioned vertical recesses ( 40 in FIGS. 4 and 5 ) and the posts ( 33 in FIGS. 4 and 5 ) are almost entirely eliminated. As a result, the reliability of the inertial igniter is significantly increased. Furthermore, the design of the striker mass and the igniter posts and their required manufacturing process are significantly simplified and the required manufacturing precision is also reduced. As a result, the manufacturing cost of the striker mass as well as the igniter body is significantly reduced. Still further, the contacting surfaces between the striker mass 205 and the posts 203 is increased, thereby allowing for a smoother up and down movement of the striker mass 205 along the inner surfaces of the posts 203 .
[0096] In the embodiment 200 of FIGS. 13 and 14 , following ignition of the pyrotechnics compound 215 , the generated flames and sparks are designed to exit downward through the opening 204 to initiate the thermal battery below. Alternatively, if the thermal battery is positioned above the inertial igniter 200 , the opening 204 can be eliminated and the striker mass could be provided with at least one opening similar to the passage 81 of the striker mass 82 of the embodiment 80 of FIG. 10 to guide the ignition flame and sparks up through the striker mass 205 to allow the pyrotechnic materials (or the like) of a thermal battery (or the like) positioned above the inertial igniter 200 (not shown) to be initiated.
[0097] Alternatively, in a manner similar to that shown in the embodiment 90 of FIGS. 11 a and 11 b , side ports (openings 91 ) may be provided to allow the flame to exit from the side of the igniter to initiate the pyrotechnic materials (or the like) of a thermal battery or the like that is positioned around the body of the inertial igniter. Alternatively, the igniter housing 261 ( FIG. 16 ) may be eliminated, thereby allowing the generated ignition flames to directly flow to the sides of the igniter 200 and initiate the pyrotechnic materials of the thermal battery or the like.
[0098] In FIGS. 13 and 14 , the inertial igniter embodiment 200 is shown without any outside housing. In many applications, as shown in the schematics of FIG. 15 a ( 15 b ), the inertial igniter 240 ( 250 ) is placed securely inside the thermal battery 241 ( 251 ), either on the top ( FIG. 15 a ) or bottom ( FIG. 15 b ) of the thermal battery housing 242 ( 252 ). This is particularly the case for relatively small thermal batteries. In such thermal battery configurations, since the inertial igniter 240 ( 250 ) is inside the hermetically sealed thermal battery 241 ( 251 ), there is no need for a separate housing to be provided for the inertial igniter itself. In this assembly configuration, the thermal battery housing 242 ( 252 ) is provided with a separate compartment 243 ( 253 ) for the inertial igniter. The inertial igniter compartment 243 ( 253 ) is preferably formed by a member 244 ( 254 ) which is fixed to the inner surface of the thermal battery housing 242 ( 253 ), preferably by welding, brazing or very strong adhesives or the like. The separating member 244 ( 254 ) is provided with an opening 245 ( 255 ) to allow the generated flame and sparks following the initiation of the inertial igniter 240 ( 250 ) to enter the thermal battery compartment 246 ( 256 ) to activate the thermal battery 241 ( 251 ). The separating member 244 ( 254 ) and its attachment to the internal surface of the thermal battery housing 242 ( 252 ) must be strong enough to withstand the forces generated by the firing acceleration.
[0099] For larger thermal batteries, a separate compartment (similar to the compartment 10 over or possibly under the thermal battery hosing 11 as shown in FIG. 1 can be provided above, inside or under the thermal battery housing for the inertial igniter. An appropriate opening (similar to the opening 12 in FIG. 1 ) can also be provided to allow the flame and sparks generated as a result of inertial igniter initiation to enter the thermal battery compartment (similar to the compartment 14 in FIG. 1 ) and activate the thermal battery.
[0100] The inertial igniter 200 , FIGS. 13 and 14 may also be provided with a housing 260 as shown in FIG. 16 . The housing 260 is preferably one piece and fixed to the base 202 of the inertial igniter structure 201 , preferably by soldering, laser welding or appropriate epoxy adhesive or any other of the commonly used techniques to achieve a sealed compartment. The housing 260 may also be crimped to the base 202 as shown in FIG. 16 for the inertial igniter embodiment 30 . The housing 260 may also be crimped to the base 202 at its open end 261 , in which case the base 202 is preferably provided with an appropriate recess 262 to receive the crimped portion 261 of the housing 260 . The housing can be sealed at or near the crimped region via one of the commonly used techniques such as those described above.
[0101] In addition, as shown in FIG. 17 , the base 202 of the inertial igniter 200 may be extended to form the cap 263 , which could be used to form the top cap of the thermal battery as is shown in FIG. 5 c and identified with the numeral 36 for the inertial igniter embodiment 30 .
[0102] The inertial igniter embodiment 200 of FIGS. 13 and 14 as provided with the aforementioned housing 260 and shown in FIG. 16 may also be hermetically sealed. To this end, and as shown in FIG. 18 , the opening 204 can be covered, preferably with a thin membrane 264 . The membrane 264 can be an integral part of the base 202 and is scorched on its bottom surface (not seen in the view of FIG. 18 ) to assist it to break open by the pressure generated by the initiation of the pyrotechnics compound 215 ( FIG. 13 ) upon initiation of the inertial igniter to allow the generated flame and sparks to enter the thermal battery through the resulting opening.
[0103] In another embodiment, more than one inertial igniter, preferably inertial igniters of the embodiment 200 type are used in a thermal battery to significantly increase the overall reliability of the thermal battery initiation under all-fire condition. As a result, if for any reason one of the inertial igniters fails to initiate or fails to initiate the thermal battery, then there would be one or more (redundant) inertial igniters to significantly reduce the chances that the thermal battery would fail to be activated. The more than one inertial igniters (preferably of embodiment 200 or any other of the aforementioned embodiments) may in general be assembled in any appropriate configuration in the thermal battery. For the case of small thermal batteries, however and if the thermal battery size allows, the inertial igniters are preferably ganged up together in one location, for example on the top or bottom compartments shown in FIGS. 15 a and 15 b or in the compartment 10 shown in FIG. 1 , to minimize the total volume and size occupied by the inertial igniters. For example, when three inertial igniters of the embodiment 200 are to be assembled within a thermal battery, for example of the type shown in FIG. 15 a , assuming that the amount of space available in the compartment 243 is appropriate, the three inertial igniters 200 may be ganged up inside the compartment 243 as shown in the top view of FIG. 19 (the top cap is removed to show the inertial igniters 200 inside the compartment 243 ).
[0104] When more than one inertial igniter 200 (or of other embodiment types) are ganged up in a compartment similar to that of 243 as shown in FIG. 19 , the body 201 of two or more of the inertial igniters 200 may be integral. For example, the bodies 201 of the three inertial igniters 200 shown in FIG. 19 may be integral as shown in the top and isometric views of FIGS. 20 a and 20 b , respectively, and identified with reference numeral 265 .
[0105] In certain applications, it is desired that the inertial igniters ganged up in a compartment such as 243 as shown in FIG. 19 be separated by a wall so that their operations and/or failure (such as flying pieces following initiation or break up of one igniter) would not interfere with the operation of the remaining inertial igniters. In such cases, the inertial igniter bodies (such as the bodies 201 of the inertial igniters 200 , FIGS. 13 and 19 ) and the separation walls 206 between at least two of the inertial igniters may be integral as shown in the isometric and top views of FIGS. 21 a and 21 b , respectively, and indicated by reference numeral 266 . In the drawings of FIGS. 21 a and 21 b , all three inertial igniters 200 are intended to be separated from each other by the walls 267 .
[0106] The present inertial igniters are designed such that when ganged up as shown in FIG. 20 a or FIG. 21 a , their integral bodies 201 can be readily machined, for example from a solid rod, using commonly used CNC machining centers or the like.
[0107] While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims.
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An inertial igniter including: a body having a base and three or more posts, each post having a hole; a locking ball corresponding to each post, wherein a portion of the locking balls are disposed in the hole; a striker mass movably disposed relative to the posts and having a surface corresponding to the posts, the striker mass further having a concave portion corresponding to the locking balls, wherein a second portion of each locking ball is disposed in a corresponding concave portion for retaining the striker mass relative to the posts; a collar movable relative to the posts; and a biasing element for biasing the collar in a first position which retains the striker mass, the biasing element permitting movement of the collar to a second position to release the striker mass relative to the posts upon a predetermined acceleration profile.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for broadening the width of a bundle of parallel filaments having a band form and thereby preparing a thinner layer therefrom, which process comprises pinching the bundle along a direction-turning bar or bars arranged obliquely to the approaching direction of the bundle to the straight bar(s) along the surfaces thereof and turning the advancing direction of the bundle to an optional direction according to the required broadened width for the bundle.
The bundle of parallel filaments having a band form referred to herein means an untwisted bundle of parallel filaments such as tow, rovings, strands or the like of organic or inorganic filaments, arranged in parallel in the form of a band having a flat long rectangle in the cross-section.
The bundle of parallel filaments having a band form will often be hereinafter abbreviated merely to "bundle".
2. Description of the Prior Art
As to fabrics used for reinforcing industrial materials, etc., it has generally been regarded as most important that the fabrics are cheap and have sufficient strengths and uniformity; if a thin layer of parallel filaments having a uniform thickness is available, a reinforced material having an optional tenacity can be manufactured at a low cost by laminating the material as wefts and/or warps, and conventional woven or non-woven fabrics using expensive yarns obtained via a number of steps such as spinning, twisting, etc. will be replaced by the above laminated fabrics.
A prior art has been proposed wherein the width of a tow of crimped filaments is broadened by an arculate guide, utilizing the property that its filaments are internally connected in order, embracing each other by their crimps in the lateral direction, and the product is used as waddings or non-woven fabrics. However, according to the technique of this kind, a thin layer of 50 g/m 2 or less is difficult to prepare and it is entirely difficult to broaden the width of uncrimped tow, rovings, strands, etc. having no connection in the lateral direction.
If a bundle of parallel filaments having a band form is laid straightly on a flat surface, and a straight bar is placed on the bundle obliquely to the lengthwise direction so that the filaments under the bar may be pinched and one end of the bundle is pulled up so that all the filaments may be directed to the same direction as that of pulling-up, then the width of the pulled-up bundle is varied according to the direction of pulling-up and the maximum width is obtained when the direction of pulling-up is perpendicular to the bar. Making use of this principle, the width of the bundle can be broadened. However, according to conventional prior art, it has been difficult to continuously carry out the above steps during the running course of the bundle. Namely, such a bundle is generally led by rotating rolls. In this case, the layer is sent toward their rotating direction along with the rotation of the roll surfaces; hence it always tends to approach the rolls in a direction perpendicular to the axial lines of the rolls. Thus it is impossible for usual pinch rolls to hold such a bundle pinching it obliquely to its advancing direction. Further, British Pat. No. 1,078,732 discloses a process wherein a film or a band is obliquely pinched by a pair of nip rolls. These rolls are specifically designed in order to prevent the film or band from sliding along the nip towards that side of the nip at the time of turning the direction of the film or band by the nip. Each of the nip rolls has a core and has its surface divided along generatices into at least two segments, each segment extending substantially along the length of the surface and being mounted to reciprocate along the core and to rotate with the core. According to the process, however, the structure of the device is so complicated that it is difficult to carry out the practice. Thus the process is not practical. No process utilizing simple stationary bar(s) has been found till now for holding a running bundle of parallel filaments by pinching it obliquely to its advancing direction.
SUMMARY OF THE INVENTION
The present invention provides a new process for broadening the width of a bundle of parallel filaments having a band form, whether crimped or uncrimped, maintaining the uniformity of the density of the filaments in their lateral direction, to thereby prepare a uniform thinner layer of the parallel filaments.
The present invention has a main aspect (1) as follows:
A process for broadening the width of a bundle of parallel filaments having a band form, which process comprises:
during the running course of said bundle in the lengthwise direction,
holding said bundle under press along a direction-turning bar or bars arranged obliquely to the advancing direction of said bundle, along its flat surfaces;
while preventing said bundle approaching the holding line formed along said direction-turning bar or bars, from varying in its approach angle and also shifting to its widthwise direction,
turning the advancing direction of said bundle having left the holding line to a direction of an optional angle against the holding line; and
taking up the resulting bundle having a required width.
The present invention has the following two aspects:
(2) A process according to the above main aspect (1), which comprises:
leading said bundle together with a belt moving in the lengthwise direction of said bundle, between two direction-turning bars arranged obliquely to the advancing direction of said bundle, and
holding said bundle and said belt under press between said bars so that one of said bars may be contacted with said bundle and the other may be contacted with the back surface of said belt, to thereby form said holding line between the former bar contacted with said bundle and the surface of said belt;
while preventing said bundle approaching said holding line, from varying in its approach angle and also shifting to its widthwise direction, by the guiding action of said belt,
turning the advancing direction of said bundle leaving said holding line to a direction of an optional angle against said holding line;
separating said bundle having left said bars from said belt; and
taking up the resulting bundle having a required width.
(3) A process according to the above main aspect (1), which comprises:
placing said bundle between an upper belt and a lower belt moving in the lengthwise direction of said bundle in an overlapping manner;
holding said bundle under press between two direction-turning bars arranged obliquely to their advancing directions along their surfaces so that one of said bars may be contacted with the back surface of said upper belt and the other may be contacted with the back surface of said lower belt, to form said holding line between said two belts corresponding to said direction-turning bars;
while preventing said bundle approaching said holding line, from varying in its approach angle and also shifting to the widthwise direction thereof, by the guiding action of said belts,
separating the overlapped belts leaving said holding line from each other by turning the advancing direction of at least one of said two belts, along the direction-turning bar contacting the belt; and
taking up the resulting bundle having a required width.
According to the process of the present invention, even when the bundle having left the guides is taken up in an optional direction, the bundle is prevented from varying in the approach angle and also moving in the widthwise direction, because the influence of the direction-turning of the bundle is intercepted at the holding part. Thus it is possible to prepare a broadened thinner layer continuously and smoothly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 and FIG. 2 illustrate an embodiment of the present invention.
FIG. 1 shows a plan view illustrating the relationship among belts, direction-turning bars obliquely installed and take-up pinch rolls.
FIG. 2 shows a side view of the above means as viewed from the axial direction of the direction-turning bars.
DETAILED DESCRIPTION OF THE INVENTION
In order to make the understanding of the present invention easier, description will be first made referring to FIG. 1 and FIG. 2 illustrating an embodiment of the present invention described above.
In FIG. 1 and FIG. 2, two circulating belts, an upper one 2 and a lower one 1, advancing under tension, are circulated at the same velocity between pulleys 3 and 4 and between 5 and 6, respectively. Belts 1 and 2 having passed through pulleys 4 and 6 advance in an overlapping state with one another, and the respective surfaces of the belts are brought into close contact by direction-turning bars 7 and 8 installed obliquely to the advancing direction by an angle of θ along the surfaces of the bars, pressing the surfaces on each other, from both the upper side and the lower side. The lower belt 1, after having left the oblique bar 7, is straightly advanced and returned to pulley 4 via pulley 3, while the upper belt 2, after having left the oblique bar 8, is separated obliquely from the lower belt 1 along the surface of the direction-turning bar 8, and returned to pulley 6, via an oblique bar 9 arranged above the oblique bar 8 and via pulley 5. A bundle of parallel filaments 10 fed onto the belt 1 at the location of the pulley 4 advances along with the belt 1 and is held under press by the belts 1 and 2 from the upper and lower sides at the locations of the direction-turning bars 7 and 8, and the filaments held along the line corresponding to the bar do not shift relative to the belt surface. The belts 1 and 2 having passed through the oblique bar 8 are separated from each other and advance toward the respective directions, releasing the holding of the bundle. The holding of the bundle of the parallel filaments 10 is released on the straight line having an oblique angle of θ to the direction of the belts. The bundle is then drawn in the perpendicular direction to the oblique bar 8 by pinch rolls 11, 11' arranged in parallel to the oblique bar 8, whereby the width of the bundle 10 is extended to 1/sin θ times the original width to give a uniformly developed layer 12.
FIG. 1 and FIG. 2 show an embodiment of pinching the bundle 10 between the upper and lower belts, whereas, in the case of fibers having a small coefficient of friction and a high abrasion resistance, if the bundle placed on the lower belt is pressed directly by the tension of the lower belt between the direction-turning oblique bar and the belt, without using the upper belt, and the bundle is drawn in the perpendicular direction to the releasing straight line along the direction-turning bar, then the same effect as that in the above embodiment is obtained. The axial line of the pinch rolls 11, 11' are not always necessary to be in parallel to the oblique bars, but, in the case where the oblique angle θ of the bars is constant, the above arrangement of the pinch rolls 11, 11' in parallel to the oblique bar affords the highest width-broadening ratio.
As the direction-turning bar or bars referred to above in the main aspect of the present invention, straight-linear bars or tubes having a circular cross-section are usually employed, and fixed at definite locations along the surfaces of the bundle and obliquely to its advancing direction, so that these bars or tubes cannot be rotated. Usually their surfaces are treated so as to be durable to frictional wearing; and their abrasion is effectively prevented if they are rotated at a far slower peripheral velocity than the running velocity of the bundle or somewhat rotated so that the contact surface is varied occasionally.
The belts may be either one belt having a width corresponding to the width of the bundle introduced or a plurality of belts arranged in parallel and adjacent to each other, and if the tension of the belt is kept high enough, it is possible to hold the bundle under the necessary pressing force by the tension of the belts even when the direction-turning bar corresponding to numeral 7 in the drawings is not provided.
In the case where the surfaces of the direction-turning bars are subjected to an anti-abrasion treatment and have a small coefficient of friction, if the filaments are abrasion-resistant, the object of the process of this invention can be attained by introducing the bundle between the direction-turning bar and the belt and pressing them directly by the belt onto the surface of the bar, but it is generally more advantageous to introduce and press the bundle between an upper belt and a lower belt advancing in an overlapping state, because there is no fear of injuries of filaments, disturbance of their arrangement, etc. caused by friction between the filaments and the bar.
If the bundle has an original width of b and the direction-turning bars have an oblique angle of θ to the approaching direction of the bundle and the belts, the length l of the holding line of the bundle held under press along the direction-turning bar is equal to b/sin θ, and if the bundle is turned and drawn in a perpendicular direction to the bar, the resulting parallel width b is equal to l which is the maximum value of the width when the oblique angle is kept at θ.
The bundle uniformly broadened in the width and made thinner according to the process of the present invention can be wound up in the form of a non-woven fabric obtained by fixing the filaments therebetween with a small amount of a sizing agent, or can be wound up in the form of a non-woven fabric consisting of laminated warp and weft, obtained according to a separate invention of the applicant disclosed in U.S. Pat. No. 4,052,243 (1977), entitled "Improved method for producing a cross-laminated cloth-like product from wide warp and weft webs".
EXAMPLE 1
A polyacrylonitrile filament tow of 100,000 d passed through a stuffing crimper was passed through zigzag bars in a steam chamber under the atomospheric pressure to stretch crimps of the filaments and also disentangle interfilamentary entanglements. The resulting tow of about 200 mm in width was fed between an upper circulating belt and a lower one, both having a width of 250 mm, shown in FIG. 1 and FIG. 2. The belts were advanced among three oblique bars of each 100 mm in diameter and 2,000 mm in length and having an oblique angle of 10° to the advancing direction of the belts, as shown in the figures. The tow placed between the surfaces of the two belts were drawn by pinch rolls in a perpendicular direction to the holding straight line along the oblique bars arranged obliquely to the belts, to give a filament tow of 1,100 mm in width having a nearly uniform density of about 9 g/m 2 at a velocity of 40 m/min.
EXAMPLE 2
Untwisted fifty ends of glass rovings of 10,000 d were warped with a comb so as to have a pitch of 5 mm and fed between an upper circulating belt and a lower one of each 300 mm in width. The web was taken as described above, using the oblique direction-turning bars having an oblique angle of 12°, to give a glass web having a width of 1,250 mm and an average density of 45 g/m 2 , wherein rovings having a uniformly extended width of about 20 mm and a density of 55 g/m 2 were arranged in parallel at pitches of 25 mm, each having a gap of 5 mm.
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A process for broadening the width of a bundle of parallel filaments having a band form is provided, which comprises, during the running course of the bundle in the lengthwise direction, holding the bundle under press by a direction-turning bar or bars arranged obliquely to the advancing direction of the bundle along its surface; while preventing the bundle approaching the resulting oblique holding line from varying in its approach angle and also shifting to its widthwise direction, turning the direction of the bundle leaving the bar or bars to a direction having an optional angle against the oblique holding line; and taking up the resulting bundle having a required width.
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FIELD OF THE INVENTION
The invention relates to an apparatus for the spinning of yarn.
BACKGROUND OF THE INVENTION
Spinning machines are known wherein the roving is wound around so-called double-roving bobbins. On each of these double-roving bobbins, two rovings, preferably of combed wool, but also optionally other fibers or mixed fibers, are wound in parallel to each other. Slivers from both of these rovings which together form a fiber strand have to be drawn from the double-roving bobbin at the same time.
The spinning machine can preferably be a ring spinning frame, but optionally also a spinning machine for yarns having drawing mechanisms, such as a cap spinning frame, or a twine spinning machine or the like.
In ring spinning frames whose rovings are not fed by double-roving bobbins, but wherein each spinning unit receives the roving from its own roving bobbin assigned only to this spinning unit, it is known to provide a separate stopping device. After a yarn break this device stops the feeding of the roving. Thereby unnecessary waste of roving is prevented and the danger of roving laps on the drawing rollers is avoided up to the moment the yarn break is fixed. In the case of spinning frames operating with double-roving bobbins, the known stopping devices are not applicable.
It is therefore an object of the invention to create a spinning frame of the afore-mentioned kind, wherein it is also possible to prevent or at least minimize the danger of roving laps on the drawing rollers and to reduce the waste of roving during yarn breaks.
SUMMARY OF THE INVENTION
This object is attained with an apparatus for spinning of yarns from rovings that comprises a spinning frame, a plurality of spinning units arranbged on the frame, a plurality of drawing means, a yarn break sensor, and stopping means. Each of two neighboring spinning units form a spinning units pair and are supplied with the roving to be drawn from a common double-roving bobbin. The plurality of drawing means for drawing the rovings are also arranged on the frame with one of the drawing means associated with each of the spinning units. A yarn break sensor is also assigned to each of the spinning units. Stopping means for arresting and restarting feeding of the rovings to the drawing means are provided where one of the stopping means is assigned to each of the spinning units pair. Each stopping means also includes a pair of shells which press both rovings against a pair of upper rollers arresting those rollers.
A second embodiment of the present invention provides an apparatus which includes a spinning frame, a plurality of spinning units arranged on the frame, a plurality of drawing means, a yarn-setting carriage, and a detecting means. The yarn-setting carriage automatically corrects for yarn breaks. Detecting means are positioned on either the yarn-setting carriage, spinning frame or both. This detecting means at the start of a first yarn-break correction attempt checks whether at each of the two spinning units there is present one or more prerequisites to achieve a successful yarn-breaking correction. If the checking indicates that the prerequisites are not met, the detecting means triggers the carriage to continued traveling without attempting this correction.
With the apparatus according to the invention first embodiment, it is ensured that in the case of yarn break, the feeding of the roving coming from the respective double-roving bobbin is completely stopped, i.e. at both spinning units of the respective spinning-unit pair. Thereby, unnecessary consumption of roving is avoided. There is also prevented the danger of extensive fiber-lap formations on the drawing rollers during yarn breakage. As a consequence, no longer is there danger of damage to the drawing frame or the like due to extensive fiber lapping.
With the apparatus according to the invention second embodiment, the consumption of roving as well as danger of fiber-lap formations on the drawing rollers can be reduced. Thus, since when at one of the two spinning units or at both spinning units of the spinning units pair a yarn break cannot be fixed through the yarn setter due to limits imposed by the detecting and/or checking means, attempts to fix the yarn breakage are interrupted at both spinning units. Otherwise, it could happen, for instance, that a simultaneous yarn break at both spinning units, as always occurs in the first and occasionally in the second embodiment, the yarn setter could manage to repair the yarn break at one of the spinning units of the respective spinning units pair but not at the other spinning unit. Here the system leads to unnecessary roving consumption and to the danger of lap formations on the drawing rollers of the spinning unit wherein the yarn break has not been fixed.
Also, unnecessary time waste of the yarn setter is avoided, which increases productivity.
Preferably, the apparatus of the second embodiment, can include certain aspects of the first embodiment such as a yarn break sensor and stopping means. However, it is to be noted that both the first and second embodiments by themselves include improvements presenting a considerable advantage.
According to the first embodiment of this invention, a yarn break causes through stoppage of the respective roving, a "sequel yarn break" to simultaneously occur in the other spinning unit of the respective spinning unit pair. This disadvantage of the respective secondary yarn break is, however, largely outweighed by the advantages of low roving consumption and by the prevention of the danger of fiber lapping at the drawing rollers, in the wake of a yarn break. The arresting means assigned to the individual spinning units pair can consist of a single common stopping device for both spinning units or of two separate stopping devices for the two spinning units. The two separate stopping devices can each be started in common by a yarn break signal coming from either one of the two yarn break sensors of the respective spinning units pair. Alternately, the common stopping device is built in such a manner that it has at both spinning units of the roving commonly arresting stopping elements or mechanically coupled stopping elements.
The separate stopping devices can have the same or a similar construction as known ring spinning frames (wherein each stopping device assigned to a spinning unit is individually actuatable) without being coupled with the neighboring stopping devices. A difference over the known art resulting from the present arrangement is that the respective separate stopping means assigned to a respective spinning units pair are each commonly actuatable, either through mechanical coupling or through actuation via a single control element assigned to each spinning unit, whereby these two control elements are each commonly actuatable. Such a control element can, for instance, have an electromagnet. Of course, also other forms of stopping means assigned to a spinning units pair are possible, since all that is needed is a means for stopping, preferably simultaneously, both rovings coming from a sliver bobbin. However, it can optionally be provided that the stopping means at the two spinning units of the spinning units pair are actuated shortly one after the other for the stoppage of the roving. In the apparatus accordiang to the first embodiment, both yarn breaks can be fixed either manually or by means of an automatically operating yarn setter. Because of the sequel yarn break in the other spinning unit of the respective spinning units pair, the fixing of a yarn break in a spinning unit presumes that the stopping devices which prior to the fixing of the yarn break have been deactivated i.e. have been set in an inactive state, are not allowed yet to be reactivated. For this purpose, manual or automatic switching means can be provided. For instance, they can consist of a manually actuatable electric switch, which is switched off by an operator prior to the start of the fixing of the two yarn breaks at a spinning units pair and thereby disconnecting the two yarn break sensors of this spinning units pair from the thereto assigned stopping device. The operator can now eliminate the two yarn breaks one after the other. He then turns the switch on, so that when a new yarn break occurs at one of these spinning units, the stopping means of the respective spinning units pair can be again actuated by each of the two yarn break sensors, to stop the roving. Alternately, here can be provided an automatic switching means which can, by sensing of a yarn break through any one of the two yarn break sensors or through the stopping means as a result of their respective actuation, effect disconnection of the two yarn break sensors from the respective stopping means. It can also be provided that, when a yarn setter serves for the automatic fixing of yarn breaks, this yarn setter after fixing the two yarn breaks, in anyone of the spinning unit pair, perform or start the reactivation of the respective switching means at that spinning units pair, so that this way also only after the two yarn breaks have been fixed, the sensors can reactivate the stopping means, but not during the repair of the yarn breaks.
It is also possible to provide signalling means which send switch-on signals to the switching means during the operation of the spinning machine at predetermined intervals, preferably periodically, namely to all these switching means on the respective spinning machine, to make sure that if such switching means assigned to a spinning unit pair are not switched on again for any reason, e.g. because the operator forgot to do so, the automatic reactivation of these switching means will still take place. For instance, such switch-on signals can be repeated at time intervals of several minutes.
The apparatus according to the second embodiment always has a yarn-setting carriage. Checking-and/or sensing means can be particularly talored to sense whether the roving can be supplied to the two spinning units of the spinning units pair, namely to their drawing frames and/or whether in ring spinning frames at both spinning units travelers are available on the spinning rings and/or whether the predetermined drawing rollers or drawing frames are free of yarn laps and/or whether the respective spinning units pair is registered as "dead".
It is of particular advantage in the case of a yarn setter to provide means which would set off an indication that the respective spinning unit or unit pair be registered as dead when the setter has not succeeded to repair the yarn breaks after a predetermined number of attempts. Moreover the yarn setter must be further provided with means to make sure that the setter recognizes the spinning units pairs registered as "dead" and that it does not attempt to repair the yarn breaks at each of these spinning units pairs. This can be so arranged that the yarn setter stops for a short while at the respective "dead" spinning units pair to check whether it is registered as "dead". However, it is better to perform this checking operation with the running yarn setter and not have to stop it at all at such spinning unit pairs.
Also it can preferably be arranged that when the yarn-setting carriage unsuccessfully abandons its effort to fix a yarn break at the first unit of a spinning units pair and thereby triggers the registration as "dead" of this spinning units pair, it does not hereafter try to fix a yarn break at the other spinning unit of this spinning units pair, but on the contrary activates therein the slubbing-stopping means, in order to interrupt the roving feed at that spinning units pair.
The registration as "dead" of a spinning unit or a spinning units pair, can be cancelled by an operator, after he has corrected the disturbance.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing, an embodiment example of the invention is represented. It shows:
FIG. 1 a schematic side view of a spinning unit of a ring spinning frame,
FIG. 2 a frontal view of the feed rollers of a spinning units pair with a device for stopping the roving feed,
FIG. 3 a detailed schematic representation of several neighboring spinning units of the ring spinning frame according to FIG. 1 and of a yarn-setting carriage traveling along these spinning units for the correction of yarn breaks.
DETAILED DESCRIPTION
The spinning unit 10 of a ring spinning frame 9, represented in FIG. 1, which has a plurality of spinning units 10 of this kind arranged on both longitudinal sides of the machine, generally several hundred up to optionally thousand such spinning units, has a drawing frame 11 with a pair of feed rollers 12, a pair of intermediate rollers 13 and a pair of delivery rollers 14, which draw the roving 15 drawn-in by the feeding rollers 12. The drawn sliver is delivered by the delivery roller pair 14 and immediately twisted into a yarn 16 by the ring spinning device 17. Twisted yarn is then wound around a bobbin or sleeve 19 mounted on spindle 18. The spindle 18 penetrates a spinning ring 20, mounted on a ring rail 21 whereon a runner 22 is slidably supported. This runner entrains yarn 16 as the latter travels on its way from the yarn guide 23 to the driven spindle 18. Twist is imparted therethrough to the yarn 16.
When a yarn break occurs, runner 22 stops and a yarn-break sensor 24, located oppositely to the travel path of the runer and which for instance can operate inductively, senses the absence of the continuous running of the steel runner 22 and indicates that a yarn break has occurred. The signal is directed towards a stopping device 25.
Device 25 is commonly assigned to two neighboring spinning units, constituting a spinning units pair and can be activated through each of the yarn break sensors 24 of this spinning units couple for the simultaneous stopping of the feeding of both rovings 15 coming to this spinning units pair from the double-roving bobbin 26. These two rovings 15 are fed in common to each of the neighboring drawing frames 11 of a spinning units pair.
The stopping device 25 has two shells 29, extrending over slightly more than 180° of the circumference of the lower feed roller 27. These shells are firmly connected through a common connection bridge 30 and are supported by themselves on the lower feed roller 27. Upper rollers 31 press against the lower roller 27. These two feed roller pairs 12, consisting of the two upper rollers 31 and the lower roller 27. Simultaneously the two rovings is coming together from the common double-roving bobbin 26 are drawn in parallel into the two neighboring drawing frames 11, and then separately spun and wound into yarns 16.
A manually operatable handle 32 is provided on the connection bridge 30 of the two shells 29. Through handle 32 the stopping device 25 can be reset in its normal operating position after it has been activated, i.e. it has triggered the arrest of the roving 15, so that it does not hinder the run of the rovings 15. This can be done manually or can be performed automatically by a yarn-setting carriage 40.
However, when a yarn break occurs at anyone of the two spinning units 10 of the spinning units pair 50 which is supplied each with a roving 15 from the same bobbin 26, the respective yarn break sensor 24 senses this and excites an electromagnet 33 of the stopping device 25. An anchor 34 associated with electromagnet 33 holds the bridge 30 and thereby the shells 29 normally in the position shown in FIG. 1 as long as no yarn breaks exist at these two spinning units 10. In this normal position, the shells 29 have no influence on the rovings 15. This is due to the fact that the anchor 34 holds a pin 36 provided at the bridge 30 in the position shown in FIG. 1, wherein the two shells 29 are at a distance from the clamping line of the two feed roller pairs 12. If a yarn break occurs at any one of these two spinning units 10, the electromagnet 33 is excited and attacts its anchor 34 which releases the pin 36. Both shells 29 thereby become entrained by their friction with the rotating lower roller 27 in the direction of arrow A. These shells then reach the clamping line of the two feed roller pairs 12 of this spinning unit pair. The two upper rollers 31 are thereby lifted somewhat from the lower roller 27 which drives them, so that these upper rollers 31 are stopped. Shells 29 now clamp the two rovings 15 against the now arrested upper rollers 31, so that the rovings break between the upper rollers 31 and the intermediate roller pair 13, and, as a result, can no longer be drawn into the drawing frames 11. Thereby a sequel yarn break occurs in each of the other spinning unit 10 of the two spinning units 10 assigned to the same stopping device 25.
A yarn-setting carriage 40 runs along this spinning frame for the automatic detection and correction of yarn breaks. Carriage 40 has the equipment required for fixing yarn breaks, which equipment can be of the known type and does not need a closer description and therefore is not illustrated. This yarn-setting carriage 40 has two yarn break sensors 41, which sense occurrence of a yarn break at the two spinning units of any spinning units pair 50. These breaks are reached by the yarn-setting carriage 40. At the breakage point the yarn-setting carriage 40 stops under certain prerequisites which are described further, whereby it fixes first one yarn break and then continues to run so that its yarn-break correction equipment can also fix the other yarn break.
Instead of the two sensors 41, it can also be sufficient to have only one yarn break sensor at the yarn-setting carriage 40, since, as already mentioned, yarn breaks occur simultaneously at two neighboring spinning units assigned to the same stopping device.
Further, to each spinning units pair 50 a signal emitter 42 is assigned, which emits signals received by receiver 44 mounted on the carriage 40 at the arrival of the yarn-setting carriage at this spinning units pair, to indicate the presence of roving at both the spinning units 10 of this spinning units pair 50. This for instance, can be sensed with two photooptical sensors, which are arranged in front of the respective drawing frames 11 at the running path of the respective rovings.
When at both spinning units 10 the roving 15 is present, this fact is signalled by the signal emitter 42 to the receiver 44 mounted on the yarn-setting carriage 40, through non-contact signalling. As a result of this received signal, a switch 44" is closed on the yarn-setting carriage through the receiver 44 via the positioning element 44' controlled by the receiver. Each of the two yarn break sensors 41 on the yarn-setting carriage 40 can further close a switch 41", via a common positioning member 41' which is actuatable by each of the sensors, when it detects a yarn brreak at the spinning unit of the spinning unit pair 50 which has been assigned to it.
At each spinning unit 10 a signal emitter 43 is further provided. At the yarn-setting carriage 40, two receivers 45 are arranged at the same distance at which the signal emitters 43 of the individual spinning unit pair 50 are arranged with respect to each other. The signal emitter 43 sends signals to the receiver 45 of the yarn-setting carriage 40 arriving at the respective spinning units pair 50, advising whether one of the two spinning units 10 has been registered as "dead". This registration can be done, for instance, by upward folding of the yarn guide 23 via an actuation device 55 mounted on the yarn-setting carriage, whenever the yarn-setting carriage 40 has made a predetermined number of unsuccessful attempts directly following one another. The receiver 45 senses then at the arrival of the yarn-setting carriage whether the yarn guide 23 is turned upwardly or not. This can for instance be done by mounting a light-reflecting foil on the yarn guide 23, which reflects the light coming from an emitter mounted on the yarn-setting carriage to the receiver 45 only in the upward-folded position.
If none of the two receivers 45 detects the upward-folded position at the yarn guide of anyone of the two spinning units 10 of the spinning units pair 50, the receiver 45 initiates the closing of a switch 45" via a positioning member 45'. The switches 41", 44", 45" are normally open. In series therewith is a switch 59, which is shortly closed and then reopened, when the receiver 44, 45 arrives oppositely to the signal emitters 42, 43.
The yarn setter 40 stops only then for the correction of both yarn breaks at a spinning unit pair 50, when at the arrival of the yarn-setting carriage 40 at the respective spinning units pair 50, all four switches 59, 41", 44" and 45" are closed. Thereby, the switch 41" is closed by each of the two yarn break sensors 41 when it senses one yarn break, e.g. it senses photooptically the absence of the yarn between the respective drawing frame 11 and the yarn guide 23.
The switches 44" and 45", as mentioned, are always closed when at both spinning units the roving is present and neither one of the two spinning units is registered as a dead unit.
This way, there are two successful prerequisites for yarn break corrections at the respective spinning units pair 50, and the yarn-setting carriage 40 is stopped by a control device which is activated when it comes to the closing of all these switches 59, 41", 44", 45", the control device being connected in series with these switches 41", 44", 45", 59 which are also connected in series, which device then causes the yarn setter 40 to stop in predetermined positions at this spinning units pair and to correct first the one yarn break and then the other. If a yarn break can not be corrected after, for instance, three attempts, the respective spinning unit 10 or the respective spinning units pair 50 is registered as "dead" by turning upwardly the respective yarn guide 23 and the immediate continuation of the search run of the yarn-setting carriage 40 is resumed for the purpose of detection of further yarn breaks.
The assigned stopping device 25 is already activated with the occurence of the first yarn break at this spinning units pair 50 and the two rovings are arrested as an described. Each activation of the stopping device 25 has an immediate consequence the disconnection of the two yarn break sensors 24 through the stopping device 25, namely by opening a switch 49 via the positioning member 58 controlled by the stopping device 25.
This way, the yarn break correction at both spinning units 10 can not be disturbed by the yarn break sensors 24. Specifically, at the onset of the first yarn correction to be performed, the stopping device has again to be inactivated at this spinning units pair, so that it is alltogether possible to spin yarn again at these two spinning units 10. Thus, the yarn setter 40, after stopping at the respective spinning unit 10, first inactivates against the stopping device 25. Inactivation can take place, for instance, through means of a positioning member 56 mounted on the yarn-setting carriage 40 as shown in dottted lines in FIG. 1. Positioning member 56 may include a lifting magnet or a cylinder-piston unit or the like which activates a pressing rod 57 to turn a lever 32 in clockwise direction (arrow D), until a pin 36 snaps again into the position shown in FIG. 1, behind the anchor 34 of the electromagnet 33. At this point, the upper rollers 31 of this spinning units pair 50 come to lie against the lower rollers 27 and the two rovings 15 are once again continuously drawn into the drawing frame 11. There the rovings are drawn and leave the delivery roller pair 14 as drawn slivers, so that the yarn-setting carriage can correct the yarn breaks.
If the switch 49 would be connected before the yarn breaks have been fixed at this spinning units pair 50, then at least one of the two yarn break sensors 24 would immediately activate the stopping device 25. In order to avoid this, the switch 49 is closed only after both yarn breaks have been corrected, which takes place due to a positioning member 52 located at the yarn-setting carriage 40, which can move a striker 53 in the direction of the double arrow towards the switch 49 to close it and then again back towards the initial position. Immediately after that, the yarn-setting carriage 40 is restarted on its search run for yarn breaks.
The opening and closing of the switch 59 of the yarn-setting carriage 50 can for instance be performed through a sender or transmitter 61, mounted on the respective spinning units pair, which cooperates with a receiver 62 mounted on the yarn setter 40.
The registration of dead spinning units by upwardly folding the yarn guide can be replaced by other types of registration. The registration of the "dead" spinning units pair can, for instance, take place in a central data storage. In this arrangement the yarn setting carriage, at its arrival at the spinning units pair, checks the data storage in order to establish whether this spinning units pair has been registered as "dead" or not. Tbhis can be the case at each arrival at the respective spinning units pair or only at spinning units pairs with yarn breaks.
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Apparatus for spinning yarn from roving including a spinning frame with spinning units arranged thereon. The roving to be drawn is fed from a common double-roving bobbin to each of two neighboring spinning units, further referred to as spinning units pair. At least one stopping device is assigned to each of the spinning units of the spinning units pair, to stop and release again the roving feed to the two drawing frames of the respective spinning units pair. The purpose of the stopping device is to reduce the loss of roving and to avoid the danger of yarn lapping on the drawing rollers. The stopping device can be actuated by each of two yarn break sensors of the spinning units pair for the simultaneous arrest of the roving. In a second embodiment a yarn-setting carriage is provided on the spinning frame to correct a yarn break, such correction occuring only when all correction hindering conditions are absent.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for sensitively detecting and quantitatively analyzing biological and biochemical substances.
2. Description of the Prior Art
With the recent progress of immunology, the application of immunity has become important and widespread. In most immunological measurement methods, the very specific nature of an antigen-antibody reaction is utilized to selectively detect any elusive substances. Diagnoses in syphilis, typhoid fever, paratyhoid, viruses, hormones or other biochemically active molecules and their binding proteins or receptors on cells, tumor antigens-antibodies, enzymes and inhibitors and the like to which such immunological measurement methods have been applied. In such known methods, however, the antigen-antibody reaction is determined by observing with naked eye any specific changes in precipitation and agglutination of the reaction. The prior art techniques are tedious and time-consuming because an inspector must have much experience and high concentration in visually observing the antigen-antibody reaction. Another problem resides in inaccurate observation of that reaction arising from the inspector's preference.
SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to eliminate the above difficulties noted by the existing techniques.
Another object of the invention is to provide an apparatus for sensitively detecting and quantitatively analyzing biological and biochemical substances with utmost ease and greatest exactness and in an extremely short length of time.
These and objects of the invention as will hereinafter become clear have been obtained by providing an apparatus for detecting and analyzing biological and biochemical substances wherein the degree of fluorescence depolarization of an antigen or antibody molecule labeled with a fluorescent dyestuff can quantitatively be calculated by electrical determination of any change in the Brownian movement of the labeled molecule.
For reducing into practice the apparatus of the invention, the labeled molecule is excited by plane polarized light, and the fluorescence intensities of the labeled molecule are obtained at electric vectors parallel with the plane of incidence and perpendicularly with the plane of incidence on a photomultiplier. The degree of depolarization is then computed by way of a calculator which is coordinated with the photomultiplier. The apparatus according to the invention is so configured that the labeled molecule can be sensitively detected and quantitatively analyzed, with its progressive changes observed, by calculating the degrees of polarization prior to and after the reaction of the labeled molecule.
Having generally described the invention, a furthter understanding can be made by reference to the detailed description and the accompanying sheets of drawings incorporating the principles of this invention which is provided only for purposes of illustration and not intended to be construed as limiting unless otherwise described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram explanatory of the principles of an apparatus according to the invention, and
FIG. 2 is a view showing the spectrum characteristics of the filters used for the optical systems of the apparatus.
DETAILED DESCRIPTION OF THE INVENTION
One preferred embodiment of an apparatus 10 according to the invention will now be described as applied to an immunological measurement method employing the specificity of an antigen-antibody reaction.
In FIG. 1 there is shown a cell 11 for accommodating therein a sample molecule such as an antigen which is labeled with a fluorescent dyestuff. Designated at 12 is an exciting optical system which is oriented in a lateral or X-axis direction relative to the cell 11 and which excites the labeled molecule within the cell 11. A polarizing optical system 13 is arranged in a vertical or Y-axis direction relative to the cell 11 and substantially at a right angle to the X-axis, and gathers parallel and perpendicularly polarized light coming from the excited molecule.
The exciting optical system 12 comprises a lens 12a which transforms fluorescent light transmitted elliptically from a light source 14 to plane fluorescent light, and a filter 12b which allows for transmission of only monochromatic light with a desired wavelength out of the plane fluorescent light passing through the lens 12a. Placed within the exciting optical system 12 are a lens 12c for collecting the monochromatic light from the lens 12b. The perpendicularly polarized light generating from a polarizer 12d of the exciting optical system 12 is caused to irradiate the labeled molecule contained in the cell 11, thereby exciting the molecule.
The light source 14 lies in opposite relation to the cell 11 in the X-axis direction and includes, as for example, a tungsten lamp.
The polarizer 12d includes, as for example, Glan-Thomonsche prisms, Rochon's prisms and Nicol's prisms formed of monoaxial crystallines such as crystal and calcite, reflections by the surface of separation of dielectrics and the like.
The monochromatic light transmitted from the filter 12b exhibits a spectrum at a wavelength of 490mm as shown at I in FIG. 2.
The polarizing optical system 13 comprises a filter 13c which transmits only light emitted by the sample molecule in the cell 11, a lens 13b serving to collect the fluorescent light from the cut-off filter 13c, and an analyzer 13a for gathering the fluorescent light from the sample molecule. Arranged further is an electric motor 15 with a speed of about 4 rpm/sec for connection to the analyzer 13a.
In this arrangement the analyzer 13a, when rotated by the motor 15, takes up parallel and perpendicularly polarized light from the tested molecule for measurement of its fluorescence intensities and subsequent conversion by a photomultiplier 16 into an electrical signal. The signal is then caused to enter a calculator 17 so that the molecule can be detected and analyzed to determine whether or not the molecule has provided any reaction.
For sensitive detection of an antigen-antibody reaction according to the apparatus 10 of the invention, a test antigen or antibody is first labeled with a fluorescent dyestuff which can be selected, for example, from fluorescent isothiocyanate, tetramethylrhodamine isothiocyanate and the like. The antigen or antibody labeled with the fluorescent dyestuff is fed to the cell 11 and is then subjected to irradiation and excitation by plane polarized light which is obtained by passing the monochromatic light from the light source 14 through the exciting optical system 12. The thus excited molecule in the antigen or antibody emits fluorescent light, with occurrence of the random Brownian movement. Parallel and perpendicularly polarized light is taken out of the fluorescent light of the molecule with the use of the analyzer 13a driven by the motor 15, and is transmitted to the photomultiplier 16 where the fluorescence intensities of both the parallel polarized light and the perpendicularly polarized light are calculated. Under the assumption that the fluorescence intensity of the perpendicularly polarized light and that of the parallel polarized light are I 1 and I 2 , respectively, the degree of polarization P is expressed by equation (1). ##EQU1##
As is well known in the art as the degree of depolarization by the Brownian movement, the degree of polarization P in which the labeled molecule is under the Brownian movement is lower than the degree of polarization Po in which the labeled molecule is in stationary condition. The degree of depolarization may be written as a function of both the fluorescence life τ of the labeled molecule and the rotational relaxation time π of the labeled molecule. Thus, the relationship between Po/P and τ/π is defined by equation (2). ##EQU2##
The coefficient A in equation (2) is variable, depending on any optical systems employed to calculate any degrees of polarization. For instance, A = 3 - Po in the optical system where an labeled antigen or antibody molecule is excited by plane polarized light. In the case where a labeled antigen or antibody molecule is of a spherical particle in solution, the rotational relaxation time πo of the labeled molecule by the Brownian movement becomes equation (3). ##EQU3## where Vo is the volume of the spherical particle, η is the solvent viscosity, T is the absolute temperature, and k is Boltzmann's constant.
Substitution of equation (3) for equation (2) gives equation (4) which is generally called as the Perrin-Levshin formula. ##EQU4##
With an increase in solvent viscosity and molecule volume, and with a decrease in solvent temperature, the degree of polarization derived from the molecule in solution becomes high. The limiting value of Po is found to be substantially equal to the degree of polarization as calculated when the Brownian movement is completely depressed.
From the foregoing consideration, it is understood that when any other molecule such as a specific antigen or antibody is brought into contact with the labeled antigen or antibody molecule, the labeled molecule increases in its molecular weight, thereby resulting in prolonged rotational relaxation time and increased degree of polarization. In contrast to the case where the labeled antigen or antibody is taken individually, the fluorescence intensities of parallel and perpendicularly polarized light of the antigen-antibody complex as measured in the same manner described hereinabove are varied since the labeled molecule increases in it molecular weight, and hence, the Brownian movement is depressed. More particularly, in view of the fact that any increase in the degree of polarization P in equation 1 means that an antigen-antibody reaction has occurred, sensitive detection can be easily made to determine if there exists an antigen or antibody molecule in the tested specimen contained in the cell 11 of the apparatus 10.
If the tested molecules produces, by intrusion of any foreign matter, scattered light which would otherwise cause operational inconveniences, the filter 13c of the polarizing optical system 13 may be replaced by any suitable filter possessing spectrum characteristics at a wavelength of 530mm. This condition is best illustrated at II, III or IV in FIG. 2.
For quantitative analysis of an antigen-antibody reaction by means of the apparatus 10 according to the invention, a labeled antigen having a specific degree of polarization Po is placed at a concentration Co together with a certain amount of an unlabeled antibody so that the antigen-antibody complex is formed as having a degree of polarization of P 1 and a concentration C 2 . The degree of polarization Pm of the resultant mixed solution of the labeled antigen-antibody complex is expressed by equation (5) ##EQU5##
Using equation (5), the concentration of the antibody as C 1 is determined from the measured value of Pm with the already known values of Co, Po and P 1 . The degree of polarization Pm is measured by the analyzer 16, and may preferably be read on a digital display and printed on a recording chart.
Advantageously, an extremely short length of time of 60 seconds is sufficiently possible for each measurement of an antigen-antibody reaction. Another advantage is that a sample to be charged into the cell is in a very limited amount ranging from 1 μl to 10 μl.
It is of interest to note that those characteristic features make the apparatus of the invention significantly effective and widely applicable. Some representative examples of usage are as follows:
(1) Antigen-Antibody reactions
(2) Hormone-binding protein interactions
(3) Enzymes, coenzymes and inhibitors-substrates
(4) Measurement of viscosity of solutions with free fluorescein
(5) Molecular weight determination of globular proteins after fluorescein conjugation
(6) Receptors for hormones
(7) Receptors for immunoglobulin on cell surface
(8) Cellular fluidity
(9) Cell membrane fluidity
(10) Assay of complement systems
(11) Liver enzymes in blood plasma
(12) Serum proteins
Having fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein.
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Apparatus is disclosed for sensitively detecting and quantitatively analyzing biological and biochemical substances. Charged into a cell is a test molecule labeled with a fluorescent dyestuff. An exciting optical system transmits plane polarized light from a light source into the labeled molecule to excite the molecule, and a polarizing optical system takes up fluorescent light emitted from the molecule. A photomultiplier is arranged to measure the fluorescence intensities of parallel and perpendicularly polarized light from the molecule. A calculator coordinated with the polarizing optical system computes and converts the fluorescence intensities into the degree of polarization of the molecule.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of German patent application 10 2005 005 382.3, filed Feb. 5, 2005, herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a top roller carrier for drafting systems in spinning machines and, more particularly, to a top roller carrier with at least one pair of feed rollers, one pair of apron rollers and one pair of output rollers as top rollers and with holding devices for the top rollers, wherein the top rollers are rotatably mounted on the ends of axles which are held centrally between the top rollers.
BACKGROUND OF THE INVENTION
[0003] Top roller carriers are generally used as a carrying and loading arm for pairs of top rollers and can be lifted relative to the bottom rollers mounted so as to be secured to the machine.
[0004] In drafting systems, it is known to carry out an adaptation, which is necessary for reasons concerning textile technology, to the fibre material or the staple length of the fibre material and, for this purpose, to change the spacing between the clamping lines formed by the pairs of rollers of the drafting system. This spacing is also called the field width. It is known, for this purpose, to configure the top roller carrier for the field width adjustment in such a way that the spacings between the top rollers can be adjusted. German Patent Publication DE 43 35 889 C2, for example, shows a top roller carrier for drafting systems of spinning machines, in which the top rollers are mounted in holders by slides. The slides can be adjusted separately from one another for the field width adjustment, in each case, in the longitudinal direction of the top roller carrier. A holder for top aprons is associated with the apron roller. Configured in the top roller carrier is an elastic hollow body, which is loaded with pressure, pneumatically or alternatively hydraulically. The pressure acts via a base plate of the hollow body on plungers and loads the feed and the output roller and also the apron roller and the holder for the top apron with a force, which presses against the bottom rollers and allows the top rollers to act as pressure rollers.
[0005] The German Utility Model G 92 14 598 U1 describes a top apron holder for spinning machine drafting systems with an apron guide, which deflects the top apron and tensions it under the pressure of a spring. The apron guide is held on a central piece of the top apron holder.
[0006] A load carrier for drafting systems of spinning machines is known from the generic German Patent Publication DE 39 37 667 A1, in which the axles of the top rollers are each fastened in holders, which can be displaced independently of one another in longitudinal guides of the top roller carrier for the field width adjustment. The drafting system is a three roller drafting system, in which the top rollers are configured as pressure roller twins. The pressure on the top rollers is applied by the holders acting like a spring element because of their shape. The holders are not set up to vary the pressure force.
[0007] The holders of the known top roller carriers, as they are described in the above-mentioned documents, have the common drawback that they require a large number of individual parts and require time-consuming field width adjustments that are prone to faults for the apron and output roller.
[0008] Swiss Patent Publication CH 656 647 A5 shows an apron drafting system, which is used in a spinning machine and has three pairs of rollers consting, in each case, of top and bottom rollers. The top rollers are held in the top roller carrier, which is arranged so as to be pivotable about a pivot pin with respect to the machine stand.
[0009] The box-shaped top roller carrier contains a guide arrangement for the top roller pins. Holding down devices, which are spring-loaded in their longitudinal central region and with which approximately the same gap contact pressure is to be achieved for all the pairs of rollers, engage thereon. The top roller carrying pins are guided for this purpose in guide slots of the top roller carrier. The play always occurring in this case between the top rollers and guide edges counteracts an exact adjustment of the clamping point and leads to wear problems. The spacing of the top rollers from one another in the longitudinal direction of the top roller carrier cannot be changed for this reason. An adjustment of the field widths, such as is necessary during adaptation to the fibre material to be respectively processed, is not possible.
[0010] Both British Patent Publication GB 691615 and U.S. Pat. No. 3,256,570 show three-roller drafting systems for spinning machines, in which the top roller carrier has slots which are spaced apart from one another in the longitudinal direction of the top roller carrier for guiding the top roller carrying pins or the axles of top rollers.
[0011] It can be inferred from British Patent Publication GB 691615 that, to change the spacing of the top rollers guided by the top roller carrier, the top roller carrier present has to be replaced by a top roller carrier, in which the arrangement or the spacing of the slots differs according to the changed requirements. For a fibre material change mentioned as an example, of cotton to viscose, it is described as sufficient to hold two or three alternatively usable or replaceable top roller carriers in readiness. A replacement of this type of the top roller carrier including disassembly and installation of the top rollers is very laborious.
[0012] In the drafting system of U.S. Pat. No. 3,256,570, all three top rollers are carried respectively at their axle ends by a frame-like top roller carrier. The guides of the top roller carrying pins are also affected by play as in the apron drafting system of Swiss Patent Publication CH 656 647 A5 and particularly prone to wear because of the top roller carrier pins co-rotating with the top roller. U.S. Pat. No. 3,256,570 describes how the pivoting up of the top roller carrier can be facilitated in magnetically held top rollers and gives absolutely no indication as to how the spacings apart of the top rollers could be changed. This is also only possible by means of a very laborious replacement of the top roller carrier in the drafting system of U.S. Pat. No. 3,256,570.
SUMMARY OF THE INVENTION
[0013] The object of the invention is to improve the known top roller carriers.
[0014] The object is achieved according to the invention by means of a top roller carrier for drafting systems in spinning machines with at least one pair of feed rollers, one pair of apron rollers and one pair of output rollers as top rollers and with holding devices for the top rollers, and wherein the top rollers are rotatably mounted on the ends of axles which are held centrally between the top rollers. According to the present invention, a common holding device is provided for the axle of the output rollers and the axle of the apron rollers and is movably connected to the top roller carrier and fixes the two axles at a rigid spacing with respect to one another.
[0015] Advantageous configurations of the top roller carrier are described more fully herein.
[0016] The holding device according to the invention movably connected to the top roller carrier combines the axle receivers for the output roller and the apron roller in one component. The position of the axle receivers in the holding device and therefore the position of the axles of the output roller and the apron roller with respect to one another can be produced with a high degree of manufacturing precision. In this manner, an extraordinarily exact positioning of the clamping points of the apron roller and output roller can be achieved and maintained. The parallelism of the output roller and apron roller is always ensured. The addition of conventional safety spacings can be dispensed with. Such conventional safety spacings are taken into account, for example, in the adjustment of the desired field width, because the achievable accuracy in the field width adjustment can only be inadequate. Manufacturing and assembly inaccuracies, which can add up with multi-part holders, allow an oblique position of the top rollers, which disadvantageously influences the adjustment of the field widths. Additions in the form of safety spacings are to counteract this. The holding device according to the invention reduces the number of components for the holding device compared to conventional holding devices. In order to be able to load the holding device with a force in the direction of the bottom rollers, only a single common mechanism, for example a spring mechanism, is necessary. The force loading of the output roller and apron roller can take place separately from other top rollers like the feed roller. The outlay occurring during a change in the significant field width adjustment between the apron roller and feed roller is small. The outlay required during production and assembly is lowered as less and only simpler parts are required.
[0017] The holding device advantageously comprises a top apron deflection device, the top apron deflection device being configured as a vane, which ends at the free end with a deflection edge. The number of components on the top roller carrier is thereby further reduced. The orientation of the top apron deflection device with respect to the apron roller is very precise and cannot disadvantageously change due to the effect of assembly tolerances or the summation of manufacturing tolerances of a plurality of components. The deflection edge cannot be deflected from the parallel orientation by poor adjustment or fibre materials which are difficult to draw. A deflection of this type would disadvantageously lead to number fluctuations or even to aprons running off axially. The degree of opening remains the same.
[0018] If the deflection edge is configured as a chromium-plated metal bar and if the metal bar is fastened to the vane, only a little friction occurs during the deflection process, and the deflection edge is only subjected to low wear. The apron slippage is minimised by the low-friction deflection edge.
[0019] Maintenance intervals can be increased. The apron roller only has to be disassembled rarely or not at all.
[0020] An apron tensioner is preferably associated with the holding device and is oriented axially parallel to the top rollers and movable relative to the holding device. This embodiment allows a simple flexible tensioning of the top aprons. An excellent apron synchronisation is ensured.
[0021] The required contact force can easily be applied with a holding device, which has a head part, and in which, by a force acting from above, a loading force can be exerted on the apron rollers and output rollers configured as a top roller, by means of the head part. If the head part is configured as a separate component which can be longitudinally displaced relative to the holding device, the division of the pressure force over the apron roller and the output roller can be changed.
[0022] Both a head part, which is configured as a pressure plate, over which an elastic hollow body is arranged, and wherein the force sufficient for generating the loading pressure can be generated, pneumatically or hydraulically, with the aid of the hollow body, and also a head part, over which a spring is arranged in the top roller carrier, by means of which spring the head part can be loaded with the force, allow a regulated loading of the output roller and the apron roller with a pressure force. With uniform pressure distribution owing to the non-interrupted pressure plate, the wear can be reduced, the service life increased and the maintenance intervals can be lengthened. To apply the loading pressure to the output roller and apron roller, only a single device is necessary for the two rollers. A common adjustable force loading of output roller and apron roller separately from other top rollers like the feed roller, is possible.
[0023] A holding device consisting of plastics material can be produced particularly economically, has only a low weight, is resistant to corrosion and satisfies the elasticity demands on the holding device. Polyoxymethylene, designated POM, is distinguished by a high degree of hardness, stiffness and toughness and is particularly suitable for this application. If the plastics material is electrically conductive, an uncomplicated discharge of electrostatic charges is ensured. Thus disturbances in the spinning operation caused by electrostatic charge are avoided.
[0024] Time-consuming field width adjustment work prone to errors for the apron and output roller is dispensed with. Only a simple adjustment for the feed roller is required.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Further details of the invention are described below with the aid of the figures, in which:
[0026] FIG. 1 shows a simplified partial view of a top roller carrier with a holding device in a side view, partially in section,
[0027] FIG. 2 shows the holding device of FIG. 1 in the view A-A, partially in section,
[0028] FIG. 3 shows a plan view of the top apron deflection device of the holding device of FIG. 1 in the view I-I, partially in section,
[0029] FIG. 4 shows the deflection edge of the top roller deflection device with metal bar, in a side view,
[0030] FIG. 4A shows a deflection edge of the top roller deflection device with the metal bar in an alternative position, in a side view,
[0031] FIG. 5 shows a simplified partial view of a top roller carrier with a spring-loaded holding device in a side view, partially in section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] FIG. 1 , shows a part of a top roller carrier 1 , which carries a holding device 2 . Top roller carriers of this type are used on drafting systems of spinning machines. The holding device 2 has axle receivers 3 , 4 for the axles 5 , 6 of the pair of apron rollers and the pair of output rollers. The position of the pair of apron rollers and the pair of output rollers is indicated in each case by an apron roller 7 and an output roller 8 . The two axle receivers 3 , 4 are part of the one-piece holding device 2 . The holding device 2 consists of the elastic plastics material POM. Because of the elasticity, the axles 5 , 6 can be pressed in a simple manner into the axle receivers 3 , 4 during assembly. The axles 5 , 6 are reliably held in the snap-on connection. The pair of apron rollers and the pair of output rollers together with the pair of feed rollers, not shown in FIG. 1 , form the top rollers of the drafting system. The associated bottom rollers 9 , 10 are positioned in such a way that their rotational axes 11 , 12 are offset with respect to the rotational axes 13 , 14 of the output roller 8 and the apron roller 7 . The rotational axis 11 of the bottom roller 9 , in the view of FIG. 1 , is not vertically beneath the rotational axis 13 of the output roller 8 , but offset slightly to the right. The rotational axis 12 of the bottom roller 10 , on the other hand, is offset slightly to the left with respect to the rotational axis 14 of the apron roller 7 . If the apron roller 7 and the output roller 8 are loaded with pressure and pressed against the bottom rollers 9 , 10 , horizontal force components occur. The horizontal force component, which acts on the output roller 8 is directed to the left in the view of FIG. 1 and is called a forward biasing force. The horizontal force component, which acts on the apron roller 7 is directed to the right in the view of FIG. 1 and is called a rearward biasing force. The forward biasing force and rearward biasing force are substantially the same in the embodiment shown in FIG. 1 , so only a small or hardly any horizontal force component acts on the holding device 2 . There is therefore an almost friction-free coupling of the holding device 2 movably connected to the top roller carrier 1 to the top roller carrier 1 . A stable position of the apron roller 7 and the output roller 8 with respect to the bottom rollers 9 , 10 is established.
[0033] The pressure loading of the apron roller 7 and the output roller 8 takes place pneumatically. A head part which is configured as a pressure plate 15 and on which the base plate 16 of an elastic hollow body 17 rests is arranged on the holding device 2 . By loading the hollow body 17 with compressed air, the holding device 2 is pressed downwardly, the pressure is transferred to the apron roller 7 and the output roller 8 and the apron roller 7 and the output roller 8 are pressed on the bottom rollers 9 , 10 . The pressure plate 15 is displaceable in the longitudinal direction of the top roller carrier 1 relative to the holding device 2 . If the pressure plate 15 in the view of FIG. 1 is displaced to the left, the pressure on the output roller 8 is increased, and the pressure on the apron roller 7 becomes less. If the pressure plate 15 is displaced to the right, the pressure on the output roller 8 reduces and the pressure on the apron roller 7 becomes greater. In this manner, the pressure distribution on the apron roller 7 and the output roller 8 can be designed so as to be variable.
[0034] The holding device 2 has an elongated hole 18 , the edges 19 , 20 of which in each case run on the radius R TR , which is placed round the pivot point of the top roller carrier 1 . A hollow bolt 21 is guided in the elongated hole 18 and is rigidly connected to the top roller carrier 1 by means of screws 22 . Owing to the interaction of the elongated hole 18 and the hollow bolt 21 , the holding device 2 can be positioned independently of the level which the top roller carrier 1 adopts. The metallic hollow bolt 21 reinforces the U-shaped, downwardly open body of the top roller carrier 1 .
[0035] The holding device 2 has an top apron deflection device configured as a vane 23 , via which the top apron 24 is guided, toward the axle receivers 3 , 4 . The free end of the vane 23 has a spacing R from the rotational axis 14 of the apron roller 7 . The spacing R is, for example, 35 mm, in an embodiment for the processing of short-staple fibre material. The free end forms the deflection edge 25 for the two top aprons 24 , 26 of the pair of apron rollers. The width of the vane 23 is matched to the greatest required spindle division. In the direction of action of the force, by means of which the top aprons 24 , 26 are tensioned, the vane 23 is configured so as to be very stiff. In the vertical direction, the deflection edge 25 at the free edge of the vane 23 can be moved without a large exertion of force. Therefore, the degree of opening X can be easily adjusted for the opening widths required in each case. The form of the vane 23 can be seen in FIGS. 2 and 3 . The position of the top apron 26 is shown in FIG. 2 by dashed lines. The vane 23 has a lug 27 on which a piston 28 applies a contact force. The contact force is transferred to the piston 28 from the base plate 16 . The piston 18 is movably guided in a bore 29 of the holding device 2 .
[0036] FIG. 4 shows an alternative embodiment to the vane 23 shown in FIGS. 1 to 3 . The vane 30 has a receiver 31 for a chromium-plated replaceable metal bar 32 . The receiver 31 is configured in such a way that the metal bar 32 can be positioned alternatively in two different positions. FIG. 4 shows a first position of the metal bar 32 in which the spacing R 1 from the rotational axis 14 of the apron roller 7 is produced. FIG. 4A shows a second position of the metal bar 32 , in which the spacing R 2 is produced. The spacing R 2 is smaller than the spacing R 1 . Because it is possible to replace the metal bar 32 , the position of the deflection edge 25 can be adapted by a suitable selection of the metal bar 32 and/or by the selection of the position of the metal bar 32 to the respective production conditions in such a way that an optimum spinning geometry is ensured. The position of the deflection edge 25 can be selected such that an adequate spacing is ensured between the output roller 8 and top apron 24 . A quality-impairing brushing of the top apron 24 on the output roller 8 is reliably avoided. The chromium-plated metal bar 32 is particularly resistant to wear and brings about low-friction deflection of the top aprons 24 , 26 . The apron slippage and the wear of the top aprons 24 , 26 is reduced.
[0037] The holding device 2 has a vertically oriented and downwardly open slot 33 between the vane 23 and the axle receiver 3 . The slot 33 is used as a guide link for the carrier axle 34 of an apron tensioner 35 . A guide element 36 , 37 is fastened, in each case, as shown in FIG. 2 , on either side on the carrier axle 34 . The guide elements 36 , 37 hold the top aprons 24 , 26 in the desired position and prevent their axial displacement. The gap 38 between the vane 23 and the lower side of the holding device 2 is slightly smaller than the diameter of the carrier axle 34 . When installing the carrier axle 34 , the vane 23 is deflected because of its elasticity and the carrier axle 34 can easily be pressed into the slot 33 . The carrier axle 34 is prevented in this manner from falling out of the holding device 2 .
[0038] A spring element 39 presses from below against the carrier axle 34 . The top aprons 24 , 26 are tensioned by means of the carrier axle 34 with a selectable force. The position of the tensioned top apron 26 is shown by dashed lines in the view of FIG. 2 . The top apron 24 adopts a corresponding mirror-inverted position on the left-hand side of the holding device 2 , but is not shown in FIG. 2 . The top rollers and the bottom rollers together with axles are also not shown in FIG. 2 .
[0039] The holding device 2 , on each side, has a knob 66 , with which the holding device 2 is secured in the top roller carrier 1 .
[0040] FIG. 5 shows a top roller carrier 40 with a holding device 41 , which is loaded by means of a spring force in order to generate the force, required for the spinning process, of the apron roller 42 and the output roller 43 on the bottom rollers 44 , 45 . The bearings of the bottom rollers 44 , 45 , 46 and the top rollers configured as feed rollers 47 are not shown in FIG. 5 for reasons of simplification. The axle receiver 48 configured as a snap-on connection holds the axle 50 of the apron roller 42 . The axle receiver 49 holds the axle 51 of the output roller 43 . The forward biasing force of the output roller 43 and the rearward biasing force of the apron roller 42 substantially balance each other out in the embodiment of FIG. 5 , so only a slight or even no horizontal force component acts on the holding device 41 , as is also the case in the holding device 2 shown in FIG. 1 . A head part configured as a pressure plate 52 is arranged on the holding device 41 . The pressure plate 52 consists of steel. The pressure plate 52 is suitable both for holding devices for processing short-staple fibre material and for holding devices, which are to be used for processing medium-staple or long-staple fibre material.
[0041] The holding devices can be replaced simply and rapidly. The pressure plate 52 and the holding device 41 fastened to it are pivotally connected to a pressure plate 54 by means of a snap-on connection and a bolt 53 . The pressure plate 54 can be pivoted about a pivot axle 55 rigidly connected to the top roller carrier 40 . The compression spring 56 is supported, on the one hand, on a transverse pin 57 of the pressure plate 54 and, on the other hand, on a support disc 58 . The support disc 58 rests on an eccentric element 59 . The eccentric element 59 is rotatably mounted on a pivot axle 60 . The pivot axle 60 is rigidly connected to the top roller carrier 40 . By rotating the eccentric element 59 , the force can be adjusted, with which the compression spring 56 loads the pressure plate 54 and therefore, via the holding device 41 , the apron roller 42 and the output roller 43 . The pressure plate 54 is configured such that the holding device 40 is loaded with a substantially constant force, even if the height position of the top roller carrier 40 is adjusted within a specific range. This range may be about 6 mm. A compression spring 61 loads the vane 65 with a specific force directed downwardly. The vane 65 is used to deflect the top apron 62 of the apron roller 42 and the other top apron and the associated other apron roller, neither of which are shown in FIG. 5 , and which in each case form a pair with the top apron 62 and the apron roller 42 . An apron tensioner 63 , as shown in FIG. 1, 2 or 4 , is used to tension the top apron 62 and the top apron arranged in a mirror-inverted manner with respect thereto. The apron tensioner 63 can be moved up and down in the slot 64 and is pressed upwardly by a spring element, not shown.
[0042] The operating position of the top roller carrier 40 shown in FIG. 5 is secured by means of the lever 67 .
[0043] The holding devices, configured in each case for the processing of short-staple, medium-staple or long-staple fibre material, can be replaced easily and simply.
[0044] The apron guides can be configured to rotate in a smooth-running manner, so the apron slippage can be further reduced.
[0045] In the scope of the invention, further embodiments of top roller carriers are possible. For example, instead of the vanes 23 , 30 , 65 shown in the figures, which form a one-piece part with the holding device 2 , 41 , a vane can be used, which is configured as a separate part and fastened to the holding device 2 , 41 .
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A top roller carrier for drafting systems in spinning machines with at least one pair of feed rollers, one pair of apron rollers and one pair of output rollers as top rollers and with holding devices for the top rollers, and wherein the top rollers are rotatably mounted on the ends of axles which are held centrally between the top rollers. According to the present invention, a common holding device is provided for the axle of the output rollers and the axle of the apron rollers and is movably connected to the top roller carrier and fixes the two axles at a rigid spacing with respect to one another.
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BACKGROUND OF THE INVENTION
This invention generally relates to the administration of parenteral fluids to a patient by means of an intravenous (IV) set and particularly to an improved means for mounting a drop sensing unit to a drip chamber dedicated to the particular IV delivery instrument.
An IV set for the administration of parenteral fluids generally comprises a drip chamber, a length of clear plastic tubing attached to the discharge end of the drip chamber, one or more clamps to adjust the fluid flow through the clear plastic tubing and a means at the distal end of the tubing for mounting a hypodermic needle which will be inserted into the patient's vein or artery. The drip chamber is generally cylindrically shaped and is provided with a pointed hollow element (i.e., piercing element) at the top thereof which is adapted to pierce the rubber or elastomeric seal on an inverted bottle of parenteral fluid in order to drain the fluid therefrom into the drip chamber. The cylindrical wall of the drip chamber is formed from clear plastic material in order to detect fluid dripping into the chamber.
Fluid flow to the patient is usually determined by detecting the number of drops of fluid which fall into the drip chamber over a period of time and then multiplying the number of drops by a standard number used for the volume of each drop. When this method of flow rate detection is done manually, it is time consuming and frequently inaccurate.
Effective instrumentation for monitoring the drop rate into a drip chamber has been developed which comprises a light source which is positioned on one side of the clear plastic wall of the drip chamber and a photoelectric cell or other light sensor on the opposite side of the chamber wall with a light path therebetween so that the drops of parenteral fluid falling into the drip chamber intersect the light path and are thereby sensed.
With the need for greater accuracy in the delivery of parenteral fluids, particularly when drugs have been added to the fluid, the drop forming elements of the drip chamber are now carefully designed and manufactured so that the size and dropping characteristics of the fluid drops are relatively constant over a period of time and do not vary greatly from drip chamber to drip chamber. To insure that drip chambers of known drop characteristics are used with a particular IV delivery instrument, the means for coupling the drop rate monitor to the drip chamber have been designed so that only matched sets can be used together. Such mounting or coupling means are described in the following list of patents which is illustrative but not exhaustive.
U.S. Pat. No. 4,397,648 (Knute)
U.S. Pat. No. 4,346,606 (Channon et al.)
U.S. Pat. No. 4,321,461 (Walter et al.)
U.S. Pat. No. 4,038,982 (Burke et al.)
U.S. Pat. No. 3,500,366 (Chesney et al.)
However, by making the mounting element unique so that only matched components can be used together, the mounting has become more complicated and more difficult to operate, particularly in low light or in emergency situations when visual accuity may not be great.
Knute, in U.S. Pat. No. 4,397.648 (assigned to the present assignee) discloses an improved mounting system which insured proper positioning of the drop sensor on the drip chamber and which had self-aligning characteristics. However, even though the mounting system developed by Knute was a substantial advance, the mounting system was not convenient in many situations and correct positioning of the drop sensor was not always effected the first time mounting was attempted. Moreover, once the sensor was mounted the sensor was subject to misalignment or displacement by accidental contact with the sensor, the drip chamber or other parts of the IV set during use.
Thus there remains a need for a drop sensing unit which can easily and accurately be positioned onto a dedicated drip chamber, which has more dependable self-aligning characteristics and which is less apt to become misaligned during use due to accidental contact with the sensor, the drip chamber or other components of the IV set. The present invention satisfies this need.
SUMMARY OF THE INVENTION
This invention generally relates to an improved system for monitoring the flow of parenteral fluid through a fluid administration set to a patient and is specifically directed to an improved system for mounting a drop sensor to a drip chamber.
The drip chamber in accordance with the invention is provided with a clear plastic, cylindrically shaped body and a pair of opposed lateral projections which facilitate mounting the drop sensor thereon.
The drop sensor, which is adapted to encircle a substantial portion of the drip chamber body, has a pair of mounting members, one of which is fixed and one of which is laterally movable. Each of the mounting members has one or more inclined guiding surfaces which cradle the opposing lateral extensions during the initial stages of mounting. The movable mounting member is urged inwardly so that the inclined surfaces cradling the lateral extension slide over the edges thereof to effect relative movement therebetween. The included surfaces guide the mounting members relative to the lateral extension so that the positioning elements on the mounting members will firmly engage the lateral extensions. Additionally, the drop sensor housing contacts the cylindrical wall of the drip chamber at one or more points vertically disposed from the contact between the lateral extensions and the mounting members. These three areas of contact provide positive positioning of the drop sensor onto the drip chamber.
The drop sensor is provided with a housing having two separate sections, one section having a light source and one section having a light sensor, with a sensor gap disposed between the two sections which allows the sections to be disposed on opposing sides of the cylindrical body of the drip chamber. The two mounting members are positioned on top of the sensor housing sections.
The laterally movable mounting member is formed in a unitary structure with a sleeve which is adapted to slidably mounted to the sensor housing and which is provided with one or more finger engaging elements to facilitate the lateral sliding movement of the sleeve over the housing and thus the lateral movement of the moveable mounting member thereon. The sleeve is preferably spring loaded to close toward the fixed mounting member. When the sleeve is moved laterally away from the fixed mounting member for mounting, the maximum distance across the sensor gap between the inclined guiding surfaces of the two mounting means must be greater than the distance between the ends of the two cantilevered extensions on the drip chamber to ensure that both ends of the wing-like or flange-like extensions on the drip chamber are cradled by the inclined surfaces on the mounting means when the drip chamber is positioned within the sensor gap. Upon release of the spring loaded sleeve member, the inclined camming surfaces on the mounting members slide over the edges of the lateral extensions effecting relative vertical and horizontal movement between the drip chamber and drop sensor. The positioning elements on top of the mounting member are brought into engagement with the lateral extension and the sensor housing is brought into contact with the clear plastic, cylindrical wall of the drip chamber at one or more places thereby. In this manner, the sensor housing mounted on the drip chamber is aligned so that the drops of fluid dripping into the chamber intersect the optical pathway between the light source and light sensor.
In a preferred embodiment, the movable mounting member is provided with an overhang at the upper end of the inclined surfaces which is adapted to engage the upper surface of the lateral extension on the drip chamber and to thereby stop the relative vertical movement of the laterally moving mounting member with respect to the drip chamber extension.
In another preferred embodiment, the movable mounting member is provided with two or more outer inclined camming surfaces and a centrally located projecting guide element or rib which is adapted to ride in the groove or notch provided in the end of the extension in contact therewith. The notch and the rib are shaped to match. The outer camming surfaces are adapted to properly cradle the end of the lateral extension of the drip chamber in contact therewith so that the projecting guide therebetween slides in the notches provided in the ends and guides the overhang to engage the top surface of the lateral extension and to stop relative vertical movement therebetween. These features are particularly important in the use of IV sets designed for use with a specific drop sensor which has been calibrated for the drop size and/or shape formed by the drop former in the dedicated drip chamber. The mating elements on the mounting means, i.e., the rib, nothces and camming surfaces, ensure that only matched components are used together.
In another preferred embodiment, the fixed mounting member is provided with a conically shaped camming surface which is inclined away from the longitudinal axis of the drip chamber in the upward direction and which leads to a plateau atop the mounting member. The plateau is provided with vertically oriented stopping surfaces to prevent relative movement in a horizontal plane between the extension and the mounting member. When mounting the drop sensor, the clamping force applied by the spring loaded mounting member causes relative sliding movement between the inclined conical surface and the edges of the lateral extension of the drip chamber until the upper plateau moves under the lateral extension.
To couple the sensor to the drip chamber in accordance with the invention, the spring loaded sleeve with the movable mounting member is pulled laterally away from the fixed mounting member, the sensor housing is positioned around the drip chamber with the cylindrical body of the drip chamber disposed within the sensing gap and with both ends of the lateral extensions of the drip chamber being cradled by the inclined camming surfaces on both the fixed and movable mounting members. The spring loaded sleeve is released thereby causing the inclined guiding surfaces to slide under the edges of the extensions until the positioning elements on both mounting members engage the ends of the extensions to fix the relative positions thereon. Simultaneously, a housing section, preferably the section having the light sensor vertically spaced from the mounting members, is urged into contact with the clear plastic wall of the drip chamber body. The drop sensor is thus positioned so that the drops of fluid dripping into the drip chamber properly intersect the light path and are thereby detected.
As is evident, the mounting system in accordance with the present invention is very simple and, because vertical, horizontal and rotational movement between the drop sensor and the drip chamber is restricted, there is considerably less chance of misalignment of the sensor on the drip chamber due to accidental contact. Moreover, because of the mating elements provided with the mounting means only matched sets of drip chambers and drop sensors will be coupled together.
These and other advantages will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of an IV set provided with a drip chamber and a drop sensor which embody features of the invention;
FIG. 2 is a perspective view on a larger scale of the drop sensor shown in FIG. 1;
FIG. 3 is another perspective view of the drop sensor shown in FIG. 1;
FIG. 4 is an elevational view in section of the sensor unit mounted on the drip chamber as shown in FIG. 1;
FIG. 5 is a top view, partially in section, illustrating the drop sensor mounted on the drip chamber as shown in FIG. 4;
FIG. 6 is an elevational view, partially in section, illustrating the initial stages of mounting the drop sensor to the drip chamber;
FIG. 7 is a plan view further illustrating the initial stages of mounting the drop sensor to the drip chamber;
FIG. 8 is an elevational view, partially in section, taken along the lines 8--8 shown in FIG. 7 illustrating the inclined guiding surfaces;
FIG. 9 is an enlarged plan view of the drop sensor mounted on the drip chamber; and
FIG. 10 is a sectional view taken along the lines 10--10 shown in FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
Reference is made to FIG. 1 which illustrates an IV set 10 embodying features of the invention. The IV set 10 is connected to an inverted bottle 11 containing parenteral fluid hanging from the arm 12 of an IV stand (not shown). The IV set 10 as illustrated comprises a drip chamber 13, clear plastic tubing 14, needle 15 and mounting means 16 therefor at the distal end of tubing 14. Other common IV components such as Y-injection sites, roll clamps, filters and the like have not been shown in the drawings in order to keep them as simple as possible.
The drip chamber 13 generally comprises a clear plastic, hollow, cylindrical body 19, an upper portion 20 provided with a pointed piercing element 21 adapted to be inserted through the piercable seal 22 in the top of the bottle 11 to drain the fluid therein through drop former 23 when the bottle 11 is in an inverted position and hung from the arm 12 as shown, and lateral extensions 24 which aid in pushing the piercing element 21 through seal 22 and which facilitate mounting the drop sensor 25 to drip chamber 13 in accordance with the invention.
As shown in FIGS. 2-10 drop sensor 25 comprises an elongated housing 26, a first housing section 27 which is provided with a light sensor 28, a second housing section 29 which is provided with a light source 30 and a sensor gap 31 between the two sections into which the drip chamber 13 fits when the drop sensor 25 is mounted thereon. The sections 27 and 29 are joined together by means of a bridge 32 to integrate the housing 25 into a single unit. A fixed mounting member 33 is provided on section 27 and a movable mounting member 34, which is formed integrally with a sleeve 35, is slidably mounted on housing 26. The sleeve 35 is spring loaded to close as shown in FIG. 5 by means of spring 36 and is provided with a pair of finger gripping elements 37 and 38 to facilitate the lateral movement of the sleeve 35 on the housing 26 during the mounting of drop sensor 25 to the drip chamber 13. The fixed mounting member 33 is provided with a conically shaped inclined guiding or camming surface 40. Movable mounting member 34 is provided with inclined or camming surfaces 41 and 42 for contact with the edges of lateral extension 24 and an inclined projecting guide element or rib 43 which is adapted to interfit and mate with the matched notches 44 and 45 provided in the ends 46 and 47 of extensions 24. Both of the ends 46 and 47 are notched so that the drop sensor 25 can be mounted from either side of the drip chamber 13. In this manner, only a drop sensor which is matched to the drip chamber 13 can be mounted on the drop chamber. While only one rib 43 and a mating notch 44 are shown, several ribs and matched notches may be used to provide even greater assurance that only dedicated IV set and drop sensor combinations will be used together.
FIG. 4 illustrates a sectional view of the drop sensor 25 mounted onto the drip chamber 13 with the mounting members 33 and 34 engaging the ends 46 and 47 of the cantilevered extensions 24, and vertical support surfaces 50 and 51 contacting the cylindrical body 20 of the drip chamber 13 to thereby fix the position of sensor 25 with respect to the drip chamber 13. Surface 50 preferably conforms to the circular shape of the cylindrical body 20. Surface 51, while helpful in firmly positioning the sensor 25 to the drip chamber 13, is not necessary. Section 27 of housing 26 contains a light sensor 28 and the second section 29 contains a light source 30. A light path 52 crosses the sensor gap 31 through body 20 of drip chamber 13 between the light source 30 and the light sensor 28. A cable 39 is provided to transmit signals from the light sensor 28 to control means, alarms or the like which are not shown and also to provide electrical power to the light source.
The inclined guiding surfaces 40-43 and the positioning means atop the mounting members 33 and 34 are best illustrated in FIGS. 3, 6, 7 and 8. The conically shaped camming surface 40 on mounting member 33 diverges in the upward direction away from the vertical axis 53 of the drip chamber 13 disposed within the sensor gap 31. A plateau or flat surface 54 is provided on top of the mounting member 33 to engage the undersurface 48 of extension 24 and vertical stops 55 and 56 are provided on the edge of plateau 54 to limit the rotational horizontal movement between the sensor housing 26 and drip chamber 13 when the plateau 54 contacts the undersurface 48.
FIGS. 2 and 6-10 illustrate the inclined guiding surfaces 41 and 42 and the inclined projecting guide element 43 provided on the movable mounting member 34. These guiding surfaces diverge in the upward direction away from the longitudinal axis 53 of the drip chamber 13 when it is properly positioned within the sensor gap 13. The angle of camming surfaces 41 and 42 with respect to longitudinal axis 53 increase at the upper portion thereof in order to aid in guiding the mounting member upwardly so the inclined projecting guide or rib 43 will properly mate with the notch 44 at the end 46 of the extension 24. This enables the stopping element 60 or overhang 60 to engage the top surface 61 of the cantilevered extension 24. Ledge 57 is provided as a stop to control the rotation of the drop sensor with respect to the channel 13 in the plane of FIG. 6.
The method of mounting or coupling of the drop sensor 25 to the drip chamber 13 is best illustrated in sequence of drawings 6-10. FIGS. 6 and 7 show the positioning of the sensor 25 about the drip chamber 13 during the initial stage of mounting with the cantilevered lateral extensions 24 cradled by the inclined guiding surfaces 40-43 on mounting members 33 and 34. The sleeve 35 is shown in its maximum open position to ensure that the ends 46 and 47 of the extensions 24 are properly cradled by the inclined camming surfaces on members 33 and 34.
When the spring loaded sleeve 35 is released, the guiding surfaces 40, 41 and 42 slidably engage the edges of extensions 24 and projecting guide element or rib 43 slides within the notch 44 provided at the end 47 of the extension 24 to thereby guide drop sensor 25 to a proper final position with the overhang 60 contacting the top surface 61 of the end 47 of extension 14, the plateau 54 contacting the undersurface 58 of the end 46 of extension 24 and the positioning vertical surfaces 50 and 51 on sensor housing 26 resting against the clear plastic cylindrical wall 62 of drip chamber body 20. Proper positioning of the drop sensor on the drip chamber 13 ensures that the drops of fluid 63 dripping from the drop former 23 into the chamber 13 (as shown in FIG. 4) will intercept the optical path 52 between the light sensor 27 and the light source 29 and will thereby be detected.
It is evident that the mounting means of the present invention provides for a simplified mounting of the drop sensor to the drip chamber. Moreover, once the drop sensor is in position, the vertical, horizontal and rotational movement thereof with respect to the drip chamber is restricted so that accidental contact does not misalign the drop sensor on the drip chamber.
It should be appreciated that a wide range of modifications and improvements can be made to the present invention without departing from the scope thereof.
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The invention is directed to an improved system for mounting a drop sensor onto a drip chamber having laterally projecting wing-like or flange-like extensions. A pair of mounting members, one fixed, one laterally movable, are provided on the drop sensor housing. The mounting members have inclined guiding surfaces which cradle both ends of the lateral extensions on the drip chamber during the initial stages of mounting the drop sensor to the drip chamber and guide drop sensor movement with respect to the drip chamber to its final mounted position thereon. The mounting system is particularly adapted to dedicated IV set and drop sensor combinations.
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BACKGROUND OF THE INVENTION
This invention relates to an aural transmitter device in which the amplification level of the voice amplifier is controlled according to the input level of a sound signal applied through an aural transmitter (such as a microphone) or the like, whereby the effect of environmental noise is minimized.
In general, a voice amplifier for amplifying sound signals outputs a sound signal in proportion to the input level thereof.
When the output sound signal of an aural transmitter is amplified, the voice for the announcer is applied, as a relatively high sound pressure to the aural transmitter, and therefore during aural transmission environmental noises may be ignored, as they are masked by the voice.
However, when aural transmission is suspended, the environmental noises only are amplified, and are therefore offensive to the ear. Especially when the device is installed on a vehicle, the environmental noise is offensive to the ear because low frequency noises such as engine noises are emphasized.
In order to eliminate this difficulty, a method has been proposed in the art, as disclosed in the Handbook "600-Type Telephone System," pp. 26-27, published July 1964 by the Telecommunications Association, in which the voice amplifier is operated with a low gain when the voice input is equal to or lower than a predetermined level Pa and with a high gain when the same is higher than the predetermined level Pa. However, this method is disadvantageous in that, when the voice input level is around Pa, the amplified output level varies abruptly and thus the aural transmission does not seem natural. Further, if the difference between the two gains is reduced in order to eliminate the aforementioned drawback, it is rather difficult to eliminate the drawback attributable to environmental noise.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to eliminate the above-described drawbacks accompanying a conventional aural transmitter device. More specifically, an object of the invention is to provide an aural transmitter device in which an expansion characteristic is provided as the transmitter input and output characteristic when the input to the aural transmitter is of low level or only environmental noises are applied thereto, and in which an ordinary proportional characteristic is provided when the input to the aural transmitter is at a high level, whereby a non-uniform variation of the output due to variations of the transmitter input level can be prevented, the effect of environmental noises is decreased, and the aural transmission seems natural.
Another object of this invention is to provide an aural transmitter device in which a non-linear input-output characteristic is provided, and wherein a frequency characteristic is given to the input-output characteristic thus provided, whereby the effect of environmental noises is minimized.
Another object of the invention is to provide an aural transmitter device, in which the effects of environmental noise are minimized by imparting a non-linear input-output characteristic to the voice amplifier.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a first example of an aural transmitter device according to the invention;
FIG. 2 is a graphical representation indicating the input-output characteristic of the device of FIG. 1;
FIG. 3 is a block diagram showing a second example of the device according to the invention, which is given a hysteresis characteristic;
FIG. 4 is a graphical representation indicating one example of the input-output characteristic of the device of FIG. 3;
FIG. 5 is a block diagram showing a third example of the device according to the invention, in which a frequency characteristic is imparted to the voice feedback amplifier;
FIG. 6 is a graphical representation indicating the input-output characteristic of the device in FIG. 5;
FIG. 7 is a block diagram showing an aural transmitter device according to a further embodiment of this invention;
FIG. 8 is a graphical representation showing input and output characteristics of the device of FIG. 7;
FIG. 9 is a block diagram showing another example of an aural transmitter device according to this invention;
FIG. 10 is a graphical representation indicating the input-output characteristic of the device of FIG. 9;
FIG. 11 is a block diagram showing still another example of the aural transmitter device according to the invention; and
FIG. 12 is a graphical representation indicating the input-output characteristic of the device of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One example of an aural transmitter device according to this invention will now be described with reference to FIG. 1.
In FIG. 1, reference numeral 1 designates an aural transmitter for converting an aural wave into an electrical signal (or a sound signal); and at 2 is an amplifier for amplifying the output of the transmitter 1 to a level such that the output can be rectified. A high-pass filter 3 having a cut-off frequency of about 1 kHz transmits the sound signal thus amplified, and a rectifier circuit 4 rectifies the output of the high-pass filter, the output of the rectifier circuit 4 being applied to a smoothing circuit 5 comprising resistors R 1 and R 2 and a capacitor C 1 where a ripple component is removed therefrom. A voltage comparator 6 is provided with a variable resistor R V for setting a voltage comparison point. Reference numeral 7 represents a voice feedback amplifier.
In the voltage comparator 6, the voltage set by the variable resistor R V is compared with the output voltage of the smoothing circuit 5, and a high or low level signal is outputted according to the result. The voice feedback amplifier 7 comprises a voice amplifier 8 made up of an operational amplifier; a feedback circuit 9 including an input resistor R i ; and an analog switch 10 for switching feedback resistors R a and R b in response to the output of the voltage comparator 6.
FIG. 2 is a graphical representation indicating the input-output characteristic of the aural transmitter device of FIG. 1. In FIG. 2, the horizontal axis represents an input sound pressure P i applied to the aural transmitter 1, and the vertical axis represents the output voltage V o of the voice feedback amplifier 7.
The operation of the device of FIG. 1 will now be described with reference to FIG. 2. When sound is applied to the transmitter 1, the output of the latter is amplified to a suitable level, and is then applied to the high-pass filter 3. Since the cut-off frequency of the high-pass filter 3 is about 1 kHz as described above, the audio component is passed through the high-pass filter as it is, and is then rectified and smoothed respectively by the rectifier circuit 4 and the smoothing circuit 5. The reference voltage E a is set by the variable resistor R V of the voltage comparator 6 such that it is equal to an output voltage provided by the smoothing circuit when the input sound pressure (P i ) is P a during aural transmission. When the input sound pressure (P i ) is higher than P a , the output of the voltage comparator 6 operates to connect the analog switch 10 to the feedback resistor R a ; and when the input sound pressure (P i ) is lower than P a , the output of the voltage comparator 6 operates to connect the analog switch 10 to the feedback resistor R b . The relation between the gains of the voice feedback amplifier 7 in the two cases mentioned above is as follows: ##EQU1## where R a >R b . Therefore, the gain difference, i.e., the output level difference is (V a -V b ) dB.
Accordingly, if the level (PN 1 ) of an environmental noise higher than 1 kHz applied to the aural transmitter 1 is smaller than P a (PN 1 <P a ), and if during aural transmission the sound pressure level (P s ) is larger than P a (P s >P a ), then the output V o of the voice feedback amplifier 7 when aural transmission is effected is increased by (V a -V b ) dB when compared with that when aural transmission is not effected (or when a noise signal is input). That is, the difficulty in hearing due to the environmental noise is reduced by (V a -V b ) dB when compared with the case of the conventional aural transmitter device.
The above-described sound pressure input-output characteristic higher than 1 kHz is indicated by the curve (A) in FIG. 2.
Environmental noise, the frequency components of which are lower than 1 kHz, is attenuated by the high-pass filter 3. Therefore, the sound pressure level (PN 2 ) of the noise would have to be increased to P c (FIG. 2) to reach the high gain region of the voice feedback amplifier 7. In the case where the noise frequency is lower than 1 kHz, as the frequency is decreased, the gain of the voice feedback amplifier 7 is maintained low until the sound pressure becomes larger than P c . This is very effective in eliminating noises lower than 1 kHz, for instance when the aural transmitter device is installed on an automobile. In FIG. 2, the degree of allowance for noises lower than 1 kHz corresponds to (P c -P a ) dB in terms of the input sound pressure.
When the input value PN to the transmitter 1 is abruptly switched to the input value P s , or vice versa, the step response of the smoothing circuit 5, i.e., the switching response time of the analog switch 10 is determined by the values of the circuit elements R 1 , C 1 and R 2 . In order to make R 1 C 1 =t 1 short to thereby prevent the top of a voice from being cut off due to the input level variation when the voice rises, and in order to make R 2 C 1 =t 2 long to thereby avoid a voice being cut off during transmission, the resistance of the resistor R 1 is made smaller than that of the resistor R 2 (R 1 <R 2 ).
When the input sound pressure P i varies around P a , a so-called chattering phenomenon occurs in which the output voltage V o varies between V a and V b . This difficulty may be eliminated by connecting the output of the voltage comparator 6 through a feedback resistor R f to the input of the same as shown in FIG. 3, to thereby allow the voltage comparator 6 to have a hysteresis characteristic.
FIG. 4 shows the input-output characteristic of the aural transmitter device of FIG. 3. As is clear from FIG. 4, if the input sound pressure becomes larger than Pa during aural transmission, the gain of the voice feedback amplifier 7 is raised and then maintained unchanged until the sound pressure is decreased to P b . Accordingly, when compared with the aural transmitter device of FIG. 1, the gain of the voice feed-back amplifier 7 of the device of FIG. 3 is less dependent on sound pressure variations during transmission. Thus, voices are outputted more naturally. The amount of hysteresis (P a -P b ) dB is determined by the ratio of the resistance of the feedback resistor R f to that of the variable resistor R V .
In the above-described examples of the aural transmitter device according to the invention, the feedback constant of the voice feedback amplifier 7 was determined by the resistors R a and R b only. However, a frequency characteristic may be imparted to the voice feedback amplifier 7 by combining a resistor and a capacitor with the feedback circuit 9 as shown in FIG. 5. One example of the input-output characteristic, in this case, is as shown in FIG. 6.
As is apparent from the above description, in the aural transmitter device according to the invention, the output of the aural transmitter is applied to a high-pass filter, and the output of the high-pass filter is rectified and smoothed, and is then compared with a predetermined voltage in a voltage comparator, the output of which is utilized to control the amount of feedback of a voice feedback amplifier, so that the gain of the amplifier is increased when ordinary aural transmission is effected, and decreased when the input sound pressure is low as in the transmission of environmental noises only or when the input sound pressure is high but the frequency components are low as in a case where the device is installed on an automobile. Thus, in the aural transmitter device according to this embodiment of the invention, noise output components offensive to the ear caused by environmental noise can be minimized. Especially when the device is installed on a vehicle, low frequency noises such as engine noises can be effectively eliminated.
A further embodiment of this invention will now be described with reference to FIGS. 7 and 8. In FIG. 7, sound signals are applied to aural transmitter 1, and the output thereof is applied to a voice amplifier 2 and a sound signal expander 14. The sound input from the transmitter 1 is amplified to a suitable level by the voice amplifier 2, and is then rectified by rectifier circuit 4. The rectified output of the rectifier circuit 4 is applied to a smoothing circuit 5 comprising resistors R 1 and R 2 and a capacitor C 1 , where a ripple component is removed. The output of the smoothing circuit is applied to one input terminal of a voltage comparator 6. The sound signal expander 14 is a variable gain amplifier designed such that over at least part of its output range its output varies by 2 dB as its input varies by 1 dB. The output of the sound signal expander 14 is rectified by a rectifier circuit 15, and the output of the rectifier circuit is applied to a smoothing circuit 19 comprising resistors R 3 and R 4 and a capacitor C 2 , where a ripple component is removed. The output of the smoothing circuit 19 is applied to the other input terminal of the voltage comparator 6.
The output of the sound signal expander 14 and the output of the voice amplifier 2 are also applied to two input terminals of an analog switch 17. One of the outputs thus applied to the analog switch 17 is outputted in response to a control signal from the voltage comparator 6.
In the voltage comparator 6, the output voltage of the smoothing circuit 5 is compared with that of the smoothing circuit 19, and a corresponding signal is output therefrom depending upon which signal is lower than the other, this signal being applied as the control signal for the analog switch 17.
FIG. 8 is a graphical representation indicating the input and output characteristics of the aural transmitter device shown in FIG. 7.
In FIG. 8, characteristic (A) indicates the relation between a sound pressure input P i to the aural transmitter 1 and an output V o of the sound signal expander 14. That is, in characteristic (A), as the sound pressure input ranges from P o to P i , the output V o varies 1 dB as the input P i is varied 1 dB; and when the sound pressure input is larger than P i , the output V o varies by 2 dB as the input P i is varied by 1 dB.
On the other hand, characteristic (B) indicates the relation between the sound pressure input P i to the aural transmitter 1 and an output V o of the sound amplifier 2.
As is apparent from FIG. 8, when the input sound pressure P i to the aural transmitter 1 is lower than P a , the output of the sound signal expander 14 is lower than that of the voice amplifier. Accordingly, in this case, the voltage comparator 6 outputs the control signal which allows the analog switch 7 to select the output of the sound signal expander 14.
When the input P i to the aural transmitter 1 is gradually increased to P a , the output of the smoothing circuit 5 is lower than that of the smoothing circuit 19, and accordingly the comparator 6 selects the output of the smoothing circuit 5 as the control signal. As a result, the output of the voice amplifier 2 is outputted through the analog switch. That is, in this operation, characteristic (B) is selected.
During normal aural transmission, the input sound pressure is higher than P a , and the aural transmitter input sound pressure is proportional to the aural transmitter device output. When the input to the aural transmitter is environmental noise only and the sound pressure is lower than P i , the output is decreased as much as (V b -V o ) dB when compared with that of the conventional aural transmitter device in which the input is proportional to the output, and accordingly the output of offensive environmental noise is suppressed. When the sound pressure is between P i and P a , the gain is changed in the ratio of 1:2 depending on the amount of sound pressure input.
As is apparent from the above description, in the aural transmitter device of this embodiment of the invention, unlike in the conventional device, the variation of the output due to large variations of the input sound pressure is not carried out stepwise, and accordingly the output seems natural even when the voice is stressed during transmission.
The step response of the smoothing circuits when the input to the transmitter is abruptly changed, i.e., the switching speed of the outputs of the voice amplifier 2 and the sound signal expander 14 depends on the values of the circuit elements R 1 , R 2 and C 1 , and R 3 , R 4 and C 2 . Thus, in order to prevent the top of a voice from being cut off when the voice rises, R 1 C 1 =t 1 or R 3 C 2 =t 2 should be made short. In order to maintain the tone variation constant during aural transmission, R 1 should be smaller than R 2 (R 1 <R 2 ) so that R 2 C 1 =t 3 or R 3 C 2 =t 4 is long.
When the input sound pressure is near P a , a chattering phenomenon occurs in which the outputs of the voice amplifier 2 and the sound signal expander 14 are alternatively provided as the outputs of the aural transmitter device. The occurrence of this chattering phenomenon is due to the fact that the output of the voltage comparator 6 may change when the inputs to the voltage comparator 6 change only slightly. This difficulty may be prevented by imparting a hysteresis characteristic to the voltage comparator 6, similarly as described above.
As is apparent from the above description, according to the invention, the output of the aural transmitter device is a signal which has passed through the sound signal expander when the aural transmitter input sound pressure is low, as in the case of environmental noise; or through the voice amplifier in which the input is proportional to the output when the aural transmitter input sound pressure is high, as with ordinary voices. Accordingly, a noisy condition caused by the application of environmental noise only to the transmitter is eliminated, and the degree of such elimination changes smoothly with the sound pressure. Accordingly, the output characteristic of the aural transmitter device seems natural.
FIGS. 9 and 11 show further modifications of the invention, and FIGS. 10 and 12 respectively show input-output characteristics of these devices. The embodiments of FIGS. 9 and 11 are substantially similar to those of FIGS. 1 and 3, discussed previously, differing in that the high-pass filter 3 of the prior embodiments has been omitted. Although the filter function is not provided in the present embodiments, good noise elimination characteristics can nonetheless be obtained, as illustrated in FIGS. 10 and 12. Where low frequency noises do not pose a special problem, the embodiments of FIGS. 9 and 11 can operate as efficiently and with the same effect as the devices of FIGS. 1 and 3. Therefore, according to the invention noise output components due to environmental noise can be effectively minimized, resulting in an aural transmitter device of superior sound quality.
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An aural transmitter device is improved by largely eliminating the amplification of ambient environmental noise. To this end, control may be effected in response to the difference between a smoothed, rectified output of an amplifier and a reference voltage, either with or without a high-pass filter for removing low frequency noise components.
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RELATED APPLICATIONS
[0001] This application is related U.S. Application Ser. No. 60/611,161 titled “Closed System Artificial Intervertebral Disc”, by Smith, et al., filed Sep. 17, 2004, the entirety of which is hereby incorporated as if fully set forth herein.
FIELD OF THE INVENTION
[0002] The invention herein relates generally to medical devices and methods of treatment, and more particularly to devices and methods used in the treatment of a degenerated or traumatized intervertebral disc.
BACKGROUND OF THE INVENTION
[0003] Intervertebral disc degeneration is a leading cause of pain and disability, occurring in a substantial majority of people at some point during adulthood. The intervertebral disc, comprising primarily the nucleus pulposus and surrounding annulus fibrosus, constitutes a vital component of the functional spinal unit. The intervertebral disc maintains space between adjacent vertebral bodies, absorbs impact between and cushions the vertebral bodies. The disc allows for fluid movement between the vertebral bodies, both subtle (for example, with each breath inhaled and exhaled) and dramatic (including rotational movement and bending movement in all planes.) Deterioration of the biological and mechanical integrity of an intervertebral disc as a result of disease and/or aging may limit mobility and produce pain, either directly or indirectly as a result of disruption of the functioning of the spine. Estimated health care costs of treating disc degeneration in the United States exceed $60 billion annually.
[0004] Age-related disc changes are progressive, and, once significant, increase the risk of related disorders of the spine. The degenerative process alters intradiscal pressures, causing a relative shift of axial load-bearing to the peripheral regions of the endplates and facets of the vertebral bodies. Such a shift promotes abnormal loading of adjacent intervertebral discs and vertebral bodies, altering spinal balance, shifting the axis of rotation of the vertebral bodies, and increasing risk of injury to these units of the spine. Further, the transfer of biomechanical loads appears to be associated with the development of other disorders, including both facet and ligament hypertrophy, osteophyte formation, lyphosis, spondylolisthesis, nerve damage, and pain.
[0005] In addition to age-related changes, numerous individuals suffer trauma-induced damage to the spine including the intervertebral discs. Trauma induced damage may include ruptures, tears, prolapse, herniations, and other injuries that cause pain and reduce strength and function.
[0006] Non-operative therapeutic options for individuals with neck and back pain include rest, analgesics, physical therapy, heat, and manipulation. These treatments fail in a significant number of patients. Current surgical options for spinal disease include discectomy, discectomy combined with fusion, and fusion alone. Numerous discectomies are performed annually in the United States. The procedure is effective in promptly relieving significant radicular pain, but, in general, the return of pain increases proportionally with the length of time following surgery. In fact, the majority of patients experience significant back pain by ten years following lumbar discectomy.
[0007] An attempt to overcome some of the possible reasons for failure of discectomy, fusion has the potential to maintain normal disc space height, to eliminate spine segment instability, and eliminate pain by preventing motion across a destabilized or degenerated spinal segment.
[0008] However, although some positive results are possible, spinal fusion may have harmful consequences as well. Fusion involves joining portions of adjacent vertebrae to one another. Because motion is eliminated at the treated level, the biomechanics of adjacent levels are disrupted. Resulting pathological processes such as spinal stenosis, disc degeneration, osteophyte formation, and others may occur at levels adjacent to a fusion, and cause pain in many patients. In addition, depending upon the device or devices and techniques used, surgery may be invasive and require a lengthy recovery period.
[0009] Consequently, there is a need in the art to treat degenerative disc disease and/or traumatized intervertebral discs, while eliminating the shortcomings of the prior art. There remains a need in the art to achieve the benefit of removal of a non-functioning intervertebral disc, to replace all or a portion of the disc with a device that will function as a healthy disc, eliminating pain, while preserving motion. There remains a need for an artificial disc or other device that maintains the proper intervertebral spacing, allows for motion, distributes axial load appropriately, and provides stability. In addition, an artificial disc requires secure long-term fixation to bone.
[0010] Further, there remains a need for an artificial nucleus that can be implanted within the annulus fibrosus, in order to restore normal disc functioning. Such a nucleus must comprise the characteristic lower durometer than the annulus fibrosus, must mimic the behavior of a healthy native nucleus upon load increase and decrease, and the annulus fibrosus must comprise the requisite stiffness as compared with the nucleus. Further, there remains a need for an artificial disc that can withstand typical cyclic stresses and perform throughout the life a patient. An artificial disc that can be implanted using minimally invasive techniques is also needed. And finally, a device that is compatible with current imaging modalities, such as Magnetic Resonance Imaging (MRI) is needed.
SUMMARY OF THE INVENTION
[0011] An artificial nucleus and/or disc is disclosed comprising a substantially impermeable membrane, a first reservoir and a second reservoir within said first reservoir, wherein said second reservoir is substantially enclosed by a selectively permeable membrane, said first reservoir comprises one or more fluids, and wherein upon the application of a load to said artificial nucleus, some or all of said one or more fluids enters said second reservoir. Upon removal of said load, said one or more fluids may return to said first reservoir. The second reservoir of the artificial nucleus may comprise a plurality of substantially enclosed structures which may include a plurality of microspheres.
[0012] The first reservoir of the artificial nucleus may comprise a hydrogel. The artificial nucleus may comprise an elastic membrane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a side view of a demonstrational system illustrating the principles of the invention, the system in a pre-load configuration.
[0014] FIG. 2 is a side view of the demonstrational system in a load configuration (following the application of a load).
[0015] FIG. 3 is a side view of the demonstrational system in a post-load configuration (following removal of the load imposed as illustrated above in FIG. 2 .)
[0016] FIG. 4 is a cross-sectional view of an alternative closed system balloon according to the invention in a pre-load configuration.
[0017] FIG. 5 is a cross-sectional view of the closed system balloon of FIG. 4 following the application of a load.
[0018] FIG. 6 is a cross-sectional view of the closed system balloon following the removal of the load applied in FIG. 5 .
[0019] FIG. 7 is a cross-sectional view of an artificial disc nucleus according to the invention in a pre-load configuration.
[0020] FIG. 8 is a cross-sectional view of the artificial disc nucleus of FIG. 7 in a load configuration (following the application of a load).
[0021] FIG. 9 is a cross-sectional view of the artificial disc nucleus of FIGS. 7 and 8 following the removal of a load.
[0022] FIG. 10 is a cross-section of an alternative closed system balloon according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] An endoprosthesis known as an artificial disc and/or an artificial disc nucleus are designed to replace a degenerated intervertebral disc. Such an artificial disc or disc nucleus may be expandable and/or self-expanding.
[0024] An “expandable” endoprosthesis comprises a reduced profile configuration and an expanded profile configuration. An expandable endoprosthesis according to the invention may undergo a transition from a reduced configuration to an expanded profile configuration via any suitable means, or may be self-expanding. Some embodiments according to the invention may comprise a substantially hollow interior that may be filled with a suitable medium, examples of which are set forth below. Such embodiments may accordingly be introduced into the body in a collapsed configuration, and, following introduction, may be filled to form a deployed configuration. Embodiments according to the invention may accordingly be implanted percutaneously or surgically. If implanted surgically, embodiments according to the invention may be implanted from either an anterior or a posterior approach, following the removal of some or all of the native disc, excepting the periphery of the native nucleus.
[0025] “Spinal fusion” is a process by which one or more adjacent vertebral bodies are adjoined to one another in order to eliminate motion across an unstable or degenerated spinal segment.
[0026] “Preservation of mobility” refers to the desired maintenance of normal motion between separate spinal segments.
[0027] “Spinal unit” refers to a set of the vital functional parts of the spine including a vertebral body, endplates, facets, and intervertebral disc.
[0028] The term “cable” refers to any generally elongate member fabricated from any suitable material, whether polymeric, metal or metal alloy, natural or synthetic.
[0029] The term “fiber” refers to any generally elongate member fabricated from any suitable material, whether polymeric, metal or metal alloy, natural or synthetic.
[0030] As used herein, the term “braid” refers to any braid or mesh or similar wound or woven structure produced from between 1 and several hundred longitudinal and/or transverse elongate elements wound, woven, braided, knitted, helically wound, or intertwined by any manner, at angles between 0 and 180 degrees and usually between 45 and 105 degrees, depending upon the overall geometry and dimensions desired.
[0031] Unless specified, suitable means of attachment may include by thermal melt, chemical bond, adhesive, sintering, welding, or any means known in the art.
[0032] As used herein, a device is “implanted” if it is placed within the body to remain for any length of time following the conclusion of the procedure to place the device within the body.
[0033] The term “diffusion coefficient” refers to the rate by which a substance elutes, or is released either passively or actively from a substrate.
[0034] Unless specified, suitable means of attachment may include by thermal melt, chemical bond, adhesive, sintering, welding, or any means known in the art.
[0035] “Shape memory” refers to the ability of a material to undergo structural phase transformation such that the material may define a first configuration under particular physical and/or chemical conditions, and to revert to an alternate configuration upon a change in those conditions. Shape memory materials may be metal alloys including but not limited to nickel titanium, or may be polymeric. A polymer is a shape memory polymer if the original shape of the polymer is recovered by heating it above a shape recovering temperature (defined as the transition temperature of a soft segment) even if the original molded shape of the polymer is destroyed mechanically at a lower temperature than the shape recovering temperature, or if the memorized shape is recoverable by application of another stimulus. Such other stimulus may include but is not limited to pH, salinity, hydration, radiation, including but not limited to radiation in the ultraviolet range, and others. Some embodiments according to the invention may comprise one or more polymers having a structure that assumes a first configuration, a second configuration, and a hydrophilic polymer of sufficient rigidity coated upon at least a portion of the structure when the device is in the second configuration. Upon placement of the device in an aqueous environment and consequent hydration of the hydrophilic polymer, the polymer structure reverts to the first configuration.
[0036] Some embodiments according to the invention, while not technically comprising shape memory characteristics, may nonetheless readily convert from a constrained configuration to a deployed configuration upon removal of constraints, as a result of a material's elasticity, super-elasticity, a particular method of “rolling down” and constraining the device for delivery, or a combination of the foregoing. Such embodiments may comprise one or more elastomeric or rubber materials.
[0037] As used herein, the term “segment” refers to a block or sequence of polymer forming part of the shape memory polymer. The terms hard segment and soft segment are relative terms, relating to the transition temperature of the segments. Generally speaking, hard segments have a higher glass transition temperature than soft segments, but there are exceptions.
[0038] “Transition temperature” refers to the temperature above which a shape memory polymer reverts to its original memorized configuration.
[0039] The term “strain fixity rate” R f is a quantification of the fixability of a shape memory polymer's temporary form, and is determined using both strain and thermal programs. The strain fixity rate is determined by gathering data from heating a sample above its melting point, expanding the sample to 200% of its temporary size, cooling it in the expanded state, and drawing back the extension to 0%, and employing the mathematical formula:
R f ( N )=ε u ( N )/ε m
where ε u (N) is the extension in the tension-free state while drawing back the extension, and ε m is 200%.
The “strain recovery rate” R r describes the extent to which the permanent shape is recovered:
R r ( N ) = ɛ m - ɛ p ( N ) ɛ m - ɛ p ( N - 1 )
where ε p is the extenstion at the tension free state.
[0040] A “switching segment” comprises a transition temperature and is responsible for the shape memory polymer's ability to fix a temporary shape.
[0041] A “thermoplastic elastomer” is a shape memory polymer comprising crosslinks that are predominantly physical crosslinks.
[0042] A “thermoset” is a shape memory polymer comprising a large number of crosslinks that are covalent bonds.
[0043] Shape memory polymers are highly versatile, and many of the advantageous properties listed above are readily controlled and modified through a variety of techniques. Several macroscopic properties such as transition temperature and mechanical properties can be varied in a wide range by only small changes in their chemical structure and composition. More specific examples are set forth in Provisional U.S. Patent Application Ser. No. 60/523,578 and are incorporated in their entirety as if fully set forth herein.
[0044] Shape memory polymers are characterized by two features, triggering segments having a thermal transition T trans within the temperature range of interest, and crosslinks determining the permanent shape. Depending on the kind of crosslinks (physical versus covalent bonds), shape memory polymers can be thermoplastic elastomers or thermosets. By manipulating the types of crosslinks, the transition temperature, and other characteristics, shape memory polymers can be tailored for specific clinical applications.
[0045] More specifically, according the invention herein, one can the control shape memory behavior and mechanical properties of a shape memory polymer through selection of segments chosen for their transition temperature, and mechanical properties can be influenced by the content of respective segments. The extent of crosslinking can be controlled depending on the type of material desired through selection of materials where greater crosslinking makes for a tougher material than a polymer network. In addition, the molecular weight of a macromonomeric crosslinker is one parameter on the molecular level to adjust crystallinity and mechanical properties of the polymer networks. An additional monomer may be introduced to represent a second parameter.
[0046] Further, the annealing process (comprising heating of the materials according to chosen parameters including but not limited to time and temperature) increases polymer chain crystallization, thereby increasing the strength of the material. Consequently, according to the invention, the desired material properties can be achieved by using the appropriate ratio of materials and by annealing the materials.
[0047] Additionally, the properties of polymers can be enhanced and differentiated by controlling the degree to which the material crystallizes through strain-induced crystallization. Means for imparting strain-induced crystallization are enhanced during deployment of an endoprosthesis according to the invention. Upon expansion of an endoprosthesis according to the invention, focal regions of plastic deformation undergo strain-induced crystallization, further enhancing the desired mechanical properties of the device, such as further increasing radial strength. The strength is optimized when the endoprosthesis is induced to bend preferentially at desired points.
[0048] Natural polymer segments or polymers include but are not limited to proteins such as casein, gelatin, gluten, zein, modified zein, serum albumin, and collagen, and polysaccharides such as alginate, chitin, celluloses, dextrans, pullulane, and polyhyaluronic acid; poly(3-hydroxyalkanoate)s, especially poly(.beta.-hydroxybutyrate), poly(3-hydroxyoctanoate) and poly(3-hydroxyfatty acids).
[0049] Suitable synthetic polymer blocks include polyphosphazenes, poly(vinyl alcohols), polyamides, polyester amides, poly(amino acid)s, synthetic poly(amino acids), polycarbonates, polyacrylates, polyalkylenes, polyacrylamides, polyalkylene glycols, polyalkylene oxides, polyalkylene terephthalates, polyvinyl ethers, polyvinyl esters, polyvinyl halides, polyvinylpyrrolidone, polyesters, polyethylene terephthalate, polysiloxanes, polyurethanes, fluoropolymers (including but not limited to polyfluorotetraethylene), and copolymers thereof.
[0050] Examples of suitable polyacrylates include poly(methyl methacrylate), poly(ethyl methacrylate), poly(butyl methacrylate), poly(isobutyl methacrylate), poly(hexyl methacrylate), poly(isodecyl methacrylate), poly(lauryl methacrylate), poly(phenyl methacrylate), poly(methyl acrylate), poly(isopropyl acrylate), poly(isobutyl acrylate) and poly(octadecyl acrylate).
[0051] Synthetically modified natural polymers include cellulose derivatives such as alkyl celluloses, hydroxyalkyl celluloses, cellulose ethers, cellulose esters, nitrocelluloses, and chitosan. Examples of suitable cellulose derivatives include methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, hydroxybutyl methyl cellulose, cellulose acetate, cellulose propionate, cellulose acetate butyrate, cellulose acetate phthalate, arboxymethyl cellulose, cellulose triacetate and cellulose sulfate sodium salt. These are collectively referred to herein as “celluloses”.
[0052] For those embodiments comprising a shape memory polymer, the degree of crystallinity of the polymer or polymeric block(s) is between 3 and 80%, more often between 3 and 65%. The tensile modulus of the polymers below the transition temperature is typically between 50 MPa and 2 GPa (gigapascals), whereas the tensile modulus of the polymers above the transition temperature is typically between 1 and 500 MPa. Most often, the ratio of elastic modulus above and below the transition temperature is 20 or more.
[0053] The melting point and glass transition temperature of the hard segment are generally at least 10 degrees C., and preferably 20 degrees C., higher than the transition temperature of the soft segment. The transition temperature of the hard segment is preferably between −60 and 270 degrees C., and more often between 30 and 150 degrees C. The ratio by weight of the hard segment to soft segments is between about 5:95 and 95:5, and most often between 20:80 and 80:20. The shape memory polymers contain at least one physical crosslink (physical interaction of the hard segment) or contain covalent crosslinks instead of a hard segment. The shape memory polymers can also be interpenetrating networks or semi-interpenetrating networks. A typical shape memory polymer is a block copolymer.
[0054] Examples of suitable hydrophilic polymers include but are not limited to poly(ethylene oxide), polyvinyl pyrrolidone, polyvinyl alcohol, poly(ethylene glycol), polyacrylamide poly(hydroxy alkyl methacrylates), poly(hydroxy ethyl methacrylate), hydrophilic polyurethanes, HYPAN, oriented HYPAN, poly(hydroxy ethyl acrylate), hydroxy ethyl cellulose, hydroxy propyl cellulose, methoxylated pectin gels, agar, starches, modified starches, alginates, hydroxy ethyl carbohydrates and mixtures and copolymers thereof.
[0055] Hydrogels can be formed from polyethylene glycol, polyethylene oxide, polyvinyl alcohol, polyvinyl pyrrolidone, polyacrylates, poly (ethylene terephthalate), poly(vinyl acetate), and copolymers and blends thereof. Several polymeric segments, for example, acrylic acid, are elastomeric only when the polymer is hydrated and hydrogels are formed. Other polymeric segments, for example, methacrylic acid, are crystalline and capable of melting even when the polymers are not hydrated. Either type of polymeric block can be used, depending on the desired application and conditions of use.
[0056] Examples of highly elastic materials including but not limited to vulcanized rubber, polyurethanes, thermoplastic elastomers, and others may be used according to the invention.
[0057] Curable materials include any material capable of being able to transform from a fluent or soft material to a harder material, by cross-linking, polymerization, or other suitable process. Materials may be cured over time, thermally, chemically, or by exposure to radiation. For those materials that are cured by exposure to radiation, many types of radiation may be used, depending upon the material. Wavelengths in the spectral range of about 100-1300 nm may be used. The material should absorb light within a wavelength range that is not readily absorbed by tissue, blood elements, physiological fluids, or water. Ultraviolet radiation having a wavelength ranging from about 100-400 nm may be used, as well as visible, infrared and thermal radiation. The following materials are some examples of curable materials: urethanes, polyurethane oligomer mixtures, acrylate monomers, aliphatic urethane acrylate oligomers, acrylamides, UV curable epoxies, photopolymerizable polyanhydrides and other UV curable monomers. Alternatively, the curable material can be a material capable of being chemically cured, such as silicone based compounds which undergo room temperature vulcanization.
[0058] Though not limited thereto, some embodiments according to the invention comprise one or more therapeutic substances that will elute from the surface. Suitable therapeutics include but are not limited to bone growth accelerators, bone growth inducing factors, osteoinductive agents, immunosuppressive agents, steroids, anti-inflammatory agents, pain management agents (e.g, analgesics), tissue proliferative agents to enhance regrowth and/or strengthening of native disc materials, and others. According to the invention, such surface treatment and/or incorporation of therapeutic substances may be performed utilizing one or more of numerous processes that utilize carbon dioxide fluid, e.g., carbon dioxide in a liquid or supercritical state. A supercritical fluid is a substance above its critical temperature and critical pressure (or “critical point”).
[0059] The use of polymeric materials in the fabrication of endoprostheses confers the advantages of improved flexibility, compliance and conformability. Fabrication of an endoprosthesis according to the invention allows for the use of different materials in different regions of the prosthesis to achieve different physical properties as desired for a selected region. An endoprosthesis comprising polymeric materials has the additional advantage of compatibility with magnetic resonance imaging, potentially a long-term clinical benefit.
[0060] As set forth above, some embodiments according to the invention may comprise components that have a substantially hollow interior that may be filled after being delivered to a treatment site with a suitable material in order to place the device in a deployed configuration. Accordingly, such embodiments may comprise a fluid retention bag having a membrane layer comprising polyvinyl chloride (PVC), polyurethane, and or laminates of polyethylene terephthalate (PET) or nylon fibers or films within layers of PVC, polyurethane or other suitable material. Such a fluid retention bag or membrane layer alternatively may comprise Kevlar, polyimide, a suitable metal, or other suitable material within layers of PVC, polyurethane or other suitable material. Such laminates may be of solid core, braided, woven, wound, or other fiber mesh structure, and provide stability, strength, and a controlled degree of compliance. Such a laminate membrane layer may be manufactured using radiofrequency or ultrasonic welding, adhesives including ultraviolet curable adhesives, or thermal energy.
[0061] A fluid retention bag as set forth above may be filled with any suitable material including but not limited to saline, contrast media, hydrogels, a polymeric foam, or any combination thereof. A polymeric foam may comprise a polyurethane intermediate comprising polymeric diisocyanate, polyols, and a hydrocarbon, or a carbon dioxide gas mixture. Such a foam may be loaded with any of numerous solid or liquid materials known in the art that confer radiopacity.
[0062] Such a fluid retention membrane and/or bag may be designed to replace an entire intervertebral disc. Alternatively, it may replace only the nucleus pulposus or only the annulus fibrosus. Such a device may comprise one or more filling ports, and include separate filling ports for the nucleus pulposus and annulus fibrosus, to allow for varying durometers, and possibly varied materials in order to mimic the properties of the native disc components.
[0063] Such a device may comprise a single unit, or may be two or more individual parts. If the device comprises two or more component parts, the parts may fit together in a puzzle-like fashion. The device may further comprise alignment tabs for stable alignment between the vertebral bodies.
[0064] Such a fluid retention membrane and/or bag may comprise interbody connections and/or baffles and/or partitions or generally vertically oriented membranes in order to maintain structural integrity after filling, to increase the devices ability to withstand compressive, shear, and other loading forces, and/or to direct filling material flow and positioning, and/or to partition portions of the disc in order to separate injection of different types or amounts of filling materials.
[0065] Following surgical or minimally invasive surgical access and removal of all or a portion of the native disc, a deflated fluid retention bag or membrane may be delivered to the intervertebral space surgically or through a catheter and/or cannula. The membrane and/or bag is positioned within the intervertebral space. The membrane inflation port or ports are then attached to the injection source. Filling material is then injected. Following injection of the filling material, which may be curable by any suitable means or may be catalytically activated or may remain in fluid form, the injection source is detached and removed.
[0066] Details of the invention can be better understood from the following descriptions of specific embodiments according to the invention which are set forth as examples of the general principles of the invention. It will be appreciated that numerous structural and material modifications may be made without departing from the spirit and scope of the invention. It will also be appreciated that the following embodiments may serve as an artificial disc nucleus, artificial disc annulus, or both. FIG. 1 illustrates the principles of the invention herein via a cross section of system 5 . System 5 comprises cylindrical chamber 10 , piston 15 , hydrogel 20 and second reservoir 25 . Shown in cross section in FIG. 1 , piston 15 is in a first configuration and with chamber 10 defines first reservoir 12 . Second reservoir 25 comprises permeable membrane 28 , but alternative embodiments according to the invention may comprise an impermeable membrane. In the pre-load configuration illustrated in FIG. 1 , system 5 is at equilibrium.
[0067] In FIG. 2 , load 30 is applied to piston 15 , exerting a downward force on piston 50 . As a result of the increased pressure place upon hydrogel 20 , water from within hydrogel 20 is forced through permeable membrane 28 into interior 27 of second reservoir 25 . Consequently, the volume of first reservoir 12 decreases. Hydrogel 20 then comprises a lower volume of water. The extent to which water is forced into the interior of second reservoir 25 depends upon the magnitude of load 30 .
[0068] FIG. 3 illustrates the interactive behavior of second reservoir 25 following the removal of load 30 . With the decrease in pressure on system 5 , previously dehydrated hydrogel 20 “pulls” water from the interior of second reservoir 25 through permeable membrane 28 . Hydrogel 20 is progressively rehydrated, and interior 27 of second reservoir 25 empties partially or completely. Upon reapplication of a force, the foregoing system 5 will again undergo the foregoing relational and configurational steps. System 5 represents the repeated load bearing and unloading of a functional spine, and the behavior of an artificial disc according to the invention during the repeated application and removal of a load.
[0069] Turning now to FIG. 4 , an alternative embodiment of the invention is illustrated in a preload configuration. Artificial nucleus 40 comprises impermeable elastic bag 45 , impermeable reservoir 47 and hydrogel 50 . Upon application of multidirectional load 55 , as illustrated in FIG. 5 , pressure is transferred to impermeable reservoir 47 and decreases volume of impermeable reservoir 47 . Consequently, the volume of elastic bag 45 decreases. The extent to which the volume of impermeable reservoir decreases depends upon the magnitude of the load applied.
[0070] Upon removal of load 55 , as illustrated in FIG. 6 , pressure upon gas 46 decreases. Consequently, the volume of impermeable reservoir 47 increases to its original pre-load volume. Similar to the embodiment discussed in relation to FIGS. 1-3 , artificial nucleus 40 can undergo numerous repetitions of the foregoing cycle.
[0071] FIGS. 7-9 illustrate artificial disc 60 in cross section. Artificial disc 60 comprises microsphere reservoir 65 and hydrogel 67 . Upon application of multidirectional load 70 , as illustrated in FIG. 8 , pressure forces water from hydrogel 67 into the interior of microsphere reservoir 65 . Consequently, the volume of artificial disc 60 decreases. The extent to which water is forced into the interior of microsphere reservoir 65 depends upon the magnitude of the load applied.
[0072] Upon removal of load 70 , as illustrated in FIG. 9 , dehydrated hydrogel 67 “pulls” water from the interior of microsphere reservoir 65 , and is thereby rehydrated. Similar to the embodiment discussed in relation to FIGS. 1-6 , artificial disc 60 can undergo numerous repetitions of the foregoing cycle.
[0073] FIG. 10 illustrates an embodiment similar to that discussed above in relation to FIGS. 7-9 . However, the example of FIG. 10 illustrates a greater concentration of microspheres 80 within hydrogel matrix 84 of microsphere reservoir 85 than the example of FIGS. 7-9 .
[0074] Desirable materials for use in the manufacture of elastic bags and/or impermeable reservoirs include, by way of example, polymers, elastomeric, viscoelastic, super elastic polymers and shape memory polymers.
[0075] While all of the foregoing embodiments can most advantageously be delivered in a minimally invasive, percutaneous manner, the foregoing embodiments may also be implanted surgically. Further, while particular forms of the invention have been illustrated and described above, the foregoing descriptions are intended as examples, and to one skilled in the art it will be apparent that various modifications can be made without departing from the spirit and scope of the invention.
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Devices and methods for manufacturing devices for treating degenerated and/or traumatized intervertebral discs are disclosed. Artificial discs and components of discs may include an artificial nucleus and/or an artificial annulus and may be comprised of shape memory materials synthesized to achieve desired mechanical and physical properties. An artificial nucleus and/or annulus according to the invention may comprise a first and second reservoir and one or more fluids, wherein upon application of a load upon the artificial nucleus and/or disc, the one or more fluids enters said second reservoir from said first reservoir.
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FIELD OF THE INVENTION
The present invention relates to a novel rubber-like crosslinked molded polymer article and a process for producing said article More particularly, the invention relates to a rubber-like crosslinked molded polymer article produced by the simultaneous metathesis polymerization and molding of a metathesis polymerizable monomer having a specific composition in the presence of a specific plasticizer, and a process for producing said molded article.
BACKGROUND OF THE INVENTION
The production of rubber-like polymers has been investigated over the past years. Ring-opening metathesis polymerization of cyclopentene yields a linear polymer known by a common name of polypentenamer having a structure similar to that of poly-1,4-pentadiene, but having slightly lower double bond density in the main chain. The polymer has properties to enable the use as a general-purpose rubber, as can be supposed from its structure.
In order to obtain a rubber having characteristic features, a metathesis polymer of norbornene, which has high ring strain and is easily polymerizable by metathesis polymerization, has been industrially produced. Since the glass transition point of poly(norbornene) is higher than normal room temperature and slightly lower than 40° C., the polymer is not rubbery, but plastic at normal room temperature. However, transition to a rubbery state takes place by slight heating of the polymer and the use of the polymer as a shape-memory polymer has been suggested to take advantage of the transition property. On the other hand, to make the polymer useful as a rubber, a rubber processing oil is added to the polymer to lower the apparent glass transition point and the polymer is crosslinked by conventional vulcanization to obtain a rubber. The rubber produced by the above process is used in various applications as a rubber having low resilience.
On the other hand, a process has been proposed to form a molded polymer article by using a low cost metathesis polymerizable cycloolefin having two metathesis polymerizable cycloolefin groups, for example dicyclopentadiene (DCPD), and carrying out the polymerization and molding of the cycloolefin in a mold (in one step) with a metathesis polymerization catalyst. More particularly, a process has been proposed to obtain a molded polymer article, taking advantage of the fact that a metathesis polymerization catalyst system is composed of two components, i.e. a catalyst component such as a tungsten chloride and an activator component such as an alkylaluminum. Two solutions each containing one of the above catalyst system components and monomer, are quickly mixed and transferred into a mold (for example, U.S. Pat. No. 4,400,340) where polymerization and shaping take place.
Such a process is attractive for producing a crosslinked molded polymer article because the molding can be carried out at a high speed simultaneously with polymerization, using a low-pressure, relatively inexpensive mold. The polydicyclopentadiene produced by this process is generally a plastic having a thermal deformation temperature of 90° C. or higher.
SUMMARY OF THE INVENTION
In accordance with the present invention the above process can be used for producing a molded article of a polynorbornene-type rubber without using a vulcanization step. More particularly, a plasticized rubber-like molded article having crosslinked norbornene units can be produced at a high speed in one step by the metathesis polymerization of a proper mixture of a cycloolefin which forms a linear polymer, e.g. norbornene, and a cycloolefin which forms a polymer having crosslinked structure, e.g. the above-mentioned dicyclopentadiene, in the presence of a high-boiling liquid hydrocarbon. Accordingly, the present invention is a rubber-like crosslinked molded polymer article that comprises
(a) a metathesis polymer consisting essentially of
(i) 95-20 mol % of recurring units derived from at least one norbornene derivative expressed by the formula ##STR1## wherein R 1 and R 2 are, independently, groups selected from hydrogen atoms, halogen atoms, and hydrocarbon groups having a carbon number of 3 or less and optionally containing halogen-substitution and wherein R 1 is bonded to the ring by a single or a double bond, and
(ii) 5-80 mol % of recurring units derived from at least one cycloolefin having two strained cycloolefin groups and having a metathesis polymerizability comparable to that of the norbornene derivative of (i); and
(b) at least one high-boiling liquid hydrocarbon or partially halogenated liquid hydrocarbon in an amount sufficient to plasticize said polymer and lower its apparent glass transition point to or below normal room temperature.
DETAILED DESCRIPTION OF THE INVENTION
Additionally, the invention is directed to a process for producing a rubber-like crosslinked molded polymer article by carrying out the metathesis polymerization and molding of
(a) a metathesis polymerizable monomer mixture consisting essentially of
(i) 95-20 mol % of at least one norbornene derivative expressed by the formula ##STR2## wherein R 1 and R 2 are, independently, groups selected from hydrogen atoms, halogen atoms, and hydrocarbon groups having a carbon number of 3 or less and optionally containing halogen-substitution and wherein R 1 is bonded to the ring by a single bond or a double bond, and
(ii) 5-80 mol % of at least one cycloolefin having two strained cycloolefin groups and having a metathesis polymerizability comparable to that of the norbornene derivative of (i) in the presence of
(b) at least one high-boiling liquid hydrocarbon or partially halogenated high-boiling liquid hydrocarbon in an amount sufficient to plasticize the polymer produced by the metathesis polymerization of said monomer mixture and lower its apparent glass transition point to or below normal temperature.
The vulcanization molding of rubber is a special process which generally necessitates a kneading process to incorporate a vulcanizing agent, followed by a vulcanization treatment for a relatively long period in a heated mold. The present invention, by effecting polymerization, crosslinking and molding in a single step makes possible the production of a molded rubber article having characteristic rubber properties in one step at a high speed.
The norbornene compound used in the present invention is expressed by the following formula ##STR3## wherein R 1 and R 2 are as previously mentioned. The bond between the group R 1 and the norbornene ring is shown by ---, which indicates that the bond may be a single bond or a double bond.
Preferred examples of the norbornenes include norbornene (R 1 ═R 2 ═H)
5-methylnorbornene (R 1 ═--Ch 3 and R 2 ═H)
5-ethylnorbornene (R 1 ═--C 2 H 5 and R 2 ═H)
5-(chloromethyl)norbornene (R 1 ═--CH 2 Cl and R 2 ═H)
5-(ethylidene)norbornene (R 1 ══CH--CH 3 and R 2 ═H)
5-chloronorbornene (R 1 ═--Cl and R 2 ═H) and
5,6-dimethylnorbornene (R 1 ═--CH 3 and R 2 ═--CH 3 ).
Among the above compounds, norbornene, 5-methylnorbornene and 5-ethylidenenorbornene, and, especially, norbornene is preferable taking into consideration the availability of raw materials.
As mentioned above, the groups R 1 and R 2 may be an acyclic olefin group having a carbon number of 3 or less except that such a group must be attached to the norbornene ring via its double bond, i.e. the group cannot be vinyl (--CH═CH 2 ) or propenyl (--CH═CH--CH 3 or --CH 2 --C═CH 2 ) as these groups act as chain-transfer agents to lower the molecular weight of the polymer during metathesis polymerization.
The norbornene compounds can be produced by the Diels-Alder reaction of cyclopentadiene with corresponding olefins such as ethylene, propylene, butylene, butadiene, pentene-1, allyl chloride, vinyl chloride, butene-(2) and the like. Ethylidenenorbornene can also be produced by the isomerization of vinylnorbornene which is a Diels-Alder addition product of cyclopentadiene and butadiene. Ethylnorbornene can be produced by the partial reduction of vinylnorbornene.
The cycloolefin having two strained cycloolefin groups and having a metathesis polymerizability comparable to that of the norbornene compound is, for example, a compound containing a norbornene group and a second cycloolefin group having a number of ring structure members to cause ring strain wherein the strain of the second cycloolefin group is increased by the condensation of said group with the norbornene ring or one or more other rings between it and the norbornene ring. Typical examples of rings having the number of members to cause straining of the ring are the 4-membered ring and the 5-membered ring, especially the 5-membered ring. In other word, the preferred group is composed of a norbornene which is further condensed with another ring for example a 4-membered ring or 5-membered ring, to form a cycloolefin compound having the above two strained cycloolefin groups.
To assist the understanding of the above, an explanation is shown by the following simplified formulas.
The norbornene ring structure (1) of the following formula (i) is a group containing a cyclopentene ring condensed with another ring at its 3,5-sites. ##STR4## The structure (2) of the following formula (ii) is a group containing a cyclopentene ring condensed with another ring at its 3,4-sites. ##STR5##
The cycloolefin compound to be used in the present invention is a compound containing two groups selected from either one or both of the structure (1) and (2) expressed by the above formulae (i) and (ii).
The cycloolefin compound may also have short side chains having a carbon number of 1-3 and can, optionally, contain halogen substitution.
Dicyclopentadiene is especially preferable as such cycloolefin compound from the viewpoint of its performance and availability.
As can be seen from the following formula (iii), dicyclopentadiene contains each of the above structures (1) and (2). ##STR6##
The cycloolefin compounds also include oligocyclopentadienes having a higher degree of condensation than dicyclopentadiene, such as, e.g. tricyclopentadiene. These oligocyclopentadienes are generally produced as a thermal equilibrium mixture with dicyclopentadiene or by thermal polymerization of cyclopentadiene or dicyclopentadiene and, accordingly, they may be used as an equilibrium mixture with dicyclopentadiene. The cycloolefin compounds further include 1,4-,5,8-dimethano-1,4,4a,5,8,8a-hexahydrona-ohthalene, 1,4-,5,8-,9,10-trimethano-1,4,4a,5,8,8a,9,9a,10,10a-decahydroanthracene and the like The above cycloolefin compounds are generally used in combination with dicyclopentadiene.
As mentioned before, dicyclopentadiene is especially preferred as the cycloolefin compound having metathesis polymerizability comparable to that of norbornene.
The term "liquid" in reference to the high-boiling liquid hydrocarbons or partially halogenated compounds used in the present invention means that the material is substantially fluid at room temperature or thereabout. However, the term "liquid" further includes a material which is solid by itself but has extremely high miscibility with the above norbornene--cycloolefin copolymer and acts as a plasticizer when mixed with the copolymer.
The term "high-boiling" means that the rate of evaporation of the hydrocarbon or partially halogenated hydrocarbon from the rubber-like molded polymer article in use is within a practically permissible range. The boiling point of the hydrocarbon depends upon the required practical conditions and is generally at least 200° C., preferably at least 250° C., and most preferably at least 300° C. under normal pressure. Hydrocarbons having carbon number of 12 or more generally meet the above requirement.
Any kind of hydrocarbons such as paraffinic, naphthenic or aromatic hydrOcarbons can be used in the present invention so long as the hydrocarbon meets the above conditiOns. Aliphatic substituted aromatic compounds or aliphatic substituted alicyclic compounds are generally preferred. Aliphatic substituted aromatics are especially preferred.
Materials commercially available as process oils for oil extension of a rubber generally correspond to the above description. Various kinds of process oils such as e.g. paraffin-rich oil, naphthene-rich oil, and aromatic-rich oil are commercially available products that can be employed.
Materials produced for other purposes which meet the requirements of the hydrocarbons of the present invention are also usable in the present process. Certain kinds of thermal media and intermediates for synthetic detergents are examples of such materials. These materials include, among others, triethylbiphenyl, trimethyldiphenylethane, dipropylnaphthalene, dodecylbenzene, didodecylbenzene, dodecylnaphthalene and mixtures thereof.
Partially halogenated hydrocarbons can be used in the present invention because of increased polarity, improved affinity with the metathesis polymer, increased boiling point and, in some casee, ability to impart flame-retardancy depending upon the halogen content. The partially halogenated compounds generally mean compounds obtained by substituting a portion of the hydrogen atoms in the aliphatic, alicyclic or aromatic group by adding halogen to unsaturated bonds in the above compound The halogen is generally chlorine or bromine and the halogen content is usually 15-75 wt. %, especially 25-55 wt. %.
Examples of the partially halogenated compounds are chlorinated paraffin, chlorinated dodecylbenzene, and brominated dodecylbenzene.
The above-mentioned norbornenes, cycloolefin compounds, high-boiling liquid hydrocarbons or partially halogenated liquid hydrocarbons should have the lowest possible content of impurities capable of reacting with the components of a metathesis polymerization catalyst system because these compounds are present together with the metathesis polymerization catalyst system during the metathesis polymerization process.
The sensitivity to impurities is different between the catalyst component and the activator component of the metathesis polymerization catalyst system. Accordingly, in the case of the polymerization and molding process wherein the catalyst component and the activator component are divided into separate solutions that are injected into a mold immediately after mixing, the substantial inhibitory action due to impurities can sometimes be prevented by adding the process oil to one or the other of the two solutions depending upon the kind of impurity existing in the compound and which component will be adversely affected by the impurity.
The ratios of the norbornenes, cycloolefin compounds and hydrocarbons or their halogenated compounds or partially halogenated compounds to be used in the present invention are essentially as follows.
The molar ratio of the norbornene compound to the cycloolefin compound is from 95:5 to 20:80 as mentioned previously. Since the glass transition point of a metathesis copolymer of a norbornene compound and a cycloolefin compound is generally normal room temperature or above, the liquid hydrocarbon or partially halogenated liquid hydrocarbon is used in an amount to reduce the glass transition point to a point not higher than normal room temperature and preferably not higher than the lower limit of the working temperature range anticipated for the specific rubber-like molded polymer article being manufactured. Accordingly, the amount of the liquid hydrocarbon or partially halogenated liquid hydrocarbon depends upon the specific compound, the monomer composition of the polymer, and the working temperature range of the rubber-like molded polymer article.
Addition of too much of the liquid hydrocarbon, or partially halogenated liquid hydrocarbon, sometimes induces blooming of the liquid on the surface of the molded articles and causes practical problems. It is necessary to select the optimum composition by correlating the kinds and amounts of the norbornenes and cycloolefin compounds with the kinds and amounts of the liquid hydrocarbons or partially halogenated liquid hydrocarbons according to the required working temperature range and the properties of the molded article.
The amount of the cycloolefin compound (e.g. DCPD) in the monomer mixture generally has influence upon crosslinking density to exert a remarkable effect on the modulus and elongation of a rubber-like elastomer. The kind of the norbornene compound has an influence upon the properties of a flexible chain segment and, accordingly, upon the modulus, elongation, residual strain, and other properties of the elastomer.
On the other hand, the type of liquid hydrocarbon or partially halogenated liquid hydrocarbon has an influence upon the compatibility with the copolymer of the norbornene compound and the cycloolefin compound. Accordingly, it is necessary to pay attention to the maximum amount of addition to keep the mixture from phase-separation and to the coagulation temperature of the mixture because the phase-separation and coagulation at the lower limit of the working temperature deteriorates the properties of the polymer. Furthermore, the resilience or, conversely, the vibration-damping property, is also influenced by the composition and structure. A molded article rich in ring-structure generally tends to have low resilience.
The optimum composition is selected according to the required properties taking the above-mentioned factors into consideration.
The molar ratio of the norbornene compound to the cycloolefin compound is preferably from 80-20 to 40-60 and the concentration of the liquid hydrocarbon or the partially halogenated liquid hydrocarbon is 10-60 wt. %, more preferably 20-50 wt. % based on the total weight of the metathesis polymerizable components plus the high-boiling hydrocarbon components.
In addition to the above monomers, the composition of the present invention may contain other metathesis polymerizable cycloolefin compounds which do not meet the description cited above as items (a) (i) and (a) (ii) of the main copolymer composition, so long as such compounds have metathesis polymerizability comparable to that of norbornene. The other metathesis polymerizable cycloolefins must be used in an amount not sufficient to deteriorate the properties of the rubber. Examples of the other cycloolefin compound are 1,4-,5,8-dimethano-1,4,4a,5, 6,7,8,8a-octahydronaphthalene, and norbornadiene.
The recurring unit in the polymer of the present invention derived from the norbornene compound has the following structure: ##STR7## wherein R 1 and R 2 are the same groups mentioned before.
The recurring unit derived from dicyclopentadiene which is cited as an example of cycloolefin compounds having two strained cycloolefin groups and having a metathesis polymerizability comparable to that of the norbornenes in the polymer of the present invention has, for example, the structure of the following formulas. ##STR8##
The recurring unit derived from a cycloolefin compound other than dicyclopentadiene, having two strained cycloolefin groups and having a metathesis polymerizability comparable to that of the norbornenes in the polymer of the present invention similarly has the structure which can be easily determined from the structure of the monomer.
The polymer of the present invention contains linear segments resulting from repeating unite of A and B with periodic crosslinks resulting from the structure C and is plasticized with the liquid hydrocarbons or partially halogenated liquid hydrocarbons to form a rubber-like molded article.
The catalyst component of the metathesis polymerization catalyst system used in the production of the molded polymer article of the present inventiOn are salts such as halides of tungsten, rhenium, tantalum, molybdenum and the like with tungsten compounds being especially preferred. Among tungsten compounds are preferred tungsten halides, tungsten oxyhalides and the like. More particularly, tungsten hexachloride and tungsten oxychloride, etc., are preferred. However, such tungsten salt compounds undesirably initiate cationic polymerization substantially immediately when added directly to said monomer. It is, therefore, preferable that the tungsten salt compounds be previously suspended in an inert solvent such as benzene, toluene or chlorobenzene and solubilized by the addition of a small amount of an alcoholic compound or a phenolic compound.
A Lewis base or a chelating agent is preferably added to the catalyst in an amount of about 1-5 mol per 1 mol of the tungsten compound in order to prevent undesirable polymerization. Those additives may include acetylacetone, acetoacetic acid alkyl esters, tetrahydrofuran, benzonitrile and the like.
Following such treatment, the monomer solution (Solution A) containing the catalyst component has sufficiently high stability for practical use. Ammonium tungstate compounds or ammonium molybdate compounds may also be used. These compounds do not require the solubilization treatment or the inactivation step as they are substantially less active than the halide salts.
The activator components of the metathesis polymerization catalyst system include organo-metallic compounds chiefly comprising alkylated compounds of metals of group I--group III in the periodic table, preferably, alkylaluminum compounds, alkylaluminum halide compounds and trialkyltin hydrides such as diethylaluminum chloride, ethylaluminum dichloride, trioctylaluminum, dioctylaluminum iodide and tributyltin hydride. The organometallic compound used as the activator component i.e. dissolved in the monomer mixture to form a monomer solution containing activator component (Solution B).
According to the present invention, in principle, the molded polymer articles are produced by mixing the Solution A with the Solution B. The polymerization reaction, however, starts very rapidly when the above-mentioned composition is used and, consequently, undesirable initiation of hardening often occurs before the mold is completely filled with the mixed solution. In order to overcome the problem, it is preferable to use a polymerization moderating agent to delay onset of polymerization.
As such moderators are generally used Lewis bases, particularly, ethers, esters, nitriles and the like. Examples of the moderators include ethyl benzoate, butyl ether, diglyme and the like. Such moderators are generally added to the solution containing the activator component comprising organometallic compound. When using the ammonium tungstate or molybdenum compounds, an alkyl alcohol is generally employed as the moderator.
When a tungsten compound is used as the catalyst component, the ratio of the tungsten compound in the metathesis polymerization catalyst system to the above-mentioned monomers is about 1000:1 - about 15000:1, and preferably about 2000:1 on molar basis. When an alkyl-aluminum compound is used as the activator component, the ratio of the aluminum compound to the above-mentioned monomers is about 100:1 - about 2000:1 and preferably around a ratio of about 200:1 - about 500:1 on molar basis. The amount of the moderator may be adjusted by experiments depending upon the amount of the catalyst system.
In order to decrease the residual monomer content, a small amount of an active halogen compound such as trichloromethyltoluene, ethyl trichloroacetate, isophthaloyl chloride or an acid anhydride such as benzoic anhydride may be added in the production of the rubber-like molded polymer article of the present invention. The residual monomer may have the action of a plasticizer in the polymer molded article of the present invention, however, the content of the residual monomer is preferably as low as possible because of the characteristic smell and volatility of monomers of the class employed.
A variety of additives may be used practically in the rubber-like crosslinked polymer molded article of the present invention to improve or to maintain characteristics of the molded articles. The additives include fillers, pigments, antioxidants, light stabilizers, flame retardants, macromolecular modifiers and the like. These additives are to be added to the starting solutions, since they cannot be added after the solutions are polymerized to the crosslinked molded polymer article.
Additives may be added to either one or both of Solution A and the Solution B. The additives should be substantially unreactive with the highly reactive catalyst component, activator component and other components of the solutions to avoid practical troubles such as an inhibitory action on polymerization. If a reaction between the additive and the catalyst component or the activator component is unavoidable but does not essentially inhibit the polymerization, the additives can be mixed with a proper combination of the monomers, the above liquid hydrocarbons or partially halogenated liquid hydrocarbons to prepare a third solution, which is mixed with the first and second solutions immediately before polymerization. When the additive is a solid filler forming gaps which can be filled sufficiently with both solutions immediately before or during the polymerization reaction, the mold may be filled with the filler prior to charging the reactive solutions into the mold.
The fillers used as additives are preferably those effective in improving abrasion resistance and fatigue resistance. They include carbon black, fine silica particles and the like. In some cases, the fillers are surface-treated e.g. with a so-called silane coupler as required. Furthermore, the filler may be a fibrous reinforcing material. Such fibrous reinforcing materials include glass fiber, carbon fiber, polyester fiber, aramid fiber, nylon fiber and the like. These fibers may be used in the form of woven fabric, mat, nonwoven fabric and the like.
The rubber-like crosslinked molded polymer article used in the present invention may also contain an antioxidant. Preferably, a phenolic- or amine-antioxidant is added to the solution in advance. Examples of the antioxidants include 2,6-t-butyl-p-cresol, N,N'-diphenyl-p-phenylenediamine, and tetrakis[methylene- (3,5-di-t-butyl-4-hydroxycinnamate)]methane.
The reactive solutions A and B for the production of the crosslinked molded polymer article by the present invention are preferably introduced into the mold in the form of laminar flow to prevent the inclusion of bubbles. To realize the laminar flow, a proper viscosity corresponding to the injection speed is necessary and the addition of a thickener to either one or both of Solutions A and B is frequently required.
The material usable as the above thickener is a polymer which is soluble in the monomer or in the liquid hydrocarbon or partially halogenated liquid hydrocarbon, is free from inhibitory action to metathesis polymerization, does not cause deterioration of the characteristic properties of the article and, preferably, imparts desirable properties to the article. The polymer usable for the above purpose is preferably a non-crosslinked hydrocarbon elastomer such as styrene-butadiene-styrene triblock rubber, styrene-isoprene-styrene triblock rubber, polybutadiene, polyisoprene, butyl rubber, ethylene-propylene-diene terpolymer and the like.
As described above, the molded polymer articles of the present invention are prepared by simultaneous polymerization and molding The molding method includes, as mentioned above, a resin injection process comprising the proper mixing of a catalyst, a raw material monomer and a plasticizer or, more preferably, mixing of the previously prepared solutions A and B with a static mixer or the like and the injection of the produced premix into a mold and a RIM process comprising the impingement mixing of the solution A and the solution B containing divided catalyst system in a head and the immediate injection of the mixture into the mold. The RIM process is used in general.
In both of RIM process and resin injection process, the mixture can be introduced into the mold under relatively low pressure, so that an inexpensive mold is usable. The temperature in the mold increases rapidly by the heat of reaction upon the start of the polymerization reaction in the mold, and the polymerization reaction is completed in a short time. The molded article of the present invention can be removed easily from the mold without using a releasing agent.
The rubber-like crosslinked molded polymer article of the present invention can be produced, as mentioned above, in one step at high speed by the simultaneous polymerization and molding of a monomer.
Conventional molding of a rubber generally necessitates a kneading step to blend various additives, including a crosslinker, into a green rubber polymer and a separate step to vulcanize and mold the kneaded mixture. The molding efficiency is not high compared with conventional molding process of plastics. The present invention enables the production of a rubber-like molded article from a monomer in one step at high speed.
For the process of such rubber-like molded article, it is already known that a polyurethane rubber can be formed in one step from a prepolymer. Since polyurethane elastomer generally necessitates heat-treatment after molding, the process of the present invention, requiring no heat-treatment, has higher efficiency. The rubber properties of the polymer of the present invention are considerably different from those of the polyurethane rubber as can be supposed from the difference in structures. Although polyurethane is preferable in some uses, the method of the present invention is superior for the production of a low-resilient and low-hygroscopic hydrocarbon rubber and the product is usable in a wide variety of applications making use of these properties.
The molded articles of the present invention are suitable especially as large-sized vibration-damping material or cushioning material having complicated shapes.
Since the rubber-like molded article of the present invention is elastic, it can be easily released forcibly from a mold even if the mold has an overhang. Thus, an article having complicated shape can be produced by the process.
The invention described herein is illustrated in detail by the following Examples. These examples are presented solely for explanation and are not intended to limit the scope of the invention.
EXAMPLES 1-10
Dicyclopentadiene, ethylidenenorbornene and norbornene used in the examples were those of commercially available high-purity grades.
5-Chloronorbornene and 5-methylnorbornene were produced by carrying out the Diels-Alder reaction of cyclopentadiene with vinyl chloride and propylene respectively in an autoclave and purifying the reaction products by distillation. The plasticizers were DUTREX 729HP (aromatic rich) SHELL FLEX 371N (napthene rich) and SHELL FLEX 210 (paraffin rich). All of these are process oils marketed by Shell Oil Co. These oils were used without purification.
20 Parts by weight of tungsten hexachloride was added to 70 parts by volume of anhydrous toluene under nitrogen stream. The obtained mixture was added to a solution consisting of 21 parts by weight of nonylphenol and 16 parts by volume of toluene to obtain a catalyst solution containing 0.5 M of tungsten. The solution was purged with nitrogen overnight to remove the hydrogen chloride gas formed by the reaction of tungsten hexachloride and nonylphenol. A catalyst solution for polymerization was prepared by adding 1 part by volume of acetylacetone to 10 parts by volume of the solution produced by the above procedure.
100 Parts by weight of a monomer mixture composed of a purified norbornene compound and purified dicyclopentadiene and having a composition shown in Table 1 was added with 2 parts by weight of methylene-bis-(4-hydroxy-3,5-di-t-butyl benzene) as an oxidation stabilizer. The obtained solution was added to the above catalyst solution for polymerization in an amount to give a tungsten content of 0.0001 M and a dichlorodiphenylmethane content of 0.0075 M. A process oil was added oil at a ratio shown in Table 1 to obtain a catalyst component solution (Solution A).
A mixed solution of activator for polymerization was prepared by mixing trioctylaluminum, dioctylaluminum iodide and dimethyl ether of ethylene glycol at molar ratios of 85:15:100.
The mixed solution was added to 100 parts by weight of a mixture consisting of the purified norbornene compound and the purified dicyclopentadiene in an amount to give an aluminum content of 0.003 M and a process oil was added to the mixture at a ratio shown in Table 1 to obtain an activator component solution (Solution B).
The mixing ratios of the mixture of the purified norbornene compound and the purified dicyclopentadiene are shown in Table 1.
A molded block of a metathesis polymerized crosslinked polymer having dimensions of 60 mm x 60 mm and a thickness of about 40 mm was produced from the above-prepared solution A and solution B with a small reaction injection molding machine. The liquid temperature and the mold temperature in the injection were 30° C. and 70° C., respectively.
Right circular cylindrical specimens having thickness of 12.70±0.13 mm and diameter of 29.0 mm were cut from the above molded product and the compression set of each specimen was measured under the heat-treatment condition of 70 1° C. and 22 hours in accordance with JIS K6301. The results are also shown in Table 1.
The Table 1 shows that the rubber-like molded articles produced from a monomer in one step at high speed using the solutions having the compositions of Examples 1-10 have small residual strain caused by compression under heating and that the articles can be used in a state subjected to static compression or shearing force.
Comparison of the Examples 1, 4 and 5 shows that the hardness of the obtained rubber-like molded article decreases by increasing the content of the high-boiling liquid hydrocarbon. Accordingly, the hardness of the rubber-like molded article can be arbitrarily selected.
The resilience of the molded article is highly dependent upon the kind of the high-boiling liquid hydrocarbon. Comparison of the Examples 1, 7 and 9 shows that the resilience decreases in the order DUTREX 729HP, SHELL FLEX 371N and SHELL FLEX 210. This decrease corresponds to decreasing cyclic structure content in the oils.
It is clear from the above results that a variety of crosslinked rubber-like molded articles can be produced in one step at high speed by varying the ratio of a norbornene compound and a cycloolefin compound having two strained cycloolefin groups to control the crosslinking density and by varying the type of the high-boiling liquid hydrocarbon or partially hydrogenated liquid hydrocarbon to be used in the process.
TABLE 1__________________________________________________________________________ Example No. 1 2 3 4 5__________________________________________________________________________Norbornene Norbornene Norbornene Ethylidene- Norbornene NorborneneCompound* 80 40 norbornene 80 80(mol %) 70Cycloolefin compound Dicyclo- Dicyclo- Dicyclo- Dicyclo- Dicyclo-having 2 strained pentadiene pentadiene pentadiene pentadiene pentadienecycloolefin groups* 20 60 30 20 20(mol %)High-boiling liquid DUTREX 729 HP DUTREX 729 HP DUTREX 729 HP DUTREX 729 HP DUTREX 729 HPhydrocarbon** 30 30 30 50 70(wt. %)Permanent set (%)*** 26 38 27 35 36Norbornene Norbornene Norbornene 5-Chloro Norbornene 5-MethylCompound* 50 80 norbornene 80 norbornene(mol %) 60 50Cycloolefin compound Dicyclo- Dicyclo- Dicyclo- Dicyclo- Dicyclo-having 2 strained pentadiene pentadiene pentadiene pentadiene pentadienecycloolefin groups* 40 20 40 20 50(mol %) Cyclopenta- diene Trimer 10High-boiling liquid DUTREX 729 HP SHELL FLEX 210 SHELL FLEX 210 SHELL FLEX 371N SHELL FLEX 371Nhydrocarbon** 70 30 30 30 30(wt. %)Permanent set (%)*** 27 24 20 26 29__________________________________________________________________________ *Molar ratio of each compound based on 100 mol of the sum of the norbornene compound and the cycloolefin compound having two strained cycloolefin groups. **Weight % of the highboiling liquid hydrocarbon based on 100 parts by weight of the sum of the norbornene compound, the cycloolefin compound having two strained cycloolefin groups and the highboiling liquid hydrocarbon. ***Measured in accordance with JIS K 6301: Heattreatment condition, at 70° C. for 22 hours.
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An elastic crosslinked metathesis polymer composition is disclosed comprised of a copolymer of a norbornene-type compound which metathesis polymerizes to a linear polymer and a norbornene-type compound having a second double bond of similar reactivity which forms a crosslinked polymer, and a hydrocarbon-based extending oil. Norbornene and dicyclopentadiene are typical comonomers. Polymerization is carried out by a RIM or resin injection molding process.
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FIELD OF THE INVENTION
[0001] This invention relates to stents, and particularly to bioresorbable stents useful in the treatment of strictures and preventing restenosis disorders.
BACKGROUND
[0002] Tubular organs and structures such as blood vessels, the esophagus, intestines, endocrine gland ducts and the urethra are all subject to strictures i.e., a narrowing or occlusion of the lumen. Strictures can be caused by a variety of traumatic or organic disorders and symptoms can range from mild irritation and discomfort to paralysis and death. Treatment is site specific and varies with the nature and extent of the occlusion.
[0003] Life threatening stenoses are most commonly associated with the cardiovascular system and are often treated using percutaneous transluminal coronary angioplasty (PTCA). This process reduces the stricture by expanding the artery's diameter at the blockage site using a balloon catheter. However, three to six months after PTCA, approximately 30% to 40% of patients experience restenosis. Injury to the arterial wall during PTCA is believed to be the initiating event causing restenosis and primarily results from vascular smooth muscle cell proliferation and extracellular matrix secretion at the injured site. Restenosis is also a major problem in non-coronary artery disease including the carotid, femoral, iliac, popliteal and renal arteries.
[0004] Stenosis of non-vascular tubular structures is often caused by inflammation, neoplasm and benign intimal hyperplasia. In the case of esophageal and intestinal strictures, the obstruction can be surgically removed and the lumen repaired by anastomosis. The smaller transluminal spaces associated with ducts and vessels may also be repaired in this fashion; however, restenosis caused by intimal hyperplasia is common. Furthermore, dehiscence is also frequently associated with anastomosis requiring additional surgery which can result in increased tissue damage, inflammation and scar tissue development leading to restenosis.
[0005] Problems with diminished urine flow rates are common in aging males. The most frequent cause is benign prostatic hypertrophy (BPH). In this disease the internal lobes of the prostate slowly enlarge and progressively occlude the urethral lumen. A number of therapeutic options are available for treating BPH. These include watchful waiting (no treatment), several drugs, a variety of so-called “less invasive” therapies, and transurethral resection of the prostate (TURP)-long considered the gold standard.
[0006] Urethral strictures are also a significant cause of reduced urine flow rates. In general, a urethral stricture is a circumferential band of fibrous scar tissue which progressively contracts and narrows the urethral lumen. Strictures of this type may be congenital or may result from urethral trauma or disease. Strictures were traditionally treated by dilation with sounds or bougies. More recently, balloon catheters became available for dilation. Surgical urethrotomy is currently the preferred treatment, but restenosis remains a significant problem.
[0007] Recent advances in biomedical engineering have led to the development of stenting i.e., mechanical scaffolding, to prevent restenosis and keep the previously occluded lumens open. There are two general types of stents: permanent and temporary. Temporary stents can be further subdivided into removable and absorbable.
[0008] Permanent stents are used where long term structural support or restenosis prevention is required, or in cases where surgical removal of the implanted stent is impractical. Permanent stents are usually made from metals such as Phynox, 316 stainless steel, MP35N alloy, and superelastic Nitinol (nickel-titanium).
[0009] Stents are also used as temporary devices to prevent closure of a recently opened urethra following minimally invasive procedures for BPH which typically elicit post treatment edema and urethral obstruction. In these cases, the stent will typically not be covered with tissue (epithelialized) prior to removal.
[0010] Temporary absorbable stents can be made from a wide range of synthetic bio-compatible -polymers depending on the physical qualities desired. Representative bio-compatible polymers include polyanhydrides, polycaprolactone, polyglycolic acid, poly-L-lactic acid, poly-D-L-lactic acid and polyphosphate esters.
[0011] Stents are designed to be deployed and expanded in different ways. A stent can be designed to self expand upon release from its delivery system, or it may require application of a radial force through the delivery system to expand the stent to the desired diameter. Self expanding stents are typically made of metal and are woven or wound like a spring. Synthetic polymer stents of this type are also known in the art. Self-expanding stents are compressed prior to insertion into the delivery device and released by the practitioner when correctly positioned within the stricture site. After release, the stent self expands to a predetermined diameter and is held in place by the expansion force or other physical features of the device.
[0012] Stents which require mechanical expansion by the surgeon are commonly deployed by a balloon-type catheter. Once positioned within the stricture, the stent is expanded in situ to a size sufficient to fill the lumen and prevent restenosis. Various designs and other means of expansion have also been developed. One variation is described in Healy and Dorfman, U.S. Pat. No. 5,670,161. Healy and Dorfman disclose the use of a bio-compatible stent that is expanded by a thermo-mechanical process concomitant with deployment.
[0013] Approximately one-third of all patients undergoing surgery, catheterization or balloon dilation to repair bulbar urethral strictures experience restenosis. In these patients the use of urethral stents has provided satisfactory relief from symptoms. (Badlani, G. H., et al., UroLume® Endourethral Prosthesis for the Treatment of Urethral Stricture Disease: Long-term Results of the North American Multicenter UroLume® Trial . Urology: 45:5, 1993). Currently, urethral stents are composed of bio-compatible metals woven into a tubular mesh or wound into a continuous coil and are inserted endoscopically after opening the stricture by urethrotomy or sequential dilation. The stent is initially anchored in place through radial force as the stent exerts expansion pressure against the urethral wall. With woven stents epithelial cells lining the urethra begin to grow through the stent's open weave between six and 12 weeks after insertion, thereby permanently securing the stent.
[0014] For most patients this is a one time process without complication. However, some men experience post insertion complications including stent migration, excessive epithelialization, and stent encrustation. In some cases excessive epithelial tissue may be resected transurethrally. In other situations stent removal may be necessary. Depending on the condition of the stent, removal procedures range from a relatively simple transurethral procedure to open surgery with excision and urethroplasty. All complications increase patent discomfort and health care costs.
[0015] Recently, a number of bio-compatible, bioresorbable materials have been used in stent development and in situ drug delivery development. Examples include U.S. Pat. No. 5,670,161 (a thermo-mechanically expanded biodegradable stent made from a co-polymer of L-lactide and ε-caprolactone), U.S. Pat. No. 5,085,629 (a bioresorbable urethral stent comprising a terpolymer of L-lactide, glycolide and ε-caprolactone) U.S. Pat. No. 5,160,341 (a resorbable urethral stent made from polylactic acid or polyglycolic acid), and U.S. Pat. No. 5,441,515 (a bio-erodible drug delivery stent and method with a drug release layer).
[0016] The bioresorbable stents discussed in these earlier references are all designed and made from co-polymers, which is in sharp contrast to the use of the blending process of the present invention. The blending aspect of the present invention overcomes disadvantages associated with the prior art co-polymers insofar as it is more cost effective than co-polymerization, which typically must be out-sourced by end product stent manufacturers. The blending process also offers greater versatility insofar as the raw materials used in earlier co-polymeric stents were fixed in design and physical qualities. Any changes in the polymer formulation necessary to improve stent performance using a co-polymerization process can only be accomplished by having new copolymer materials manufactured by the supplier. This often results in excessive delays in product development and significantly increases research and development costs.
[0017] Furthermore, co-polymers of L-lactide and ε caprolactone are typically mostly amorphous and may be more susceptible to hydrolytic decomposition than a blend of poly-L-lactide and poly-ε-caprolactone of similar composition. Additionally, it is more difficult to maintain consistency in the manufacture of co-polymers than homopolymers, resulting in significant batch to batch variation in copolymers.
[0018] Consequently, there remains a need for a self expanding stent with stable and predictable physical characteristics suited for a wide variety of physiological conditions. In particular, there is a need for a stent making process and stent design that can be easily and cost effectively implemented for any number of application requirements.
SUMMARY
[0019] It is an object of the present invention to provide a blended polymeric stent providing short to intermediate-term functional life in vivo.
[0020] It is another objective of the invention to provide a medical device that remains bio-compatible during prolonged intimate contact with human tissue and is fully bioresorbable, thus eliminating the need for costly, painful and potentially damaging post insertion removal.
[0021] Furthermore, it is another object of the present invention to provide a medical device that will temporarily restore, or maintain patency of the male urethra while permitting voluntary urination, thereby liberating the patient from catheterization, permitting voluntary urination, and reducing the risk of catheter associated urinary tract infections.
[0022] These and other objectives not specifically enumerated here are addressed by a self expanding, bioresorable stent and stent making process in accordance with the present invention, which stent may include a tubular-shaped member having first and second ends and a walled surface disposed between the first and second ends. The walled surface may include a substantially helical-shape of woven monofilaments wherein the monofilaments are composed of a blend of bioresorbable, bio-compatible polymers.
[0023] Another embodiment of the present invention may include a bioresorbable stent having a radially self expanding, tubular shaped member which may also expand and contract along its horizontal axis (axially retractable). The stent having first and second ends and a walled surface disposed between the first and second ends. The walled surface may include a plurality of substantially parallel pairs of monofilaments 14 with the substantially parallel pairs of monofilaments woven in a helical shape. The stent is woven such that one-half of the substantially parallel pairs of monofilaments are wound clockwise in the longitudinal direction and one-half of the substantially parallel pairs of monofilaments are wound counterclockwise in the longitudinal direction. This results in a stent having an alternating, over-under plait of the oppositely wound pairs of monofilaments.
[0024] Still another embodiment of the present invention may include a radially expandable, axially retractable bioresorbable stent made from a blend of at least two bio-compatible, bioresorbable polymers injection molded into a substantially tubular shaped device. The injection molded or extruded tubular shape device may have first and second ends with a walled structure disposed between the first and second ends and wherein the walled structure has fenestrations therein.
[0025] According to another aspect of the invention, a method for producing a stent may include blending at least two bioresorbable, bio-compatible polymers in a predetermined ratio to form a blend and producing a monofilament from the blend by an extrusion process. The monofilament may have a diameter between approximately 0.145 mm and 0.6 mm. The monofilaments may be extruded to a draw ratio of between approximately 3.5 to 5.5, preferably about 4.5. The monofilaments may be braided into a substantially tubular device. Then the tubular device may be annealed at a temperature between the glass transition temperature and melting temperature of the blended polymers for between five minutes and 18 hours.
[0026] Additional objects and advantages of the present invention and methods of construction of same will become readily apparent to those skilled in the art from the following detailed description, wherein only the preferred embodiments are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of modification in various respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] A detailed description of the invention is hereafter described by non-limiting examples with specific reference being made to the drawings in which:
[0028] [0028]FIG. 1 depicts a 30 strand version of the bioresorbable stent in accordance with a preferred embodiment of the present invention;
[0029] [0029]FIG. 2 depicts a 48 strand version of the bioresorbable stent in accordance with a preferred embodiment of the present invention;
[0030] [0030]FIG. 3 depicts a bioresorbable stent with fenestrations in accordance with a preferred embodiment of the present invention;
[0031] [0031]FIG. 4 diagramatically depicts the manufacturing method of the first embodiment of the present invention;
[0032] [0032]FIG. 5 diagramatically depicts the manufacturing method of the second embodiment of the present invention;
[0033] [0033]FIG. 6 graphically compares compression resistance of a 48 monofilament stent in accordance with a preferred embodiment of the present invention versus the UroLume® in a first compression cycle in air at ambient temperature;
[0034] [0034]FIG. 7 graphically compares compression resistance of a 48 monofilament stent in accordance with a preferred embodiment of the present invention versus the UroLume® in a second compression cycle in air at ambient temperature with a one minute hold. The stents in this test were held in the fully compressed state for one minute during the first compression-expansion cycle;
[0035] [0035]FIG. 8 graphically compares the self expansion force of a 48 monofilament stent in accordance with a preferred embodiment of the present invention versus the UroLume® in a first compression and expansion cycle in air at ambient temperature with a one minute hold during the first cycle;
[0036] [0036]FIG. 9 graphically compares self expansion force of a 48 monofilament stent in accordance with a preferred embodiment of the present invention versus the UroLume® in a second compression and expansion cycle in air at ambient temperature with a one minute hold during each cycle;
[0037] [0037]FIG. 10 graphically compares compression resistance of a 30 monofilament stent in accordance with a preferred embodiment of the present invention versus the UroLume® in a first compression cycle in air at ambient temperature;
[0038] [0038]FIG. 11 graphically compares compression resistance of a 30 monofilament stent in accordance with a preferred embodiment of the present invention versus the UroLume® in a second compression and expansion cycle in air at ambient temperature with a one minute hold during the first cycle;
[0039] [0039]FIG. 12 graphically compares self expansion force of a 30 monofilament stent in accordance with a preferred embodiment of the present invention versus the UroLume® in a first compression and expansion cycle in air at ambient temperature with a one minute hold;
[0040] [0040]FIG. 13 graphically compares self expansion force of a 30 monofilament stent in accordance with a preferred embodiment of the present invention versus the UroLume® in a second compression and expansion cycle in air at ambient temperature with a one minute hold during each cycle.
DETAILED DESCRIPTION
[0041] A bioresorbable stent 10 , 14 , in accordance with a first embodiment of the present invention comprises either woven monofilaments (FIGS. 1 and 2) or, in a second embodiment 23 an injection molded or extruded fenestrated tube (FIG. 3) formed from blends of at least two bioresorbable, bio-compatible polymers. These polymers may include, but are not limited to poly=L-lactide (PLLA), poly-D,L-lactide (PDLA) and poly-ε-caprolactone (PCL). A preferred polymeric substrate is made by blending PLLA and PCL.
[0042] This stent 10 , 14 , 23 is used for temporary obstruction relief associated with various disease conditions of the bulbar, membranous or prostatic urethra. Moreover, the stent 10 , 14 , 23 is designed to be self-expanding and can be formulated to have different nominal functional lives. As the urothelium covered stent 10 , 14 , 23 reaches the end of its usable life, it is slowly absorbed into the surrounding tissues and metabolized via the tricarboxylic acid cycle and is excreted as carbon dioxide and water. If the stent 10 , 14 , 23 remains uncovered by urothelium, it will slowly disintegrate and be excreted in the urine flow.
[0043] In the first embodiment the stent 10 , 14 is a tubular shaped member having first and second ends 17 , 18 , 17 ′, 18 ′ and a walled surface 19 , 19 ′ disposed between the first and second ends 17 , 18 , 17 ′, 18 ′. The walls are composed of extruded polymer monofilaments woven into a braid-like embodiment. In the second embodiment, the stent 23 is injection molded or extruded. Fenestrations 24 are molded, laser cut, die cut, or machined in the wall of the tube.
[0044] The stent 10 , 14 , 23 is provided as a sterile device that is compressed to a first diameter of between approximately 6 mm to 10 mm and inserted into a reusable delivery tool (not shown) in the operating room immediately before implantation. Once the stent 10 , 14 , 23 is deployed, it self expands outwardly to a variable second diameter conforming to the lumen. The size of the lumen together with the elasticity and circumferential pressure of the surrounding tissues determine the stent's final nominal diameter. The stents' non-compressed, or resting state, diameter, is between approximately 12 mm to 18 mm.
[0045] The method for formulation of the stent 10 , 14 will now be described (FIG. 4). The PLLA and PCL polymers are first dry blended 25 under an inert atmosphere, then extruded in a rod form 26 . In a preferred embodiment of the present invention, granules of PLLA and PCL are dry-blended with a PLLA/PCL ratio of between approximately 80:20 to 99:1, preferably 90:10.
[0046] The blended PLLA and PCL polymer rod is pelletized 27 then dried 28 . The dried polymer pellets are then extruded 29 forming a coarse monofilament which is quenched 30 . The extruded, quenched, crude monofilament is then drawn into a final monofilament 31 with an average diameter from approximately 0.145 mm to 0.6 mm, preferably between approximately 0.35 mm and 0.45 mm. Approximately 10 to approximately 50 of the final monofilaments 31 are then woven 32 in a plaited fashion with a braid angle 12 , 16 from about 100 to 150 degrees on a braid mandrel of about 3 mm to about 30 mm in diameter. The plaited stent 10 , 14 is then removed from the braid mandrel and disposed onto an annealing mandrel having an outer diameter of equal to or less than the braid mandrel diameter and annealed 33 at a temperature between about the polymer-glass transition temperature and the melting temperature of the polymer blend for a time period between about five minutes and about 18 hours in air, an inert atmosphere or under vacuum. The stent 10 , 14 is then allowed to cool and is then cut 34 .
[0047] The manufacturing flow chart of stent 23 is presented in FIG. 5. In the first step 37 a blend is made of PLLA and PDLLA in a ratio of between approximately 50:50 to 70:30, preferable 60:40. The blending is done in an inert atmosphere or under vacuum. The blended PLLA and PDLLA is extruded in rod form 38 , quenched 38 , then pelletized 39 . Typically, the polymer pellets are dried 40 , then melted in the barrel of an injection molding machine 41 and then injected into a mold under pressure where it is allowed to cool and solidify 42 . The stent is then removed from the mold 43 . The stent tube may, or may not, be molded with fenestrations in the stent tube.
[0048] In a preferred embodiment of the fenestrated stent 23 the tube blank is injection molded or extruded, preferably injection molded, without fenestrations. After cooling, fenestrations are cut into the tube using die-cutting, machining or laser cutting, preferably laser cutting 43 a . The resulting fenestrations, or windows, may assume any shape which does not adversely affect the compression and self-expansion characteristics of the final stent.
[0049] The stent is then disposed on an annealing mandrel 44 having an outer diameter of equal to or less than the innner diameter of the stent and annealed at a temperature between about the polymer-glass transition temperature and the melting temperature of the polymer blend for a time period between about five minutes and 18 hours in air, an inert atmosphere or under vacuum 44. The stent 23 is allowed to cool 45 and then cut as required 46 .
[0050] The blends of PCL, PLLA, and PDLLA made in accordance with the present invention have been found to provide improved processability and stability versus a co-polymerization process. Without intending to be bound by this theory, one possible explanation for the improvements can be attributed to the difference in physical states in which the individual polymers exist once combined. Typically, co-polymers are mostly amorphous compositions, but blends of PLLA and PCL may exist as different size semicrystalline domains of each polymer with a greater percentage of PCL at the surface. Morphology of both domains may be manipulated by thermal treatments. This increased concentration of PCL at the surface is believed to contribute to the blended composition's increased resistance to hydrolytic attack. Control over the morphology of the final polymer blend is an advantage to providing the improved physical and biological properties of the stent.
[0051] The stent's 10 , 14 , 23 mechanical properties and strength generally increase proportionally with the molecular weight of the polymers used. The optimum molecular weight range is selected to accommodate processing effects and yield a stent with desired mechanical properties and in vivo degradation rate. The preferred PLLA raw material of the stent 10 , 14 , 23 should have an inherent viscosity of approximately ≧4.5 dl/g (preferably ≧8.0 dl/g) and a number average molecular weight of approximately 450,000 daltons or greater (preferably ≧750,000 daltons). The preferred PCL raw material of the stent 10 , 14 , should have an inherent viscosity of approximately ≧1.6 dl/g (preferably ≧3.0 dl/g) and a number average molecular weight of approximately 100,000 daltons or greater (preferably ≧200,00 daltons). The preferred PDLLA raw material should have an inherent viscosity of ≧3.0 dl/g (preferably ≧5.0 dl/g) and a number average molecular weight of approximately 100,000 daltons or greater (preferably ≧500,000 daltons). Inherent viscosity is determined under the following standard conditions: 0.1% solution in chloroform at 25° C. using a Cannon-Fenske capillary viscometer.
[0052] Two physical qualities of the polymer or polymer blend used to fabricate the stent 10 , 14 , 23 play important roles in defining the overall mechanical qualities of the stent 10 , 14 , 23 : tensile strength and tensile modulus. Tensile strength is defined as the force per unit area at the breaking point. It is the amount of force, usually expressed in pounds per square inch (psi), that a substrate can withstand before it breaks, or fractures. The tensile modulus, expressed in psi, is the force required to achieve one unit of strain which is an expression of a substrate's stiffness, or resistance to stretching, and relates directly to a stent's self-expansion properties.
[0053] The PLLA and PCL blend in the woven embodiment possesses a tensile strength in the range from about 40,000 psi to about 120,000 psi with an optimum tensile strength for the stent 10 , 14 , of approximately between 60,000 to 120,000 psi. The tensile strength for the fenestrated stent 23 is from about 8,000 psi to about 12,000 psi with an optimum of about 8,700 psi to about 11,600 psi. The tensile modulus of polymer blends in both embodiments ranges between approximately 400,000 psi to about 2,000,000 psi. The optimum range for a stent application in accordance with the present invention is between approximately 700,000 psi to approximately 1,200,000 psi for the woven embodiment and approximately 400,000 psi to 800,000 psi for the fenestrated embodiment.
[0054] In one embodiment, thirty spools are wound with monofilament and a 30 strand braid is prepared (FIG. 1). The monofilaments 35 are interwoven in a helical pattern on a round bar mandrel such that one-half of the monofilaments are wound clockwise. Each monofilament intersects 11 the oppositely wound monofilaments in an alternating over-under pattern such that a tubular braid is made with crossing angles 12 between overlapping monofilaments in the longitudinal or axial direction (when the stent 10 is in a non-compressed, resting position) of 100-150 degrees. The braided device is transferred to an annealing mandrel having a diameter equal to or less than the round braiding mandrel. The ends 13 of the braid are compressed or extended to yield the optimum post annealing geometry; then the ends are secured to the annealing mandrel. The device is then annealed by heating the annealing bar and stent to 90° C. for one hour in an inert atmosphere followed by a second heating cycle for 2 hours at 140° C. in the same inert atmosphere. The stent is not allowed to cool between heating cycles. Finally, the stent is cooled, removed from the annealing bar and cut to the desired length. FIG. 4 diagramatically depicts this process.
[0055] In another preferred embodiment the stent 14 is made as described above except that a 24 carrier weave is used to produce a 48 strand device as shown in FIG. 2. Twenty-four monofilament pairs 36 are interwoven in a helical pattern on a round bar mandrel such that one-half of the monofilament pairs are wound clockwise and one-half are wound counter clockwise. Each monofilament pair intersects 15 the oppositely wound monofilament pairs in an alternating over-under pattern such that a tubular braid is made with crossing angles 16 between overlapping pairs of monofilaments in the longitudinal or axial direction (when the stent is in a non-compressed, resting position) of 100-150 degrees.
[0056] In yet another preferred embodiment a non-toxic radio-opaque marker is incorporated into the polymer blend prior to extruding the monofilaments used to weave the stent. Examples of suitable radio-opaque markers include, but are not limited to, barium sulfate and bismuth trioxide in a concentration of between approximately 5% to 30%.
[0057] Two important physical properties required of a self-expanding stent are compression resistance and self-expansion, or radial expansion, force. Compression resistance relates to the stent's ability to withstand the surrounding tissue's circumferential pressure. A stent with poor compression resistance will not be capable of maintaining patency. Self expansion force determines the stent's capacity to restore patency to a constricted lumen once inserted. The combination of self-expansion with resistance to compression are competing qualities and must be carefully considered when a stent is designed. The combination of polymer blending, processing, (including post-weaving annealing) and overall stent design and construction results in a superior stent 10 , 14 , 23 capable of surpassing the best performing metal stents found in the prior art.
[0058] Compression relaxation tests were conducted on an Instron test machine using a specially designed test fixture and a Mylar® collar. The test fixture consisted of a pair of freely rotating rollers separated by a 1 mm gap. The collar was a composite film of Mylar® and aluminum foil. Each 30 mm long stent was wrapped in a 25 mm wide collar and the two ends of the collar were passed together through the gap between the rollers; a pulling force was applied to the ends of the collar, thus compressing the stent radially.
[0059] The raw data of crosshead displacement versus force was treated to obtain the constrained diameter versus force curve of the stent specimen. In this test method, the stent was subjected to two cycles of the following three sequential steps. First, the stent was compressed to 7 mm OD at a controlled speed. This portion of the test characterized the compression resistance of the stent. Second, the stent was held in the compressed state for a given duration, typically one minute. This portion of the test characterized the force decay or loss of recovery force. Third, the constraint on the stent was relaxed at a controlled rate. This portion of the test characterized the self-expansion force of the stent. The test may be conducted in air at room temperature, in water at a set temperature, or in an environmental chamber.
[0060] The 48 monofilament stent 14 in FIG. 2 can be compressed to a nominal diameter of approximately 6 mm to 7 mm and exerts a radial self-expansion force of approximately 18 N after release from the insertion tool. The fully deployed stent 14 expands to a diameter sufficient to restore or maintain patency in the patient. Returning the expanded stent to the fully compressed state requires approximately 25 N of circumferential pressure.
[0061] In another embodiment of the present invention, the 30 monofilament stent 10 can be compressed to a nominal diameter of approximately 6 mm to 7 mm which exerts a radial self-expansion force of approximately 25 N after release from the insertion tool. The fully deployed stent expands to a diameter sufficient to restore or maintain patency in the patient. Returning the fully expanded stent to the fully compressed state requires approximately 35 N of circumferential pressure. These high levels of radial expansion force and resistance to compression are benefits of the manufacturing process and stent design in accordance with the present invention. The all metal UroLume® stent manufactured by American Medical Systems of Minneapolis, Minn. has been tested to have an expansion force of 5 N at 7 mm and withstands 5 N of circumferential pressure at that diameter.
[0062] Furthermore, it was determined that bioresorbable stents 10 , 14 , 23 maybe manufactured in accordance with the present invention which are capable of retaining their initial self-expansion force and resistance to compression for a minimum of up to twelve weeks after deployment.
[0063] [0063]FIG. 6 graphically compares the compression resistance of one embodiment of the present invention (designated CL10-48Strand) with the all metal urethral stent marketed by American Medical Systems under the trademark UroLume®. As illustrated, the present invention demonstrates superior compression resistance throughout the entire range of stent outer diameters (OD). Each stent was subjected to two rounds of compression and expansion to simulate conditions during actual use. The starting point in these two rounds of compression and expansion represents the stent in resting state prior to insertion into the application device. The first compression represents the forces used to compress the device into the applicator. The first expansion and the second compression simulate conditions exerted by and on the stent following release from the applicator and in situ circumferential pressures, respectively. The maximum compression resistance of the UroLume® at 7 mm was 6 N compared with 26 N at 7 mm for the stent made in accordance with the present invention. FIG. 7 compares the same two stents subjected to a second compression test. Similar results were obtained.
[0064] [0064]FIGS. 8 and 9 depict the relative self expansion forces of the UroLume® stent and the 48 strand embodiment of the present invention during the first and second expansion cycles, respectively. At every corresponding diameter over the entire range of both tests the 48 monofilament, polymeric blend of the present invention demonstrated self expansion forces greater than or equal to that of the all metal UroLume® stent.
[0065] [0065]FIG. 10 graphically compares the compression resistance of another embodiment of the present invention (designated CL10-30Strand) with the all metal urethral stent marketed by American Medical Systems under the trade mark UroLume®. As illustrated, the present invention demonstrates superior compression resistance throughout the entire range of stent outer diameters (OD). The maximum compression resistance of the UroLume® at 7 mm was 6 N compared with 35 N at 7 mm for the present invention. FIG. 11 compares the same two stents subjected to a second round of compression tests; similar results were obtained.
[0066] [0066]FIGS. 12 and 13 depict the relative self expansion forces of the UroLume® stent and the 30 monofilament embodiment made in accordance with the present invention. The 30 monofilament, polymeric blend demonstrated self expansion forces greater than or equal to that of the all metal UroLume® stent throughout the entire OD range during both the first and second expansion cycles.
[0067] From the foregoing description, one skilled in the art can readily ascertain the essential characteristics of the invention and, without departing from the spirit and scope thereof, can adapt the invention to various usages and conditions. Changes in the form and substitution of equivalents are contemplated as circumstances may suggest or render expedient, and although specific terms have been employed herein, they are intended in a descriptive sense and not for purposes of limitation. Furthermore, any theories attempting to explain the mechanism of actions have been advanced merely to aid in the understanding of the invention and are not intended as limitations, the purview of the invention being delineated by the following claims.
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A bio-compatible and bioresorbable stent is disclosed that is intended to restore or maintain patency following surgical procedures, traumatic injury or stricture formation. The stent is composed of a blend of at least two polymers that is either extruded as a monofilament then woven into a braid-like embodiment, or injection molded or extruded as a tube with fenestrations in the wall. Methods for manufacturing the stent are also disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject matter of the present invention pertains to computer systems, and more particularly, to an arbitration mechanism which resolves priority of access to a shared bus based on a rotating priority scheme, the scheme being selectively changeable by the user.
2. Description of the Prior Art
In a computer system, various processors and input/output units disposed within the computer system may require access to a common shared data bus at approximately the same time. However, the data bus can handle only one access at a time. Therefore, some mechanism must be utilized to determine which unit and which processor may be granted access to the bus.
Various arbitration mechanisms have been utilized by prior art computer systems. In an article entitled "Performance Analysis of High Speed Digital Buses for Multiprocessing Systems" by W. L. Bain and S. R. Ahuja, Bell Laboratories, Murray Hill, N.J., several arbitration mechanisms are discussed. For example, the article discusses the Static Priority Algorithm, the Fixed Time Slice Algorithm, Dynamic Priority Algorithms including the Least Recently Used Algorithm and the Rotating Daisy Chain Algorithm, and the First Come First Served Algorithm. This article is incorporated by reference into the specification of this application.
Most of the above identified prior art arbitration mechanisms arbitrate based on a fixed priority in descending order. None take into account the following special features: dual level input/output (I/O) requests for preventing I/O timeouts, a rotating, selectively changeable, highest priority at all I/O levels for preventing I/O lockouts, processor bus operation cycle steal requests for preventing processor lockouts, an instruction cache preemptive grant which saves one arbitration cycle, data cache inpage and castout operation in one cycle which saves one arbitration cycle, and Processor Bus Operation (PBO) grants during refresh for utilizing otherwise wasted cycles.
U.S. Pat. No. 4,449,183 to Flahive et al discloses a mechanism for granting access to a shared bus on a "rotating priority basis". However, the arbitration scheme discussed in this patent resembles the rotating daisy chain algorithm referenced above. There is no discussion of the above mentioned special features.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide an improvement for the arbitration mechanisms of the prior art by supplying an arbitration mechanism which comprises a plurality of individual arbiters arranged in a particular configuration that resembles a parallel-like configuration, each arbiter having a request terminal for receiving access request signals and an enable terminal for receiving enabling signals and generating a grant signal, granting access to a shared bus, in response to the request signals and the enabling signal, an enabling signal not being generated for a particular arbiter when an access request signal energizes the request terminal of a higher arbiter in the particular configuration.
It is a further object of the present invention to supply an arbitration mechanism which comprises the plurality of arbiters arranged in the particular configuration, the particular arbiter ranking lower in priority vis-a-vis a higher arbiter in the configuration but higher in priority vis-a-vis a lower arbiter in the configuration, the lower arbiter denying access to the shared bus if any higher arbiter has granted access to the bus.
It is a further object of the present invention to supply an arbitration mechanism which provides a dual level of input/output (I/O) requests, that is, input/output command requests and input/output normal requests.
It is a further object of the present invention to supply an arbitration mechanism which provides a rotating, selectively changeable, priority of access to the shared bus when a plurality of access request signals energize an arbiter, the rotating, selectively changeable, priority of access being supplied by a command rotor attached to the arbiter for providing, to the plurality of access request signals, sequential access to a shared bus in response to the "rotation" of the command rotor.
It is a further object of the present invention to supply an arbitration mechanism which provides for processor bus operation (PBO) cycle steal (CS) requests.
It is a further object of the present invention to supply an arbitration mechanism which generates an instruction cache preemptive access grant, granting access to the shared bus, in the absence of an instruction cache access request, an instruction cache preemptive access grant to the shared bus being developed, even in the absence of an instruction cache access request, when no higher requests and no lower grants are present, no refresh cycle is pending, and arbitration is allowed to continue.
It is a further object of the present invention to supply an arbitration mechanism which provides data cache inpage and castout operation in one arbitration cycle.
It is a further object of the present invention to supply an arbitration mechanism which provides a Processor Bus Operation Cycle Steal (PBO CS) grant during refresh since the granting of the PBO CS request is not dependant upon the existence of a "no refresh pending" signal.
It is a further object of the present invention to supply an arbitration mechanism which grants to a refresh request access to a shared bus, thereby generating a refresh grant signal, in spite of the existence of access request signals energizing the request terminals of higher arbiters in the particular configuration, the refresh grant signal being generated when an allow arbitration signal is developed indicating that arbitration is allowed to continue.
Further scope of applicability of the present invention will become apparent from the detailed description presented hereinafter. It should be understood, however, that the detailed description and the specific examples, while representing a preferred embodiment of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become obvious to one skilled in the art from a reading of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the present invention will be obtained from the detailed description of the preferred embodiment presented hereinbelow, and the accompanying drawings, which are given by way of illustration only and are not intended to be limitative of the present invention, and wherein:
FIG. 1 illustrates a system block diagram of a computer system which incorporates an arbiter logic circuit, the arbitration mechanism of the present invention;
FIGS. 2a through 2c illustrate the construction of the arbiter logic circuit of FIG. 1 according to the present invention, the arbiter logic circuit including command rotors for providing a rotating, selectively changeable, priority for all subunits at all I/O levels and a plurality of individual arbiters for determining if a subunit shall access the shared bus;
FIGS. 3a through 3b illustrate various embodiments of a command rotor illustrated in FIG. 2a;
FIGS. 4A and 4B illustrate an alternate embodiment of the command rotor and the construction of each of said individual arbiters of FIGS. 2a through 2c;
FIG. 5 represents a timing sequence for either an input/output (I/O) request or a Data Cache (D-cache) request;
FIG. 6 represents an instruction cache (I-cache) request timing sequence when a shared facility is not active; and
FIG. 7 represents a normal I-cache grant timing sequence when the shared facility is busy.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a computer system 10, incorporating the arbiter logic circuit of the present invention, is illustrated. In FIG. 1, an instruction processor unit 10a is connected to an instruction cache (I-cache) 10b and a data cache (D-cache) 10c. The instruction cache 10b and the data cache 10c are further connected to a common storage facility 10d and to an input/output interface unit logic circuit (IOIU logic) 10e via a storage bus 10f.A storage control logic circuit 10g is connected to the common storage facility 10d via a control bus 10h and interfaces with the IOIU logic circuit 10e. The IOIU logic circuit 10e further interfaces with an arbiter logic circuit 10i according to the present invention. Refresh logic 10x is disposed within said arbiter logic circuit 10i. The arbiter logic circuit 10i receives access requests from the instruction cache 10b via line 2 and from the data cache 10c via line 1. The IOIU logic circuit 10e is further connected to an input/output interface controller 1 (IOIC 1) 10j, to an input/output interface controller 2 (IOIC 2) 10k, to an input/output interface controller 3 (IOIC 3) 10L, and to an input/output interface controller 4 (IOIC 4) 10m via an adapter bus 10n. The arbiter logic circuit 10i receives access requests from IOIC 1 10j via line 3, from IOIC 2 10k via line 4, from IOIC 3 10L via line 5, and from IOIC 4 10m via line 6. The IOICs 10j, 10k, 10L, and 10m are connected to various I/O subunits 10p, 10q, 10r, and 10s via I/O buses 10t, 10u, 10v, and 10w, respectively. The arbiter logic circuit 10i receives bus adaptor access requests from the storage control logic 10g via line 7, an access request from the refresh logic 10x via line 8, and a PBO CS request from the storage control logic 10g via line 9.
The functional operation of the computer system of FIG. 1 will be described in the following paragraphs with reference to FIG. 1.
The instruction processor unit (IPU) 10a executes instructions stored in the instruction cache 10b utilizing data stored in the data cache 10c. The results of the execution of the instructions are stored in the common storage facility 10d. If it is necessary to transfer the results to various ones of the I/O subunits 10p, 10q, 10r, and 10s, the results are retrieved from the common storage facility 10d by the storage control logic 10g and are transferred to the adapter bus 10n via the IOIU logic 10e and to the I/O subunits 10p through 10s via the IOICs 10j through 10m. However, the instruction cache 10b, the data cache 10c, and/or one or more of the IOICs 10j through 10m may require access to the shared buses (storage bus 10f, and the adapter bus 10n) simultaneously. Since the shared buses can handle only one access at a time, some arbitration mechanism must be utilized to determine which unit will access the shared bus at a particular point in time. In order to make this determination, a plurality of units needing access, comprising the data cache 10c, the instruction cache 10b, the IOIC 1 10j, the IOIC 2 10k, the IOIC 3 10L, the IOIC 4 10m, the storage control logic 10g and the refresh logic 10x, each generate an access request signal which is directed to the arbiter logic 10i via lines 1 through 9. In accordance with a particular arbitration scheme, the arbiter logic 10i determines which of the plurality of units will access the shared bus. The particular arbitration scheme and the construction of the arbiter logic circuit 10i will be discussed in the paragraphs below with reference to FIGS. 2a through 7 of the drawings.
Referring to FIGS. 2a through 2c, a block diagram representing the construction of the arbiter logic circuit 10i is illustrated.
Referring to FIG. 2a, the arbiter logic circuit 10i comprises a plurality of individual arbiters arranged, in the drawings, in priority order. A first individual arbiter 10i1, first in order of priority relative to other individual arbiters, represents the IOIC command request rotator arbiter. The first arbiter receives command access requests from the IOICs 10j through 10m. A second individual arbiter 10i2, second in order of priority relative to other individual arbiters, represents the IPU bus operation cycle steal request arbiter. The second arbiter receives the processor bus operation (PBO) cycle steal access requests from the storage control logic 10g after decoding an IPU request. A third individual arbiter 10i3, third in order of priority relative to other individual arbiters, represents the IOIC normal request rotator arbiter used for data transfers. This second IOIC level of arbitration prevents the normal data transfers from interfering with the command transfers which could cause device overruns. The third arbiter receives normal requests from the IOIC subunits 10j through 10m.
Referring to FIG. 2b, a fourth individual arbiter 10i4, fourth in order of priority relative to other individual arbiters, represents an I-cache request fixed priority arbiter The fourth arbiter receives access requests from the instruction cache 10b. A fifth individual arbiter 10i5, fifth in order of priority relative to other individual arbiters, represents a D-cache request fixed priority arbiter The fifth arbiter receives access requests from the data cache 10c. A sixth individual arbiter 10i6, sixth in order of priority relative to other individual arbiters, represents a bus adapter, fixed priority, arbiter. The sixth arbiter receives access requests from the storage control logic 10g.
Referring to FIG. 2c, the refresh logic 10x is illustrated. The refresh logic 10x comprises a seventh individual arbiter 10i7, seventh and last in order of priority relative to the other individual arbiters. The seventh arbiter 10i7 represents a refresh arbiter. This arbiter receives refresh access requests for refreshing the common storage facility 10d from the refresh timer located within the arbiter 10i.
Referring to FIG. 2a, the first individual arbiter 10i1 has a request input terminal and an enable input terminal. The request input terminal is connected, in parallel, to each of IOIC's 1 through 4 representing I/O subunits 10p, 10q, 10r, and 10s, respectively, of FIG. 1. The enable input terminal of the first individual arbiter 10i1 is connected to an output terminal of a AND gate 10i1a. The input terminals of the AND gate 10i1a receive the "no refresh pending" input signal and the "allow arbitration" input signal. The AND gate 10i1a has the following truth table: all inputs must be positive for the output to be positive; any inputs which are negative will cause the output to be negative.
The first individual arbiter 10i1 is connected to a first command rotor 10i1b. The command rotor 10i1b stores numbers 1 through 4 corresponding to subunits 1 through 4, respectively, the command requests of which are being input to the request input terminal of the first individual arbiter 10i1. Although the command rotor 10i1b stores, in FIG. 2a, numbers 4, 1, 2, and 3, in sequence, any sequence of numbers may be stored in the command rotor. For example, command rotor 10i1b could easily store numbers 1, 1, 2, 3, or numbers 1, 2, 3, 3, etc. In FIG. 2a, the command rotor 10i1b may be depicted as "rotating". That is, as the command rotor "rotates", numbers 4, 1, 2, 3 will be input to the first individual arbiter 10i1 representing IOIC's 4, 1, 2, and 3, in sequence.
The rotors are not limited to four entries, they may contain any number of entries. The number of entries or slots available will determine the granularity of the percent priority each entry possesses.
The functional operation of the first individual arbiter 10i1 will be described in the following paragraph with reference to FIG. 2a.
Assume that IOIC's command requests are being input to arbiter 10i1 by all four IOIC's 1-4. Therefore, the request input terminal of arbiter 10i1 is receiving four command request signals from IOIC's 1 through 4, respectively. Further, assume that the command rotor 10i1b is positioned as shown in FIG. 2a, that is, the number 4 is being input to arbiter 10i1. This first arbiter 10i1 can be thought of as an arbiter having 4 input request lines but containing 5 levels of fixed descending priority arbitration. The top priority level is determined by the value contained in the rotor 10i1b. If the "no refresh pending" signal and the "allow arbitration" signal are positive (meaning that there is no refresh pending and there is no data transfer operation or refresh operation in progress, which would prohibit arbitration), a positive signal energizes the enable terminal of arbiter 10i1. As the command rotor 10i1b begins to "rotate", IOIC's 4, 1, 2, and 3 are sequentially granted access to the shared bus. Therefore, command request signals corresponding to IOIC's 4, 1, 2, and 3 sequentially energize the shared bus. If either or both of the "no refresh pending" or "allow arbitration" signals are not positive, a negative signal energizes the enable terminal of arbiter 10i1. If a negative signal energizes the enable terminal, IOIC's 1-4 are all denied access to the shared bus.
Access to the shared bus by IOIC's 1-4 via arbiter 10i1 is higher in priority than a PBO cycle steal access request to the shared bus via arbiter 10i2. If IOIC's 1-4 are not requesting access to the shared bus via arbiter 10i1, the PBO cycle steal request via arbiter 10i2 may be granted. The IOIC command requests via arbiter 10i1 have highest priority, among the arbiters of FIGS. 2a-2c, and the PBO cycle steal request via arbiter 10i2 has secondary priority.
The enable terminal of arbiter 10i2 is connected to the output terminal of another AND gate 10i2b having a truth table which is the same as the truth table for AND gate 10i1a. The input terminals of AND gate 10i2b receive the "allow arbitration" signal and the "no IOIC command requests" signal. The "no IOIC command requests" signal represents an output signal from a negative AND gate 10i2a.
It is noted that the IOIC command access requests (IOIC 1 command req, IOIC 2 command req, etc), which energize the request terminal of arbiter 10i1, also energize the input terminals of the negative AND gate 10i2a. Therefore, if any IOIC command request is high, the output of negative AND gate 10i2a is low, whereas, if all IOIC command requests are low, the output of negative AND gate 10i2a is high. The output of AND gate 10i2a is appropriately labelled "+no IOIC command req's". This labelling convention indicates that, if there are no high (active) IOIC command requests energizing the request terminal of arbiter 10i1, the first input terminal of AND gate 10i2b is high. This labelling convention is used throughout the specification of this application. For example, the "+no PBO CS request" signal energizing AND gate 10i3a is high if there is no PBO CS REQUEST signal energizing the request terminal of arbiter 10i2. Throughout the specification, it may be implied that either an inverter or a negative AND gate would be utilized in generating the "no---" signal, as exemplified above, in implementing the labelling convention.
If the "no IOIC command request" signal is positive (meaning that no IOIC command request lines via arbiter 10i1 are active), and the "allow arbitration" signal is positive (meaning that there is no signal which would prevent arbitration from continuing), the enable terminal of arbiter 10i2 is positive, and the PBO cycle steal request is granted access to the shared bus. The "no refresh pending" signal is absent as an input to the enable AND gate 10i2b. As a result, the PBO and Refresh operations are allowed to occur simultaneously.
Arbiter 10i3 receives IOIC 1-4 normal requests for access to the shared bus. If IOIC's 1-4 are not requesting access to the bus via arbiter 10i1, and if a PBO cycle steal request is not requesting access to the bus via arbiter 10i2, arbiter 10i3 may grant to the IOIC's 1-4 access to the bus. The IOIC normal requests via arbiter 10i3 rank third in order of priority, relative to arbiters 10i1 and 10i2. The enable terminal of arbiter 10i3 is connected to an output terminal of AND gate 10i3a. The input terminals of AND gate 10i3a receive the following input signals: "no refresh pending", "no IOIC command request", "no PBO CS request", and "allow arbitration". AND gate 10i3a has a truth table which is the same as that of AND gate 10i1a, that is, all positive inputs yield a positive output; any other combination yields a negative output. A negative signal, energizing the enable terminal of arbiter 10i3, will block all IOIC normal requests from gaining access to the shared bus via the request terminal of arbiter 10i3. A command rotor 10i 3b is connected to the arbiter 10i3 and functions in the same manner as that of rotor 10i1b. Therefore, if a positive signal energizes the enable terminal of arbiter 10i3 (indicating no refresh pending, no IOIC command requests, no PBO cycle steal request, and nothing blocking arbitration), IOIC's 1-4 will be granted access to the bus via arbiter 10i3 in an order defined by the "rotation" of command rotor 10i3b. According to FIG. 2a, in response to a counterclockwise rotation of rotor 10i3b, IOIC's 1-4 will be given highest priority to the bus in the following order: subunits 3, 4, 1, and 2. If the selection for highest priority is not matched with its respective request, the remaining requests are handled in a fixed descending priority order.
In FIG. 2b, arbiter 10i4 receives an I-cache request at its request terminal. If access requests are not being received by arbiters 10i1, 10i2, or 10i3 of FIG. 2a, the I-cache request received by arbiter 10i4 may be granted access to the shared bus, provided the signal being received at the enable terminal of arbiter 10i4 is positive. Arbiter 10i4 ranks fourth in priority relative to arbiters 10i1, 10i2, and 10i3. The enable terminal of arbiter 10i4 is connected to the output of a AND gate 10i4a. The AND gate 10i4a possesses the same truth table as that of AND gate 10i3a. The input terminals of AND gate 10i4a receive the following input signals: "no refresh pending", "no IOIC command requests", "no PBO CS request", "no IOIC normal requests", and "allow arbitration". If any of the input signals being received by AND gate 10i4a are negative, a negative input signal is received at the enable terminal of arbiter 10i4 thereby blocking the I-cache request from gaining access to the shared bus. The output terminal of arbiter 10i4 is connected to an input terminal of the two input OR gate 10i4b. The second input of OR gate 10i4b is connected to the output terminal of AND gate 10i4c. The output terminal of OR gate 10i4b is labeled "I-cache grant". The output terminal of AND gate 10i4c is labeled "I-cache preemptive grant". The input terminals of AND gate 10i4c receive the following signals: "no higher requests", a positive signal indicating that no requests are being received by arbiters 10i1, 10i2, and 10i3; "no lower grants", a positive signal indicating that arbiters 10i5, 10i6 and 10i7, to be discussed below, have not granted access to the shared bus; "no refresh cycle", a positive signal indicating that a refresh cycle is not currently being performed; and "allow arbitration", a positive signal indicating that there are no signals which would prohibit arbitration from continuing. Assume that the enable terminal of arbiter 10i4 is positive and assume that an I-cache request has not yet been received at the request terminal of arbiter 10i4. If the "no higher req" and the "no lower grants" signals are positive, and if the "no refresh cycle" and the "allow arbitration" signals are positive, the AND gate 10i4c generates the "preemptive grant" signal which energizes OR gate 10i4b. An "I-cache grant" signal is generated from OR gate 10i4b. However, an I-cache request has not yet been received by arbiter 10i4. When the I-cache request is received, since the I-cache grant signal is already generated, the I-cache request will be given access to the shared bus on the next, succeeding machine cycle. This preemptive grant saves one machine cycle which improves system performance. (See FIG. 6 which shows the preemptive grant and FIG. 7 which shows the normal grant)
Arbiter 10i5 receives a D-cache request at its request terminal. This represents an access request to the shared bus from the data cache 10c. Arbiter 10i5 may grant the D-cache access request if arbiters 10i1, 10i2, 10i3, and 10i4 are not receiving access requests. Arbiter 10i5 ranks fifth in order of priority relative to arbiters 10i1 through 10i4. The enable terminal of arbiter 10i5 is connected to the output terminal of AND gate 10i5a. The AND gate 10i5a possesses a truth table which is the same as that of AND gates 10i4a and 10i3a. The input terminals of AND gate 10i5a receive the following input signals: "no refresh pending", a positive signal indicating that no refresh is pending; "no IOIC command requests" (see AND gate 10i2b description); "no PBO CS REQ" (see AND gate 10i3a description); "no IOIC normal requests" (see AND gate 10i4a description); "no I-cache request", a positive signal meaning that there is no I-cache request being received by arbiter 10i4; and "allow arbitration", a positive signal indicating nothing is prohibiting arbitration. If all of these signals are positive, a positive signal is received at the enable terminal of arbiter 10i5, and, as a result, the D-cache request, received at the request terminal of arbiter 10i5, is granted access to the shared bus.
Arbiter 10i6 receives a bus adapter access request from the storage control logic 10g at its request terminal. Arbiter 10i6 may grant the bus adapter access request if arbiters 10i1, 10i2, 10i3, 10i4, and 10i5 are not receiving access requests Arbiter 10i6 ranks sixth in order of priority relative to arbiters 10i1 through 10i5. The enable terminal of arbiter 10i6 is connected to an output terminal of the AND gate 10i6a. AND gate 10i6a receives the following input signals: "no refresh pending"; "no IOIC cmd requests" (to arbiter 10i1); "no PBO CS REQ" (to arbiter 10i2); "no IOIC normal requests" (to arbiter 10i3); "no I-cache req" (to arbiter 10i4); "no D-cache req", a positive signal indicating that a D-cache request is not received by the request terminal of arbiter 10i5; and "allow arbitration". If any one or more of the above input signals, energizing AND gate 10i6a, are negative, a negative signal energizes the enable terminal of arbiter 10i6. As a result, the bus adapter request signal from the storage control logic 10g energizing the request terminal of arbiter 10i6 is blocked and denied access to the shared bus.
Referring to FIG. 2c, refresh logic 10x, including arbiters 10i7 and 10i8, is illustrated. In FIG. 2c, arbiter 10i7 receives a refresh request signal at its request terminal. If arbiters 10i1, 10i2, 10i3, 10i4, 10i5, and 10i6 do not receive access requests, arbiter 10i7 may grant the refresh access request if the signal at its enable terminal is positive. Arbiter 10i7 ranks seventh in order of priority relative to arbiters 10i1 through 10i6. The enable terminal of arbiter 10i7 is connected to an output terminal of AND gate 10i7a. AND gate 10i7a possesses the same truth table as that of AND gate 106a and the other AND gates. AND gate 10i7a receives the following input signals: "no IOIC command requests", a positive signal indicating that IOIC's command requests are not received by arbiter 10i1; "no IOIC normal requests", a positive signal indicating that the subunit normal requests are not received by arbiter 10i3; "no I-cache request", a positive signal indicating that an I-cache request is not received by arbiter 10i4; "no D-cache request", a positive signal indicating that a D-cache request is not received by arbiter 10i5; and "allow arbitration", a positive signal indicating that no signal exists which would prevent arbitration from continuing. The enable terminal of arbiter 10i7 is also connected to an AND gate 10i7b via an inverter 10i7c. The other input terminal of the AND gate 10i7b is connected to the refresh request signal which is energizing the request terminal of the arbiter 10i7. The output of the AND gate 10i7b is connected to the set terminal of a set/reset latch circuit 10i7d. The Q output of the latch circuit 10i7d is connected to the request terminal of a further arbiter 10i8. The output terminal of the further arbiter 10i8 is connected to one input terminal of an OR gate 10i9. The other input terminal of the OR gate 10i9 is connected to the output terminal of the arbiter 10i7. The output terminal of the OR gate 10i9, labelled "refresh grant", is connected to the reset terminal of the latch circuit 10i7d. The Q output of the latch circuit 10i7d is labelled "+refresh pending" and the Q bar output of the latch circuit 10i7d is labelled "no refresh pending". This is the signal connected to the enable AND gates of arbiters 10i1, 10i3, 10i4, 10i5, 10i6.
The functional operation of the refresh logic 10x will be described in the following paragraph with reference to FIG. 2c.
If one of the input signals to AND gate 10i7a is negative, the enable terminal of arbiter 10i7 is negative. Therefore, if the "refresh request" signal is energizing the request terminal of arbiter 10i7, it will be blocked and denied access to the shared bus due to the existence of the negative signal at the arbiter's enable terminal. However, the negative signal at the arbiter's enable terminal is inverted via inverter 10i7c, a positive signal energizing one terminal of AND gate 10i7b. The other terminal of AND gate 10i7b is energized with the "refresh request" signal. Therefore, a positive output from the AND gate 10i7b sets the latch circuit 10i7d. A positive Q output signal (the +REFRESH PENDING signal) from the latch circuit 10i7d represents a refresh pending condition (which means that some higher request was active at the same time the refresh request was active and the refresh operation will be delayed until the other operation has completed). As soon as the other operation has completed the "allow arbitration" signal goes active which allows the output of arbiter 10i8 to become active. This output signal is fed to the input of OR gate 10i9 which now causes the refresh grant signal to be generated. Since the "refresh request" signal is only active for one cycle, the latch 10i7d will be set during the time some other storage operation is in progress. The Q-output signal of the latch circuit 10i7d, which generates the +REFRESH PENDING signal, signifies that a refresh operation is pending and will be taken as soon as the "allow arbitration" signal becomes active.
Referring to FIG. 3a, a simple construction of the command rotors 10i1b and 10i3b is illustrated. In FIG. 3a, the command rotor 10i1b and 10i3b may be a simple memory with a pointer addressing the memory. The memory would store the subunit numbers therein. For example, in FIG. 3a, subunit numbers 1 through 4 are stored in the memory. As the pointer addresses the memory, the subunit numbers 1, 2, 3, and 4 are read out in sequence.
Referring to FIG. 3b, a similar simple construction of the command rotors 10i1b and 10i3b is illustrated. In FIG. 3b, the command rotors represent, as in FIG. 3a, a simple memory with a pointer addressing the memory. As the pointer addresses the memory, the subunit numbers stored therein are read out in sequence. However, in FIG. 3b, a different set of subunit numbers are stored in the memory. In fact, any set of subunit numbers may be stored in the memory. Therefore, the set of subunit numbers to be stored in the memory is selectively changeable by the user. In the FIG. 3b embodiment, subunit numbers 1, 2, 2, 3, 3, and 4 are read out in sequence. Consequently, if subunit 3 must be granted access to the shared bus more frequently than subunit 1, or subunit 4, the subunit number 3 should be stored a multiple number of times in the memory. The percentage of top priority grants is established by the number of times a subunits address appears in the memory array. The granularity of the percentage of highest priority is inversely proportional to the number of slots used. In other words, if only four memory slots were used, each subunit would be guaranteed highest priority 25% of the time. If eight slots were used, the percentage would be 12.5 thus giving 37.5% to a subunit having 3 entries.
Referring to FIGS. 4A and 4B, an alternative construction of the command rotors 10i1b and 10i3b is illustrated. Further, a detailed construction of the arbiters 10i1 through 10i8 is illustrated.
In FIGS. 4A and 4B, method of implementing the command rotors 10i1b and 10i3b is shown. Each command rotor comprises a multiplexer b1, a plurality of registers b2 connected to the multiplexer b1, a gate means b3 connected to the multiplexer b1 for selecting one of the registers associated with the plurality of registers b2, and a decoder means b4 for decoding the output of the multiplexer b1 and for energizing the arbiter 10i1 or 10i3. The plurality of registers b2 comprise register b2a, b2b, b2c, . . . , and b2n. The gate means b3 comprises latch circuit b3a, latch b3b, latch b3c, . . . , and latch b3n. The decoder means b4 comprise decoder b4(1), gate b4a, gate b4b, . . . , and gate b4n. Gates b4a through b4n are positive NAND gates. An access request is input to gate means b5 and a final grant is generated from gate means b6. In FIGS. 4A and 4B, One input terminal of each AND gate b5b through b5e and the input of inverter b5a is connected to the output of decoder means b4, and specifically, to the outputs of gates b4a through b4n. Another input terminal of AND gates b5b through b5e are connected to a positive request terminal (+request 1 through +request 4). The positive request terminals represent the request terminal associated with subunits 1 through 4 for arbiters 10i1 and 10i3. Another input terminal of AND gates b5a through b5e are connected to a negative request terminal. The negative requests associated with AND gate b5e (-request 1 through -request 3) represent the enable terminal of the arbiters 10i1 or 10i3. Grants 1 through 4 are generated from latches b5f through b5j via gates b6a through b6h.
Gates b6a, b6b, . . . ,b6d, associated with gates b6e, b6f, . . . ,b6h, receive an input 1DCD, 2DCD, . . . , 4DCD. The inputs 1DCD, 2DCD, . . . , and 4DCD, represent the individual outputs from decoder b4(1)
The functional operation of the command rotor 10i1b or 10i3b in association with an arbiter 10i1 or 10i3 will be described in the following paragraphs with reference to FIGS. 4A and 4B of the drawings
A number is stored in each of the registers b2a, b2b, b2c, . . . ,b2n, each of the numbers representing a particular subunit command request, energizing the request terminal of arbiter 10i1, or representing a particular subunit normal request, energizing the request terminal of arbiter 10i3. Assume that the numbers, stored in these respective registers, are binary numbers "10, 11, 10, . . . , and 01". The numbers are selected from each of the registers b2a, b2b, b2c, . . . , and b2n, in sequence, starting with the binary number 10, by the gate means b3. Latch circuit b3a generates an output signal energizing gate b3 thereby selecting the output from register b2a, latch circuit b3b generating an output signal energizing gate b3 thereby selecting the output from register b2b, etc. In response to this selection, multiplexer b1 generates output signals representing the numbers stored in registers b2a, b2b, b2c, . . . , and b2n, respectively. The decoder b4(1) receives the output signals from the multiplexer b1 and develops corresponding output signals, in sequence, labeled 1DCD, 2DCD, . . . , 4DCD, starting with the "1DCD" output signal. These corresponding output signals developed from the decoder b4(1) sequentially energize a plurality of gates b4a, b4b, . . . , b4n. Each of these gates b4a, . . . ,b4n also simultaneously receive request signals labeled "+request 1, +request 2, . . . , +request 4". These request signals represent the IOIC command request signals energizing the arbiter 10i1 and the IOIC normal request signals energizing the arbiter 10i3. The gates b4a, b4b, . . . , b4n generate an output signal representing the fact that the selected highest priority, determined by the priority register selected by the gate means b3, matched its associated request signal and will therefore be granted access to the shared bus on the next cycle. This "- any highest priority requested" signal energizes inverter b5a which in turn activates the latch b5f. At the same time, gates b5b, b5c, . . . , and b5e will all be deselected by virtue of the negative signal on the first input terminal of each block. The Q output signal from latch b5f energizes one of the inputs of NAND gates b6a, b6b, . . . ,b6d and when ANDed with the same output from the decoder b4(1), signal "1DCD", "2DCD", . . . , or "4DCD", causes one of the gates b6a through b6d to go active. This active signal will energize the associated negative OR gate, b6e, b6f, . . . , b6h and the appropriate grant signal will occur.
If the "- any highest priority requested" signal is inactive, the first input terminal to gates b5b, b5c, . . . ,b5e, will be positive. This will allow the normal descending arbitration for the subunit request signals to occur.
The functional operation of the arbiter logic circuit 10i of FIG. 1, according to the present invention, will be described in the following paragraphs with reference to FIGS. 2a through 2c of the drawings.
Referring to FIG. 2a, assume IOIC's 1 thru 4 command request signals are received at the request terminal of arbiter 10i1, and assume, further, that rotor 10i1b is in the position as shown in FIG. 2a. If the "no refresh pending" signal and the "allow arbitration" signal are both positive, a positive signal energizes the enable terminal of arbiter 10i1. Therefore, as rotor 10i1b "rotates", in the counterclockwise direction, IOIC's 4, 1, 2, and 3 will, sequentially, be granted access to the shared bus.
If a Processor Bus Operation cycle steal request (PBO CS REQUEST) is received by the request terminal of arbiter 10i2, it will be granted access to the shared bus provided the "allow arbitration" signal is positive, indicating that there is no signal which would prevent arbitration, and the "no IOIC command request" signal is positive, indicating there is no IOIC command request signal energizing the request terminal of arbiter 10i1.
If IOIC's 1, 2, 3, and 4 normal request signals energize the request terminal of arbiter 10i3, in accordance with the "rotation" of rotor 10i3b as shown in FIG. 2a, IOIC subunits 4, 1, 2, and 3 will be granted access to the shared bus provided the "no refresh pending" signal is positive, indicating that there is no refresh pending, the "no IOIC command request" signal is positive, indicating there are no IOIC command requests energizing the request terminal of arbiter 10i1, the "no PBO CS request" signal is positive indicating there is no PBO cycle steal request energizing the request terminal of arbiter 10i2, and the "allow arbitration" is also positive, indicating there is no operation in progress which would prevent arbitration from continuing.
If the I-Cache request signal energizes the request terminal of arbiter 10i4, the I-Cache will be granted access to the shared bus provided that the "no refresh pending" is positive, indicating there is no refresh pending, the "no IOIC command request" signal is positive, indicating there are no IOIC command requests energizing the request terminal of arbiter 10i1, the "no PBO CS request" signal is positive indicating there is no PBO cycle steal request energizing the request terminal of arbiter 10i2, the "no IOIC normal request" is positive, indicating there are no IOIC normal requests energizing the request terminal of arbiter 10i3, and the "allow arbitration" is also positive, indicating there is no operation in progress which would prevent arbitration from continuing. There is a second method of generating an I-Cache grant called the I-Cache preemptive grant. It is generated from the 10i4c AND gate if the "no higher requests" signal is positive, indicating arbiters 10i1, 10i2, and 10i3 do not have their respective request terminals active, the "no lower grants" signal is positive, indicating no grants were given to the D-Cache, the Bus Adapter, or refresh, and the "allow arbitration" as well as the "no refresh cycle" signals are positive, indicating that no data transfer operation or refresh operation is in progress.
In FIG. 2b, if the "D-cache request" signal is energizing the request terminal of arbiter 10i5, it will be granted access to the shared bus, and the "D-cache grant" signal will be developed from arbiter 10i5, provided that the "no refresh pending" signal, energizing gate 10i5a, is positive, indicating that there no refresh is pending, the "no IOIC cmd req" signal is positive, indicating that there are no command request signals energizing arbiter 10i1, the "no PBO cs req" signal is positive, indicating that the PBO cs request signal is not energizing arbiter 10i2, the "no IOIC normal req" signal is positive, indicating that there are no normal request signals energizing arbiter 10i3, the "no I-cache req" signal is positive, indicating that an I-cache request signal is not energizing arbiter 10i4, and the "allow arbitration" signal, energizing gate 10i5a, is positive.
If the "bus adapter request" signal is energizing the request terminal of arbiter 10i6, it will be granted access to the shared bus, and the "bus adapter grant" signal will be developed from arbiter 10i6 provided that all higher requests are not energizing the request terminals of arbiters 10i1 through 10i5, and provided that the "no refresh pending" and the "allow arbitration" signals, energizing gate 10i6a, are positive. Each of the signals energizing gate 10i6a must be positive in order to allow the "bus adapter request" signal access to the shared bus.
Referring to FIG. 2c, assume that a refresh request signal is energizing the request terminal of arbiter 10i7. However, assume that one of the signals energizing gate 10i7a is negative (this indicates that a higher request is energizing the request terminal of at least one of arbiters 10i1 through 10i6). Therefore, the signal energizing the enable terminal of arbiter 10i7 is negative, blocking the refresh signal from gaining access to the shared bus. The negative signal, energizing the enable terminal, is inverted via inverter 10i7c, converting it to a positive signal which energizes one terminal of AND gate 10i7b, the other terminal of AND gate 10i7b being energized by the "refresh req" signal. An output from AND gate 10i7b sets latch 10i7d. As a result, an output from the Q output terminal energizes the request terminal of arbiter 10i8. An output signal is generated from arbiter 10i8 when the allow arbitration signal goes active at the end of the operation currently in progress. This signal energizes OR gate 10i9 which causes a "refresh grant signal to be generated." The refresh operation will commence immediately following the termination of the previous operation (the previous operation is causing one of the signals energizing gate 10i7a to be negative). This grant signal from OR gate 10i9 will also force the refresh pending latch 10i7d to be reset
In FIGS. 5 through 7, a set of timing diagrams 1 through 3 illustrate a typical timing sequence of the arbitration process.
In FIG. 5, timing diagram 1 depicts the timing sequence for either an I/O request or a D-Cache request. In cycle 1 the "NO HIGHER REQUEST" signal is positive, meaning no higher request than the current level of request is active, and "ALLOW ARBITRATION" signal is positive, meaning it is safe to arbitrate at the next T0. In cycle 2 the GRANT is given out at T1 to the unit whose request was active at T0. Note also the fact that the I-Cache grant signal is taken away since some other grant was activated during this cycle. The "allow arbitration" signal is deactivated to prevent further arbitration while the current operation is in progress. The requesting unit will continue to sample its grant signal at T3 until it finds the signal active, and will then place its command and address on the shared bus on the following cycle, in this case, cycle 3.
In FIG. 6, timing diagram 2 depicts the I-Cache request timing sequence when the shared facility is not active. The "NO HIGHER REQUEST" signal is positive, meaning no requests are active for devices with higher priority, the "NO LOWER GRANTS" signal is positive, meaning no grant was given to devices lower in priority during that cycle, and "ALLOW ARBITRATION" signal is positive, meaning it is safe to arbitrate on the next T0. In cycle 1, the I-Cache activates its request signal, and at the same time senses the grant signal for an active level. If both signals are active at T3, the I-Cache can then place its command and address on the shared bus during the next cycle, in this case cycle 2. Since the normal arbitration cycle, which would have taken place during cycle 2, has been bypassed, the command and address is able to be sent one cycle early, thus saving time and improving performance. This sequence is know as an I-Cache preemptive grant.
In FIG. 7, timing diagram 3, depicts the normal I-Cache grant sequence when the shared facility is busy. In cycle 1, the I-Cache request signal is activated, however, I-Cache grant is not active since the "ALLOW ARBITRATION" signal is inactive at T0. Arbitration takes place in cycle 2 since the "ALLOW ARBITRATION" signal is positive at T0. Since the "NO HIGHER REQUEST" signal is also positive, the arbiter activates the "I-CACHE GRANT" signal which is detected by the I-Cache at T3. The I-Cache then activates the command and address on the shared bus during cycle 3. This sequence is known as a normal I-Cache grant.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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An arbitration apparatus for use within a computer system comprises a plurality of individual arbiters arranged in a particular configuration wherein some individual arbiters are higher in the particular configuration than a specific arbiter and some individual arbiters are lower in the particular configuration than the specific arbiter. Each arbiter has a request terminal for receiving access request signals, requesting access to a shared system bus, and an enable terminal for receiving an enabling signal. The enabling signal is generated and energizes the enable terminal of the specific arbiter if access requests are not received by higher arbiters in the particular configuration relative to the specific arbiter. If an access request signal energizes an arbiter and an enabling signal energizes the arbiter, an access grant signal is developed from the arbiter. If more than one access request signal energizes the arbiter at the same time, a command rotor, connected to the arbiter, determines the priority of access of the request signals to the shared bus in response to the "rotation" of the command rotor. If the access request signal is of a predetermined type, a pre-emptive grant signal may be developed from its arbiter even in the absence of an access request if there are no higher requests and no lower grants. If a refresh request is received by an arbiter when its enabling signal is not received, the refresh request is latched, and a refresh takes place when the enabling signal is finally generated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for controlling a valve having a mechanically journalled movable element for regulating the opening of the valve, the movable element being journalled in a stationary bearing, and to an electromagnetic valve whose degree of opening is adjustable with an element movable in a stationary mechanical bearing.
2. Description of the Prior Art
In a valve having a mechanically journalled movable element which regulates the degree of opening of the valve, friction in the bearing can cause problems. Friction is often unpredictable, since it changes with the age of the valve, the pressure of the movable means against the bearing etc., and friction often causes the movable element to stick in a particular position. This problem is greatest in the regulation of small flows through the valve, a procedure which requires small, precise movements by the movable element. When larger flows are involved, an error in the degree of opening of the movable means is not as critical.
For valves in closed regulatory systems, the aforementioned undesirable effects caused by friction can, in principle, be eliminated by means of feedback regulation. European Application 0 360 809 describes such a feedback valve device for exact regulation of an emitted flow to achieve a flow of the desired magnitude.
There are limits, however, on the degree of amplification permissible in such feedback systems, i.e. in the size of the error signal representing the difference between the desired flow and the true flow, since the system becomes unstable when amplification is too large. These problems in feedback regulatory systems are discussed in Swiss Application 430 837. This document also describes another device for damping oscillations in such a system by the addition of a special stabilization signal to the feedback error signal constituting the difference between the reference signal set and the actual signal.
SUMMARY OF THE INVENTION
An object of the present invention is to eliminate, or at least to reduce, the friction in a movable element used for regulating the opening of a valve.
The above object is achieved in a method according to the invention wherein a valve having a movable element for regulating the opening of the valve is journalled in a stationary journal arrangement, and wherein, in order to reduce the friction of the movable element in the journal arrangement, the movable element is caused to perform a friction reducing movement in an opening position which determines the prevailing degree of opening of the valve.
When the valve's movable element is made to move in relation to its bearing, friction is reduced to a low, well-defined value. This accordingly eliminates the aforementioned problems caused by friction, making precise regulation of even very small flows possible with the valve.
In embodiments of the method according to the invention, the movable element and bearing are made to move back and forth in relation to each other, e.g. in an oscillating, rotary or by movement, via translator.
With a valve, whose degree of opening is varied through a translators movement of the movable means (an example of this type of valve is described in U.S. Pat. No. 5,265,594) the oscillating movement then occurs around the opening position of the movable means, the magnitude of oscillating movement here being so small that fluctuations, caused by variations in the valve's degree of opening, in the flow passing through the valve, are held within acceptable limits. A certain amount of fluctuation, or inaccuracy, in the set flow is normally acceptable, and inaccuracy in the flow caused by the oscillating movement of the movable element, after damping in any connected tube, must lie within permissible limits.
In another advantageous embodiment of the method of the invention, the translator's movement amounts to one percent or less of the maximum translators movement which is possible for varying the valve's degree of opening.
In another embodiment of the method of the invention, the movable element can be made to rotate in the bearing around its own axis of symmetry.
In embodiments of the valve of the invention, the movement-imparting device is arranged to be optionally connectable and disconnectable. It can, e.g., be connected when an error signal, representative of the difference between the desired degree of valve opening and the true degree of valve opening, exceeds a predefined value, or it can be connected when the valve's degree of opening is less than a predefined value, i.e. when sufficiently small values are to be regulated. The movement device can also be arranged so it is disconnected when there are large changes in the valve's opening, i.e. when there are large changes in the set flow. The movement-imparting device can also be arranged to be connected in response to the aforementioned error signal and to impart relative motion, whose magnitude varies with the magnitude of the error signal, to the movable element and bearing. This optional connection and disconnection capability for the movement-imparting device is advantageous, since the movement-imparting device is normally electrically powered and its operation therefore increases power consumption. The movement of the movable means in relation to its bearing can also cause disruptive acoustic effects, however, this disruption can be reduced if the movement-imparting device is only operated periodically.
In other embodiments of the valve of the invention, the movable element is formed by a valve body and/or a driver means for positioning the valve body. The valve body can be a membrane, devised to rebound away from a valve seat and the driver can be a rod, devised to push the membrane to a desired position in relation to the valve seat, overcoming the membrane's own resiliency. The rod can be made at least partially of, or can be coated with a magnetic material, and arranged inside a coil, movable toward or away from the valve seat in order to position the rod and, accordingly, the membrane in relation to the valve seat by controlling the current applied to the coil. Here, the movement-imparting device superimposes a much smaller current on the current to the coil in order cause the rod and, accordingly, the membrane to move around the prevailing degree of opening. Alternately, the rod can be movable in a magnetic field generated by two opposed coaxial coils, the rod and, accordingly, the membrane being movable to a desired position in relation to the valve seat when current to the coils is controlled. Here, the movement-imparting device superimposes a much smaller current on the current to at least one of the coils in order to cause the rod and, accordingly, the membrane to move around the prevailing degree of opening.
In another embodiment of the valve of the invention, the superimposed current is sinusoidal and has a frequency in the 100 to 500 Hz range. The frequency is then less than the upper limit frequency of the electromagnet while simultaneously being high enough for oscillations, arising in the gas flow caused by the movement induced by the superimposed current, to be filtered out in connected tubing.
DESCRIPTION OF THE DRAWINGS
The single figure is a schematic illustration, partly in section, of a valve arrangement constructed and operating in accordance with the principles of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The valve according to the invention has an inlet 2 whose opening 4 can be opened and closed with a membrane 6.
The membrane 6 is elastically resilient. To close the valve, a rod 8 pushes the membrane 6 against the opening 4. To open the valve, the rod 8 retracts, (upward in the drawing), whereupon the membrane 6 rebounds resiliently away from the opening, so a flow can pass through the inlet 2, via the opening 4, and out through the outlet 10. The membrane 6 is devised to rebound resiliently away from the opening 4.
The rod 8 passes through an enclosure 12 and is journalled at journals 14 and 16 for movement along its longitudinal direction. The journals 14 and 16 are made with close tolerances, since they serve as guides for the rod 8.
An armature 18 made of magnetic material is arranged on the rod 8, and this armature 18 is movable inside a coil 20, so the armature 18 and, accordingly, the rod 8,can be moved back and forth in the longitudinal direction of the rod 8 when an appropriate current is applied to the coil 20.
Instead of having a separate armature 18 arranged on the rod, at least a part of the rod 8 itself can be made of a magnetic material which serves as the armature. Alternately, the rod 8 can be at least coated with magnetic material.
For safety reasons, the rod 8 can be spring-loaded to press against the closed position (not shown), so the valve shuts as soon as the current I to the coil 20 is removed.
Instead of having the spring-loaded rod press against the valve's closed position and opening the valve with an electromagnetic force which counteracts the resilient force, the rod 8 can be positioned with opposing magnetic fields from two coaxial coils, the superimposed current then appropriately being applied to one of the coils.
The valve's degree of opening, i.e. the magnitude of the distance between the opening 4, serving as a valve seat, and the membrane 6 can also be adjusted by controlling the current I to the coil 20.
A position sensor 22 can be arranged to sense the position of the valve and is connected to a current control unit 24, so the current I to the coil 20 is regulated at values enabling the rod 8 and, accordingly, the membrane 6 to assume the desired position.
Friction in the journals 14 and 16 often causes the rod to stick. This friction is an unpredictable factor which e.g. changes with the age of the valve, the side of the rod 8 which presses against the journal, etc. When the error signal generated by the position sensor 22 achieves a sufficient magnitude, the current I to the coil 20 is increased, dislodging the rod 8 and causing it to assume a new position. When large flows are regulated, the problems caused by friction are normally negligible, e.g. because errors in the position of the rod 8 and, accordingly, the membrane 6 are small in relation to the valve's total movement. When regulation of small flows is involved, however, friction in the journals 14 and 16 can cause serious problems.
For that reason, a smaller current, preferably a sinusoidal signal, is superimposed on the current l, causing the rod 8 to oscillate around the valve's opening position, and, accordingly, the membrane 6. The current I is governed by the desired degree of valve opening. Since the rod 8 is accordingly kept in motion the whole time, in relation to the journals 14 and 16, the rod is prevented from getting stuck.
The frequency of the superimposed signal is lower than the upper limit frequency of the electromagnet but still high enough for oscillations in flow to be quickly filtered out in the valve tubing normally connected to the outlet 10. A suitable frequency is in the 100 to 500 Hz range.
The amplitude of the superimposed current must be so small that ensuing oscillations in flow always remain within permissible limits. The amplitude of the superimposed current thus should be such that the magnitude of the ensuing movement is on the order of one percent or less of the maximum travel possible for varying the valve's degree of opening.
The superimposed current will increase the electromagnet's power consumption, so the current control unit 24 supplies the superimposed current only when needed, e.g. when the error signal from the position sensor 22 becomes unacceptably large, or when a small reference signal is sent to the electromagnet, i.e. in the regulation of small flows. The disruptions which acoustic effects in the valve can cause when the superimposed current is applied are also reduced accordingly.
Moreover, disconnection of the superimposed current may be appropriate when major changes occur in flow through the valve, i.e. when there are major changes in the position of the rod 8.
The amplitude of the superimposed signal can be constant, or can be governed by the error signal or the reference signal.
One embodiment has been described above in which a oscillating, translatory movement is generated in a rod 8 journalled in journals 14 and 16 with the aid of a superimposed current in the coil 20 to keep the rod 8 from getting stuck in the journals 14 and 16. Alternatively, the valve can be devised so the rod 8, with the aid of the superimposed current, is made to rotate on an axis perpendicular to its longitudinal axis around a mid- position, or the rod 8 can be continuously rotated around its longitudinal axis.
The membrane 6 is appropriately compressible, so the rod 8 is able to perform an oscillating, translatory movement even with the membrane 6 pressed against the valve seat 4. The membrane 6 will then be alternatively compressed and expanded.
Sticking between the valve seat and the valve membrane 6, which can also contribute to the valve becoming stuck in the closed position, can also be reduced by imparting motion to the rod 8 as described above.
One embodiment was described above in which a valve membrane is positioned with a special electromagnetic driver device. Other types of valve bodies, directly positioned by an electromagnet, can also be used.
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.
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In a valve having a mechanically journalled movable element for regulating the valve's degree of opening, and in a method for controlling such a valve, the movable element and journals are made to move in relation to each other in order to reduce friction in the journals of the movable element. The movable element is then in a position governed by the valve's prevailing degree of opening.
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This invention relates to injector apparatus and in particular, but not exclusively, to such apparatus used for injecting multiple doses of variable magnitude, for example of insulin.
BACKGROUND OF THE INVENTION
In our earlier Autopen® device, a rotatable dose setting knob attached to the rear end of the pen injector is connected to a hollow drive sleeve that carries an annular ratchet surface at its front end which engages a corresponding ratchet surface on a threaded drive collar. The threaded drive collar is threadedly engaged with the stem of a plunger so that rotary movement of the drive collar is converted into a linear advance of the plunger. A trigger can be moved to release the drive collar for rotary movement. During a dose setting routine, with the drive collar held against rotation by the trigger, a dose is dialled in by rotating the dose setting knob and the drive sleeve against a spring bias provided by a main drive spring. The dose setting movement is unidirectional only due to the ratchet action between the drive sleeve and the drive collar. Upon release of the trigger, the drive collar rotates by an angular amount equivalent to the angular amount initially dialled in, and the plunger is advanced by the corresponding amount to deliver the dose of the required number of units.
This device performs extremely well and enjoys considerable success but we have identified a number of improvement opportunities. In the above device, in setting a dose the user winds up the spring to provide the motive force that is needed for the next dose. This means that it can be awkward for those of limited dexterity to exert sufficient grip to rotate the dose setting knob against the bias of the drive spring. Also in this design, because the action of dose setting winds up the drive spring, a ratchet action is required so that when the user releases their grip on the dose setting knob, the knob stays in that position and does not immediately return to the zero position under the influence of the drive spring. To allow dose setting reversal in case of setting overshoot, a bi-directional ratchet mechanism is then needed, or otherwise a disconnection mechanism is required, either of which complicate the device.
SUMMARY OF THE INVENTION
We have therefore designed an injector apparatus in which a clutch arrangement is provided to isolate the dose setting element from the force of the drive spring during the dose setting routine.
Accordingly, in one aspect, this invention provides an injector apparatus for use with a cartridge or syringe to deliver a plurality of doses therefrom, the injector apparatus comprising:
a housing for the cartridge or syringe; a plunger for cooperating in use with the cartridge or syringe to express successive doses; a dose setting arrangement to select a dose volume; a drive mechanism releasable to advance said plunger in respective predetermined increments of magnitude to express said successive selected doses; characterised in that said drive mechanism includes a drive spring for applying expulsion drive movement directly or indirectly to said plunger, and said dose setting arrangement comprises a dose setting element moveable in a dose setting routine to set a magnitude of an increment of movement of said plunger for a given dose, said drive mechanism further including a clutch arrangement operable during said dose setting routine to isolate said dose setting element from the force of said drive spring and optionally to inhibit directly or indirectly forward movement of the plunger.
In an arrangement where the dose setting element is isolated from the force of the drive spring during the dose setting routine, the dose setting element can be rotated easily, and also preferably can be moved in the reverse sense if the user moves the dose setting element past a required dose. Isolating the dose setting element means that the dose-setting movement of said dose setting element is not resisted by said spring.
It follows from the above that if the dose setting action does not energise the drive spring, the drive spring needs to be energised in some fashion. Conveniently, the drive spring is preloaded to an extent sufficient to deliver substantially the entire useable contents of the syringe or cartridge in a succession of doses. Where the dose setting element is isolated from the force of the drive spring during the dose setting routine, a more powerful spring may be used than would be appropriate for the conventional user-wound device. Instead of providing a fully preloaded drive spring, the drive spring could be partially preloaded or with no preload but with suitable separate means for energising the spring. It will also be appreciated that in such arrangements the drive mechanism will usually already be under load from the drive spring prior to dose setting, in contrast to prior art devices where the drive mechanism is under load only once the dose has been dialled in.
Preferably, the dose setting element is moveable angularly to set said increment of plunger movement.
The clutch arrangement preferably includes a clutch element moveable between disengaged and engaged positions. Thus the clutch element may be adapted to move axially with said dose setting element, whereby axial movement of said dose setting element from a first, rest, position to a second, dose setting position causes said clutch element to engage to inhibit movement of said plunger. It is also convenient for the dose setting element and the housing to include complementary abutments that engage to prevent relative rotation of said dose setting element relative to said housing when the dose setting element is in its rest position, but which disengage to allow dose setting rotation of the dose setting element when it is in its setting position. In this manner, the dose setting element may be moved axially from its rest position to its dose setting position, then turned to dial in a required dosage volume, and then returned axially to its rest position to lock it against rotation.
Preferably, upon moving the dose setting element from its rest position to its setting position, the clutch engages to inhibit movement of the drive plunger a predetermined distance before the abutments on the dose setting element and the housing disengage to release the dose setting element for dose setting movement.
In a preferred arrangement, when the dose setting element is in its rest position, it receives and reacts the thrust of the drive spring so that the dose setting element thereby inhibits movement of the drive plunger. In this manner, when the dose setting element is in its rest position the thrust of the drive spring is reacted by the dose setting element and thence to the housing, but when the dose setting element is in its setting position, the thrust of the drive spring is reacted by the clutch member having engaged with the housing.
Preferably, having set a dose, returning the dose setting element axially to its first position disengages the clutch element to release the drive mechanism to cause the plunger to advance by a predetermined increment corresponding to the predetermined set dose.
Preferably, said plunger is threadedly engaged with an associated drive or control element whereby advance of said plunger is accompanied by rotation of the plunger or the drive or control element, with the magnitude of the incremental advance being set by constraining said rotation.
Preferably a stop member is associated with the dose setting element and is adjustable by moving the dose setting element, thereby to define an angular increment for the relative rotation between the plunger and the drive or control element upon release of the drive mechanism.
The stop member could simply be an abutment surface provided on the dose setting element. This would allow the maximum useable extent of angular movement of the dose setting element to be just short of 360°. This would mean that the indicia needed to be fairly closely packed in some instances. Accordingly it is preferred for there to be an intermediate dial or shuttle member threadedly engaged with the dose setting element and constrained to rotate with the rotatable one of the plunger and the control member, with the extent of relative angular movement of the dial or shuttle member and the dose setting element being set by the relative position of the stop member associated with the dose setting element. The provision of a threaded dial or shuttle member means that it is now possible to set a dose of several turns. This has advantages both in terms of the available size for the indicia, and also allows greater flexibility over the choice of the pitch of the thread between the plunger and the control member. In a particularly preferred arrangement, the dosage indicia may be provided as a helical strip on one of said complementary dose setting elements, and read off via a marker or window on the other dose setting element.
The drive spring in the various arrangements described above may be either a torsion spring that imparts a rotary movement when released, or a compression spring that imparts a linear movement.
In many applications it may be desirable to provide a multiple dose injector device that is supplied preloaded so that it is not necessary to re-energise the drive between each dose, for example if the device is intended to be disposable.
Accordingly, in another aspect, this invention provides an injector apparatus for use with a cartridge or syringe to deliver a plurality of doses therefrom, the injector apparatus comprising:
a housing for the cartridge or syringe; a plunger for cooperating in use with the cartridge or syringe to express successive doses; a dose setting arrangement to select a dose volume; a drive mechanism releasable to advance said plunger in respective predetermined increments of magnitude to express said successive doses;
characterised in that said drive mechanism includes a rotary stored energy element with a preload sufficient to deliver at least a plurality of said successive doses.
In the above arrangement, the injector apparatus may for example be provided with a fully preloaded spring so that the user is not required to input the mechanical energy required to express the doses. This renders the device particularly suitable for those with limited dexterity or poor grip.
As noted above, conventional Autopen® and similar devices have an angular range of dose setting movement that is limited to 360°, and this places constraints on the marking indicia, the pitch of the drive thread, and the properties of the drive spring. We have therefore designed an arrangement in which the dose setting arrangement includes threadedly engaged first and second complementary dose setting elements which enables the dose setting movement to be several turns if required.
Accordingly, in another aspect of this invention, there is provided an injector apparatus for use with a cartridge or syringe to deliver a plurality of doses therefrom, the injector apparatus comprising:
a housing for the cartridge or syringe; a plunger for cooperating in use with the cartridge or syringe to express successive doses; a dose setting arrangement to select a dose volume; a drive mechanism releasable to advance said plunger in respective predetermined increments of magnitude to express said successive doses and in which advance of said plunger is controlled by a control member that moves angularly in response to advance of said plunger;
characterised in that said dose setting arrangement includes first and second complementary dose setting elements threadedly engaged for relative threaded movement away from a limit position, with said first dose setting element being moveable relative to said housing in a setting routine from a rest position to a variable angular position that sets the dose volume, and said second dose setting element being constrained to rotate with said control member,
whereby on release of said drive mechanism said control member and said second dose-setting element rotate until the second element returns to said first limit position with respect to the first element, thereby preventing further rotation of the control member.
According to another aspect, the invention provides an injector apparatus for use with a cartridge or syringe to deliver a plurality of doses therefrom, the injector apparatus comprising:
a housing for the cartridge or syringe; a plunger for cooperating with the cartridge or syringe to express successive doses; a drive mechanism energised by a drive spring, and releasable to advance said plunger in predetermined increments as determined by adjustment of a dose setting element, and a re-energising element for re-energising said spring independently of movement of said dose setting element.
Preferably said drive spring is a torsion spring and said re-energising element is a rotary element, for example a manually rotatable element.
According to another aspect, this invention provides an injection apparatus for use with a cartridge or syringe to deliver a plurality of doses therefrom, the injector apparatus comprising:
a housing for the cartridge or syringe; a plunger for cooperating in use with the cartridge or syringe to express successive doses; a dose setting element movable to select a dose volume; a drive mechanism releasable to advance said plunger in respective predetermined increments of magnitude to express said selected dose volumes, said drive mechanism including a drive spring for providing motive force directly or indirectly to said plunger to advance said plunger, and the apparatus being configurable between a first position in which the motive force of the drive spring is transmitted via the dose setting element to the housing to be reacted thereby, and a second position in which a clutch element is moved into a position in which motive force of the drive spring is transmitted via the clutch element to the housing to be reacted thereby, so that dose setting movement of the dose setting element is not resisted by the drive spring.
Whilst the invention has been described above, it extends to any inventive combination of the features set out above or in the following description of claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be performed in various ways, and an embodiment thereof will now be described by way of example only, reference being made to the accompanying drawings in which:
FIG. 1 is a side view of a first embodiment of pen injector in accordance with this invention:
FIG. 2 is a side section view of the pen injector of FIG. 1 ;
FIG. 3 is an exploded view of the pen injector of FIGS. 1 and 2 ;
FIG. 4 is an enlarged view of the main body of the pen injector of FIGS. 1 to 3 , containing the drive mechanism, with one body half shown transparent;
FIG. 5 is a perspective section view of the dose setting knob showing the thread on the inside of the dose setting knob;
FIG. 6 is a perspective section view on the rear part of the drive mechanism showing the clutch and dose setting knob and dose dial;
FIG. 7 is an exploded view of a second embodiment of pen injector in accordance with the invention having a rewind facility;
FIG. 8 is a detailed view of the rewind knob, and
FIG. 9 is a side section view of a third embodiment of pen injector driven by a compression spring.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment of pen injector illustrated in FIGS. 1 to 6 is designed to be a disposable automatic pen type injector capable of expelling a succession of doses of variable preset magnitude from a cartridge. The injector comprises a body made up of symmetric body halves 10 1 and 10 2 which may be snap-fitted or glued together. A cartridge or syringe 12 is received in a transparent forward cartridge housing 14 which is a snap-fit on the forward end of the body halves 10 1 , 10 2 . On the rear end of the body is mounted a dose setting knob 16 having a window 18 through which a dose dial 20 is visible. As to be described below, the device contains a preloaded torsion spring which in this particular embodiment supplies the entire force required to express all the useable dosage volume in the cartridge. Doses are set by pulling the dose setting knob 16 rearwardly, rotating it until the required dosage unit is visible on the dose dial and then pushing the dose dial back in to release the drive mechanism to expel the required dose.
Referring now more particularly to FIGS. 2, 3 and 4 the body 10 1 , 10 2 defines an internal cylindrical space in which a torsion spring 22 is located in an energised state, with the forward end of the spring being anchored on an inner part 23 of the body. A hollow tubular drive shaft 24 is disposed concentrically within the spring having a radial flange 26 which is rotatably held within an annular recess 28 on the forward part of the body to allow rotation of the drive shaft but to prevent axial movement thereof. Towards its rear end, the diameter of the shaft increases at a shoulder 30 in which is provided an anchorage hole 32 for the rear end of the drive spring. When assembled and prior to first use, the torsion spring 22 is fully energised and acts on the drive shaft to rotate it in the dispensing direction. The enlarged portion 34 at the rear end of the drive shaft is provided with upstanding splines 36 adjacent the shoulder 30 , with four of the splines 38 at 90° extending the full length of the enlarged portion 34 .
At the front end the drive shaft has an internally threaded bore 39 into which is threaded the lead screw of a plunger 40 . The plunger has an enlarged head 42 which engages the bung 44 of the cartridge 12 . Immediately behind the enlarged head 42 the drive shaft has two diametrically opposed keyways 46 which cooperate with respective keys 48 on the front end of the body halves 10 1 and 10 2 , to allow axial movement of the plunger, but prevent rotation thereof, as the drive shaft 24 rotates to advance the plunger.
The dose dial 20 is slideably mounted on the enlarged portion 34 of the drive shaft 24 but prevented from rotation thereof by means of four, internal, equispaced, keyways 50 that engage the longer splines 38 on the enlarged portion. The forward end of the dose dial has an enlarged internal diameter so as to be clear of the shorter splines 36 . The external surface of the dose dial 20 carries a coarse helical thread 21 which threadedly engages a corresponding internal threaded portion 52 on the inner surface of the dose setting knob 16 . The threaded portion 52 on the inside of the dose setting knob 16 has a forward limit position set by termination of the thread (see blind end 54 in FIG. 5 ). A rear limit position stop may optionally be provided, for example, on the inner part of a hinged cap portion 17 of the dose setting knob.
The dose setting knob 16 is connected at its forward end to a clutch collar 56 by means of a snap-fit which allows the clutch and the dose setting knob to rotate relative to each other but secures them against relative axial movement (see FIG. 6 ). The clutch collar 56 is mounted for axial sliding movement in the body 10 but prevented from rotation with respect thereto by means of two lugs 58 in the body engaging opposed respective slots 60 in the cylindrical wall of the clutch collar 56 . At its rear end, the clutch collar 56 has an internal splined arrangement 57 designed to slide into splined engagement with the splines 36 on the enlarged portion 34 of the drive shaft so as to lock the drive shaft against movement under the influence of the spring by reacting the thrust into the body by via the lugs 58 . Referring now more particularly to FIGS. 4 to 6 , the forward end of the dose setting knob 16 has a series of axially extending fingers 62 which are an axial sliding fit with a series of pockets 64 provided in the body.
The axial lengths of the fingers 62 and of the pockets 64 are carefully selected having regard to the axial spacing between the internal splines 57 on the clutch collar 56 and the external splines 36 on the drive shaft 24 such that, on pulling the dose setting knob 16 out axially, the splines 57 on the clutch collar 56 engage the splines 36 on the drive shaft 24 some distance before the fingers 62 of the dose setting knob 16 are withdrawn axially from the pockets 64 on the body. The reason for this is that, in the position shown in FIG. 2 , as indicated above, the thrust of the drive spring is transmitted via the drive shaft splines 38 to the dose dial 20 and thence to the dose setting knob 16 (by virtue of the dose dial being at its forward limit position relative to the dose setting knob). It is therefore important to ensure that the clutch 56 has engaged the drive shaft 24 to react the load of the torsion spring 22 through the clutch 56 and the lugs 58 to the housing before the dose setting knob has withdrawn enough to rotate.
Once the dose setting knob has been withdrawn far enough to disengage the fingers 62 from the pockets 64 , it is in a setting position in which it may be rotated to set a dose against a light detent action provided by the fingers 62 , which provide a audible/tactile click to enable the user to count the number of units dialled in. It will be appreciated that during dose setting, the body 10 , drive shaft 24 , clutch 56 all remain stationary, both axially and rotationally. The dose dial is fixed against rotation due to its splined engagement with the large portion 34 of the drive shaft but is capable of moving axially. Thus in this condition, with the dose setting knob 16 axially in its setting position, rotation of the dose setting knob in the appropriate direction moves the dose dial 20 axially in a lead screw fashion. The dose dial numbers are visible through the window 18 . The threaded arrangement allows multiple turns of the dose setting knob. Also at this point there is no loading between the dose dial and the cap and so there is little resistance to rotary movement of the dose setting knob apart form that provided by the detent.
Once the required dose has been dialled in on the helical scale, the device is ready for firing. In this arrangement this is achieved by pushing the dose setting knob 16 back in. As the dose setting knob is pushed back in, the fingers 62 re-engage the pockets and thereafter the clutch 56 is shifted forwardly off the enlarged portion of the drive shaft to disengage it so that the drive shaft is now free to rotate. The drive shaft rotates by the angular amount dialled in.
In the above arrangement, as the setting of the dose is independent of the drive spring, the operating stroke length and force can be reduced to design a device in which a large dose is delivered with a small movement and force. This contrasts with existing devices in which the user has to apply a large user movement to set a dose and/or expel the set dose.
There is a potential issue in existing multi-dose devices in which after expulsion of a dose the plunger remains in contact with the bung. Due to the friction between the bung and the cartridge wall and its resilience, at the end of an injection the bung will be under residual compression. Vibrations transmitted to the bung either via the plunger or the wall of the cartridge can cause the bung to expand slightly and expel a drip which can affect dose accuracy. As a modification of the above embodiment the clutch arrangement can be designed so that, as it is pulled to disengage, it backs off the plunger 40 from the bung 44 a fraction, so that the bung 44 is unloaded.
This unloading effect may be achieved for example by putting a slight form on the splines 57 of the clutch collar 56 and on the splines 36 of the drive shaft 24 so that, as the dose setting knob is pulled out to engage the clutch collar 56 on the drive shaft, the drive shaft is rotated a few degrees against the spring bias to unload the bung.
Whilst in this embodiment the body is formed in two separate halves it may instead be formed in a clamshell type arrangement where the two halves are hinged by a live hinge.
In order to ease manufacture, the torsion spring in the illustrated embodiment may be formed with a wave or compression portion at its forward end to apply a light axial load to the cartridge in order to hold the cartridge firmly in a forward position. This allows variations in length due to production variances to be accommodated. Furthermore although the wire that is coiled to make the spring may be circular in section in some applications it is preferred for it to be non-circular, such as of square or rectangular section.
Referring now to FIGS. 7 and 8 , a second embodiment provides an arrangement for rewinding the plunger 40 and simultaneously energising the drive spring 22 (see FIGS. 3 and 4 ) of the first embodiment. In the second embodiment most of the components are similar to those of the first embodiment and will not be described again and will be given like reference numerals. Referring to FIG. 7 , the forward part of the housing which defines the keys 48 that engage the keyways 46 on the lead screw of the plunger is formed as a separate rewind knob 70 which is uni-directionally rotatable about the longitudinal axis of the housing. The knob 70 is formed in two halves 70 1 , 70 2 and defines a central aperture with the diametrically opposed keys 48 . The knob 70 has an outer circumferential groove 72 in the base of which are two diametrically opposed sprung ratchet teeth 74 , as seen in FIG. 8 . The knob 70 is rotatably received in the forward end of the housing by means of an inwardly directed toothed annular rib 76 locating in the groove 72 and cooperating with the ratchet teeth 74 to allow rotation in one direction only. The rear end of the rewind knob 70 is provided with two slots 76 into one of which the front end of the torsion drive spring 22 (not shown) is anchored. Engagement of the keys 48 on the knob 70 with the keyways 46 on the lead screw of plunger 40 ensures that the plunger 40 rotates with the knob in one direction only but is capable of axial sliding movement. The knob and the plunger may therefore be rotated in the direction permitted by the ratchet to wind up the drive spring 22 and to retract the plunger back into the driveshaft 24 by virtue of the threaded engagement between the lead screw of the plunger 40 and the driveshaft.
The rewind knob will normally be accessible only when the cartridge housing (see first embodiment) has been removed from the body.
In the above arrangements, a torsion spring provides the motive force for expelling the useable contents of the cartridge. It would of course be possible to use other suitable drive configurations. For example, as shown in FIG. 9 , the torsion spring could be replaced by a compression spring 80 which acts on the plunger 82 to apply a thrust in the longitudinal direction. In this case, instead of the drive shaft there is a drive control shaft 84 that is used to modulate forward movement of the plunger 82 under the influence of the compression spring 80 .
The rear end of the plunger 82 is formed with a threaded portion which threadedly engages an internal bore on the drive control shaft 84 so that as the plunger 82 is urged forwardly by the compression spring the drive control shaft rotates. The drive control shaft 84 is formed at its rear end with an enlarged portion 34 provided with upstanding splines 36 similar to those of the drive shaft 24 of the first embodiment, and fulfilling a similar function in conjunction with a clutch collar 56 , the dose setting knob 16 and the dose dial 20 of the first embodiment. The construction and operation of these elements will not be described in detail again. As previously, the drive control shaft 84 is alternately held and released by the clutch collar 56 and the dose setting knob 16 .
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An injector apparatus includes a housing ( 10 1 , 10 2 ) for a cartridge or syringe, a plunger ( 40 ) for cooperating in use with the cartridge or syringe to express successive doses, a dose setting arrangement ( 16, 20 ) to select a dose volume, and a drive mechanism ( 22, 24 ) releasable to advance the plunger in respective predetermined increments of magnitude to express the successive doses. The drive mechanism includes a drive spring ( 22 ) for imparting movement directly or indirectly to the plunger ( 40 ), and the dose setting arrangement includes a dose setting element ( 16 ) moveable in a dose setting routine to define a magnitude of an increment of movement of the plunger for a given dose. The drive mechanism further includes a clutch arrangement ( 56 ) operable during the dose setting routine to inhibit forward movement of the plunger and/or to isolate the dose setting element from the force of the drive spring.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a National Phase Application (35 USC 371) of PCT/EP2003/012409 and claims priority of German Application No. 102 57 532.0 filed Dec. 10, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a marking device for encoding metallic workpieces with two-dimensional matrix codes in which the information is present in the form of recessed embossed dots in a square or rectangular arrangement. The presence or lack of these embossed dots at the respective grid points represents the binary encoded information.
[0004] 2. The Prior Art
[0005] To read back the information without error, the precision in placing the embossed dots is of high importance. The precise shape, size and depth of the dots are critical quality features. This is directly connected to the type of reading technology for such embossed or punched encodings, respectively, by means of CCD cameras. Illumination from the top or the side must create a contrast between light and dark from the respective recess by means of corresponding reflections, which is much more difficult than with printed black and white surfaces located on one level, for which the code was originally developed. A deviating shape or size of the individual recesses can easily cause (or undesirably not cause) a reflection which can lead to an undesired distortion of information. In the aerospace industry, requirements are even stricter for critical components under high load; these requirements aim at avoiding the reduction of mechanical stability due to the “notch effect”.
[0006] In order to achieve the required precision, the striking tool, normally embodied as a hard metal needle, must strike the metallic workpiece, on the one hand, very rapidly, but on the other hand, with precisely defined and reproducible energy. Many conditions must be taken into account as counteracting the desired precision. In case of an electric drive, for instance, the temperature of the copper coil of the electromagnet can increase during operation, reducing current flow and thus the power consumption of the electromagnet. During longer standstill periods of the marking device, the striking tool which is formed as a magnet keeper, or connected to or operatively connected with a magnet keeper, sticks so that the impact energy at the first dot is reduced. In principle, a striking movement which is too slow causes an oval distortion of the recess when the impact unit moves on during encoding. On the other hand, an impact speed which is too fast leads to a great variation in impact depth, since even minimum differences, e.g. due to overlaid mechanical oscillations in the striking mechanism, lead to slightly different energy outputs of the impact system during the formation of the recess. Furthermore, the material properties of the workpiece also influence the formation of the recess. Finally, mechanical tolerances also lead to errors, if they cause the movement of the magnet keeper to exceed the magnetically substantially linear range.
[0007] In known arrangements, the current is only intended to be switched on and off for the electromagnet. Clamping diodes or other overvoltage protection equipment are used for protection against overvoltage, when the electromagnet is switched off, as an inductive load. Bias resistors before the electromagnet for inducing a faster rise or drop of current in the magnet coil by increasing the time constant are also known. In these simple systems, in addition to one-time dimensioning, only the time of disconnecting can be varied after the current is switched on, whereas the entire time course of the working movement results exclusively from dimensioning and the prevailing boundary conditions. With such systems, the required precision cannot be attained.
[0008] In controlling solenoid valves, on the one hand, it is well-known to switch back to a lower holding current after the high turn-on current, which is first required for a fast movement. This switchover, however, does not take place until after switching of the valve, i.e. after the movement of the valve member, and is intended first to save energy and secondly to reduce heating of the solenoid valve.
SUMMARY OF THE INVENTION
[0009] The invention has as an object the improving of the movement of a striking tool driven by an electromagnet arrangement such that markings in the form of recesses can be formed with substantially higher precision.
[0010] Accordingly, the present invention provides a marking device for encoding a metallic workpiece with a two-dimensional matrix code which includes a striking tool; an electromagnetic device for driving the striking tool, with a working movement, to form the two-dimensional matrix code, as plural indentations, in the metallic workpiece; a return device for generating a force in opposition to the working movement; and a positioning device, displaceable in two dimensions within a plane perpendicular to the direction of the working movement, for positioning the striking tool in a desired encoding position. The marking device of the present invention further includes an electronic control unit for controlling the working movement of the striking tool, said electronic control unit setting a first current I 1 for the electromagnetic device during a first, acceleration phase of the working movement and setting a second current I 2 , lower than the first current, during a second, moving phase of the working movement, the second, moving phase extending from the first, acceleration phase until impingement of the striking tool on the metallic workpiece.
[0011] Advantageously, according to the invention, the current flow through the electromagnet can be set differently for the acceleration phase and the subsequent moving phase of the striking tool. On the one hand, this results in a fast acceleration, with the striking tool being moved against the workpiece in a defined manner after switchover to the lower current. This results in high regularity and reproducibility of the recess formed. Due to the substantially uniform movement because of the fact that the current is lower during the moving phase, a larger tolerance for the marking device's distance to the workpiece is permissible. With the known devices, a distance which becomes larger causes a deeper recess due to the longer acceleration phase. Also, because the current is lower during the moving phase, an uncontrollable, merely ballistic phase of “free flight” of the striking tool until it impinges on the workpiece surface is avoided, which would otherwise occur if the current were switched off before the tool impinges the workpiece; which, in turn, would be associated with larger tolerances of the markings.
[0012] In a simple embodiment, current switchover from the higher to the lower value in one or more steps, or continuously, takes place by means of a time control. Alternatively, this switchover can also take place in dependence on the position, with a position measuring device for controlling switchover being provided in at least one preset position. In the simplest case, this position measuring device can be a simple position sensor in a specific position or an end position sensor which responds after a certain distance traveled during the striking movement.
[0013] Advantageously, position measurement can also be employed to measure the length of the entire moving distance of the striking tool, i.e. for measuring the distance to the workpiece. The corresponding measured value can then also be used as a working parameter for defining the current intensities and times or positions, respectively.
[0014] For switching off the current exactly after the striking tool has impinged on the workpiece, preferably means for switching off the current when the impinging position is reached can be provided. In a particularly simple manner, the current increase of the supply current for the electromagnet arrangement can be detected with a current sensor, with this current increase taking place when the movement of the magnet keeper, i.e. the striking tool, has been stopped and there is no longer any change in inductivity in the coil of the electromagnet.
[0015] After the striking tool has impinged on the workpiece, the current is switched off so that the striking tool is returned to the rest position by the force of the reset device, such as e.g. a spring. Now, for avoiding rebound or need for absorption of the kinetic energy of the striking tool upon return to the rest position by absorption and/or rebounding, advantageously braking means for creating a brake current before the rest position is reached during the return motion of the striking tool can be provided. These means can be controlled in dependence on the time and/or the position, and the current value is selected such that the striking tool is braked, preferably, to a zero speed when the rest position is reached. In this manner, a very fast working cycle can be ensured.
[0016] The control equipment advantageously contains a microcomputer with a storage unit in which the working parameters are stored, especially current intensities, times, distance parameters, workpiece properties, temperatures, and the like. The working parameters are suitably contained in the form of tables and can be selected and/or altered in dependence on the respective marking process. Whereas some parameters have to be entered which take into account, e.g., the workpiece properties of the workpiece to be marked, other parameters, such as the temperature, can be detected by sensors, and again others are measured in the manner already indicated, e.g. the position of the striking tool along the entire distance of movement.
[0017] Advantageously, the control equipment in the form of a separate module is interposed between a main controller for the marking device and the electromagnet and can be retrofitted.
[0018] The various current values can be controlled in open-loop or closed-loop control, dependent on position or time, over the entire moving distance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Embodiments of the invention are shown in the figures and explained in detail in the subsequent description.
[0020] FIG. 1 is a schematic view of the marking device for encoding metallic workpieces with two-dimensional matrix codes,
[0021] FIG. 2 is a schematic view of a first embodiment with a position-dependent control for the driving movement of the striking tool, and
[0022] FIG. 3 is a schematic diagram of a second embodiment with time-dependent control for the driving movement of the striking tool.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The marking head 10 which is schematically shown in a pictorial schematic in FIG. 1 is equipped with an electromagnet coil 11 adapted for generating the striking movement of a striking tool 12 which, in this embodiment, is exemplified by a hard metal needle. The striking tool 12 is connected to a magnet keeper 9 which can be moved towards a workpiece 14 against the force of a return spring. Of course, a different well-known return device can also be envisaged, e.g. a return device with pneumatic, hydraulic or electromagnetic action.
[0024] The marking head 10 is adjustable, by means of a positioning device (not shown), in the x- and y-directions of a plane arranged in parallel with the plane of the workpiece 14 . In this manner, the marking head 10 can reach any position of the workpiece 14 . The marking head 10 is used to emboss coding dots in the form of recesses (indentations) in the metallic workpiece 14 . These coding dots form a two-dimensional matrix code representing binary encoded information. After the desired grid point has been reached, the striking tool 12 is moved against the workpiece 14 to create the desired code indentation.
[0025] Basic control of the marking head 10 is performed by a main controller 15 which controls the position of the marking head 10 , by means of the positioning device (not shown), and the triggering of the movement of the striking tool 12 .
[0026] Between the main controller 15 and the electromagnet coil 11 , a control unit 16 is interposed by means of which the exact movement of the striking tool 12 is controlled. A first embodiment of this control unit 16 is shown in FIG. 2 and a second embodiment in FIG. 3 . In the embodiment shown in FIG. 2 , a current control stage 17 , which can be triggered from the main controller 15 , controls the electromagnet coil 11 of the marking head 10 via an amplifier unit 18 . The position signal S of a position detecting device 20 is fed into a position presetting stage 19 for detecting the current position of the striking tool 12 . This position detecting device is e.g. an inductive path-measuring system which is arranged outside the electromagnet coil 11 in FIG. 1 but which can also be integral with the magnet drive. In the position presetting stage 19 , this position signal S is compared during the striking movement with a stored switchover value S 0 , and if the same is reached, a switchover is made from an initially high current value I 1 to a lower current value I 2 . The initially high current value I 1 is used for fast acceleration of the striking tool 12 during an acceleration phase, wherein the lower current value I 2 is selected such that after this acceleration phase, the striking tool can be guided to the workpiece with as uniform a speed as possible. Naturally, the return to the lower current value I 2 can also take place in several steps. When the striking tool 12 impinges on the workpiece 14 , the supply current for the electromagnet coil 11 rises, since when the movement of the magnet keeper 9 is finished, no change in inductivity in the electromagnet coil 11 any longer takes place. This rise in current is detected by a current sensor 21 and fed into an evaluation stage 22 for the rise in current, which evaluation stage 22 can contain e.g. a differentiation stage. When this rise in current is detected, the current for the electromagnet coil 11 is switched off by means of a reset signal R.
[0027] After the current has been switched off, the striking tool 12 and the magnet keeper 9 , are moved back into the rest position shown in FIG. 1 by the force of the return spring 13 . If during the return motion, a position S 1 is detected before the rest position is reached, the current is switched on again by means of the current control stage 17 and then serves as a braking current. During this process, the position S 1 and the current intensity are selected such that the striking tool 12 is braked to a speed which is as close to zero as possible when the rest position is reached. For this purpose, either one of the currents I 1 or I 2 or a different current value can be set.
[0028] In a storage unit 23 , the working parameters for setting the positions and currents are stored. Such working parameters are e.g. current intensities, times, distance parameters, workpiece properties, temperatures and the like are stored in the form of tables. By means of these tables, the current intensities I 1 and I 2 as well as the positions S 0 and S 1 are then preset, e.g. calculated. These are parameters influencing the movement of the striking tool 12 . For instance, the temperature of the marking head 10 or the electromagnet coil 11 , respectively, can be measured in a manner which is not described in detail. Other working parameters, such as the material properties of the workpiece 14 , can be stored by means of an input device which is not shown. Another important parameter is the working stroke, i.e. the distance of the working movement until the tool impinges the workpiece 14 . By means of a measuring movement of the striking tool 12 , which takes place before the actual marking process, the distance can be measured by the position detecting device 20 . The measurement takes place until the tool impinges on the workpiece 14 which is signaled by the evaluation stage 22 .
[0029] Based on this measured value, the control parameters to be currently used for the respective workpieces 14 are then respectively altered, individually, in such a way that the striking energy effective for marking again corresponds to the desired value.
[0030] In another embodiment, this distance measurement can be applied to the position of the workpiece surface to be marked in relation to the assembly height of the marking head 10 . To this purpose, the height of the marking head 10 is set adjustably on a third NC axis. Now the striking tool 12 is completely extended with a current set by the current control stage 17 , sufficient to overcome the restoring force, and then the marking head 10 is driven against the workpiece surface from a known higher position. As soon as the striking tool 12 strikes the surface, it is retracted until the proximity sensor 20 in the marking head 10 emits a signal. Since the distance from the completely extended striking tool 12 to the switchpoint of the sensor is known, the position of the workpiece surface can be precisely determined from the entire traveling distance and used for precisely setting the desired distance of the striking tool 12 from the workpiece 14 . This procedure as well helps to eliminate the negative effects of workpiece tolerances.
[0031] After a certain standstill period, the magnet keeper 9 sticks more firmly (adheres) in its rest position than during the stroke movements of the marking process. For this reason, the control unit can increase the acceleration current I 1 for the first stroke movement. This increase can be set by reference to stored tables as well.
[0032] The current control stage 17 can control the current values I 1 and I 2 or other current values simply by open-loop control, or it can be adapted as a stage for closed-loop current control.
[0033] As a variation of the embodiment explained above, a simple position sensor can also be provided instead of the position measuring device 20 ; this sensor would only emit a switchover signal in case a fixed predetermined position S 0 or S 1 , respectively, is reached. It can be e.g. an end position sensor which emits a signal when the rest position has been distanced by a certain distance S 0 or when the magnet keeper 9 has come closer by a certain distance S 1 during the return motion.
[0034] The control unit 16 shown in FIG. 2 is, for example, a microcomputer or microcontroller. The storage unit 23 will then be a non-volatile working memory of the microcontroller.
[0035] In FIG. 3 , a modified control unit 16 a is shown. Same or similarly working modules or elements are labeled with identical reference numbers and not again described in detail.
[0036] In the second embodiment, a time presetting stage 24 replaces the position presetting stage 19 . The time presetting stage 24 is triggered by a signal of the main controller 15 . After a certain time to, switchover from the higher current value I 1 for the acceleration phase to the lower current value I 2 for the movement phase takes place. Correspondingly, the braking current is switched on during the return motion of the striking tool 12 after a time t 1 . The storage unit 23 contains the stored values t 0 and t 1 which are preset in the working parameter tables according to the first embodiment.
[0037] For open-loop and/or closed-loop control of the current, combinations of the two embodiments can also be implemented, i.e. the setting or control of the currents, respectively, take place partly depending on time and partly depending on the position.
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A marking device for encoding metallic workpieces with two-dimensional matrix codes includes a striking tool for forming the code recesses, driven by an electromagnetic device. The driving movement is performed against the force of a return device. A positioning device displaceable on two axes (x, y) of a plane perpendicular to the striking direction (z) is used for positioning the striking tool in the desired code positions. An electronic control device for controlling movement of the striking tool includes means for presetting a higher current for the electromagnet device during a first acceleration phase of the striking tool and a lower current during a subsequent moving phase until the workpiece is impinged. In this manner, the precision of the code recesses in the workpiece can be exactly set or maintained, so that readability of the coding is substantially improved.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is entitled under 35 U.S.C. § 119(e)(1) to the filing dates of earlier co-pending provisional applications U.S. Ser. No. 60/006,259, filed Nov. 7, 1995, U.S. Ser. No. 60/009,983 filed Jan. 16, 1996, and U.S. Ser. No. 60/025,284, filed Sep. 19, 1996.
FIELD OF THE INVENTION
This application relates to ureteral stents.
BACKGROUND OF THE INVENTION
Ureteral stents are used to assist urinary drainage from the kidney to the bladder in patients with ureteral obstruction or injury, or to protect the integrity of the ureter in a variety of surgical manipulations. More specifically, stents may be used to treat or avoid ureter obstructions (such as ureteral stones or ureteral tumors) which disrupt the flow of urine from the kidneys to the bladder. Serious obstructions may cause urine to back up into the kidneys, threatening renal function. Ureteral stents may also be used after endoscopic inspection of the ureter.
Ureteral stents typically are tubular in shape, terminating in two opposing ends: a kidney (upper) end and a bladder (lower) end. The ends may be coiled in a pigtail or J-shape to prevent the upward or downward migration of the stent, e.g., with physiological movements. The kidney coil is designed to retain the stent within the renal pelvis of the kidney and to prevent stent migration down the ureter. The bladder coil sits in the bladder and is designed to prevent stent migration upwards toward the kidney. The bladder coil is also used to aid in retrieval and removal of the stent.
Ureteral stents, particularly the portion positioned in the ureter near the bladder and inside the bladder, may produce adverse effects including blood in the urine, a continual urge to urinate, strangury, and flank pain accompanying reflux of urine up the stent (e.g., when voiding) as pressure within the bladder is transmitted to the kidney. In short, stents may cause or contribute to significant patient discomfort and serious medical problems.
FIG. 10 is a schematic drawing of the human urinary tract without a stent, showing the renal pelvis, the kidney, the ureter, and the ureteral orifices opening into the bladder. FIG. 11 depicts a typical double-J stent 10 which comprises a small tube 12 which sits inside the urinary system and assists the flow of urine from the kidney (renal pelvis) to the bladder. FIG. 12 depicts prior art indwelling ureteral stent 10 in position. Such stents are typically made of biocompatible plastic, coated plastic, or silicone material. Tube 12 typically varies in size from 4-8 fr. (mm in circumference), and it has multiple small holes throughout its length. A coiled shape pre-formed at each end 14 and 16 is designed to confine its movement within the urinary system, so that it will be maintained in the desired position. The upper (kidney) end 14 of the stent may be closed or tapered, depending on the method of insertion (e.g., the use of a guidewire). The tubular stent extends through the ureteral orifice 18 a and into the bladder, fixing orifice 18 a open, and thereby enhancing the opportunity for reflux. For clarity, the ureter entering bladder 20 through orifice 18 b is not shown. A monofilament thread 22 may be attached to the bladder end of the stent for removal, usually without cystoendoscopy.
U.S. Pat. No. 4,531,933 (“the '933 patent”) discloses a ureteral stent having helical coils at each end which are provided for preventing migration and expulsion.
SUMMARY OF THE INVENTION
We have discovered a ureteral stent design that avoids patient discomfort and urine reflux upward toward the kidney. Rather than rely on a tubular structure to contain and facilitate all (or, in some embodiments, any) urine flow along the ureter, the invention features a thin flexible elongated tail member having an elongated external urine-transport surface. Urine flows along the outside surface of the structure, between that surface and the inside wall of the ureter. Without limiting ourselves to a specific mechanism, it appears that urine may remain attached to, and flow along, the external urine transport surface. The use of a foreign body that is as small as possible in the lower (bladder) end of the ureter and in the bladder itself decreases patient discomfort. Typically, the external urine transport surface is sized and configured to extend along at least part of the ureter near the bladder, across the ureter/bladder junction, and from there through the ureteral opening into the bladder.
While most or all of the length of the stent may rely on such an external surface to assist flow, more typically the stent will also include an upper elongated tubular segment to transport urine along a significant portion of the upper ureter. The upper tubular segment is connected at its lower end to an elongated tail which has the above described external urine-transport surface. The upper tubular segment comprises: a) an upper region having at least a first opening; b) a lower region having at least a second opening to be positioned in the ureter outside the bladder, and c) a central lumen connecting the first opening to the second opening. The elongated tail is a thin flexible tail member or filament(s) extending from the lower region of the tubular segment at a point outside the bladder so as to receive urine from the second opening of the tubular segment and to transport urine along the ureter from the lower region of the tubular segment across the ureter/bladder junction and into the bladder. Typically, but not exclusively, the upper region of the tubular segment is configured and sized for placement in the renal cavity.
Typically the elongated tail member comprises at least one (and more preferably at least two) thread filament(s). Two or more of the filaments may be configured in at least one filament loop, and, advantageously, the tail comprises no unlooped filaments, so that the tail is free from loose ends. The loop(s) can be made by joining the ends of a single filament, in which case the filament loop comprises a junction of individual filament ends, which junction typically is positioned at the point where tail joins to the elongated tubular segment. Preferably, the tail is long enough to effectively prevent migration of the entire tail into the ureter, and the tail has a smaller outer diameter than the outer diameter of the tubular segment.
The tubular stent segment is stiff enough to avoid crimping during insertion through the ureter, so that it can be inserted by typical procedures. The tail, on the other hand, is extremely flexible (soft) in comparison to the tubular segment, and it has a much smaller diameter than the tubular segment to avoid discomfort. Even quite thin structures will provide urine transport, and the thinner and more flexible the tail is, the less likely it is to cause patient discomfort. On the other hand, the tail (and its connection to the rest of the stent) should have sufficient strength so the stent can be retrieved by locating the tail in the bladder and pulling on the tail to retrieve the stent from the kidney and ureter. Details of the tail size are discussed below. The use of reinforcing materials (e.g., sutures as described below) permits the use of thinner tails while still providing the ability to locate the tail in the bladder and to retrieve the stent. The tail may be a suture, and the suture may be coated to avoid encrusting.
The external urine-transport surface of the tail can be convex (circular or oval in section), concave or flat. The tail filament may be fluted. The tail may, but need not, include an accurately shaped anchor segment to control migration up the ureter. The tail may be either solid or hollow; even when hollow, it is not designed to transport a significant amount of urine internally. The tail may also be tapered.
The upper region of the tubular segment may have a portion designed for placement in the renal cavity, which portion has enlarged diameter and/or straight sides and corners. The stent may include an extractor thread attached to the lower end of the elongated tail member.
To make the stent, the tail may be molded in one piece with the tubular segment, or it may be made separately and attached to the bladder end region of the tubular segment at a point toward the kidney from the bladder end of the lower region of the tubular segment. In one specific embodiment, the tail is attached near or at the bladder end of the bladder end region of the tubular segment. The stent may include a suture securing the tail to the tubular segment, and the suture may be incorporated into the tail to impart strength to the tail so the tail may be used to retrieve the stent. If the tail includes a hollow lumen, the suture may be positioned inside that lumen. The suture may be attached to the tubular segment at a point in the bladder end region of the tubular segment, and the suture may extend from the point of attachment through an opening in the bladder end region to the central lumen of the tubular segment and from there to the hollow tail. Alternatively, at least the bladder end region of the tubular segment may include two lumens, a main urine-transporting lumen and a bladder lumen to encase the suture, so that the suture does not become encrusted.
The outer diameter of the tubular segment can be tapered so that it decreases approaching its lower region. The lower region of the tubular segment may include multiple openings positioned, e.g., axially along include its length or radially around its circumference, or in other patterns. In addition, the outer diameter of the stent's tubular segment may decrease approaching the upper region. In other words, the maximum diameter may be at the site of the injury to encourage a sufficiently large inner diameter in the repaired structure, and the tubular segment's outer diameter may decrease moving away from that point of maximum diameter to sections of the normal ureter that are not in need of a broad support structure. Typically, the outer diameter of the upper end of the tubular segment will be greater than the outer diameter of the bladder end. The upper region may include multiple openings (inlets).
In an alternative embodiment, the elongated external urine-transport surface is a continuous surface extending from the kidney to the bladder, e.g., it is the outer surface of a solid member extending from the kidney to the bladder.
Another aspect of the invention features a method of introducing a ureteral stent (described above) into a patient, by (a) positioning the kidney end region of the tubular segment within the renal pelvis; and (b) positioning the elongated flexible member(s) in the bladder.
Yet another aspect of the invention features a method of manufacturing a ureteral stent as described above. The method comprises: (a) providing a polymer pre-form having a tubular shape; (b) forming an elongated tubular stent segment from the polymer pre-form, and (c) providing tail member(s) at an end region of the tubular segment designed to be positioned toward the patient's bladder.
As described in greater detail below, the stent may be manufactured from a polymer form having a tubular shape by forcing the form onto a mandrel to produce the desired three dimensional shape (coils, etc.). The elongated tubular member(s) is attached to one end of the tubular member(s) using sutures as described above. Heat treatments to fuse the structures and/or standard adhesives may be used. Alternatively, the tubular member(s) and the elongated member constitute a one-piece stent.
The use of relatively thin, flexible elongated member(s) to assist urine flow across the ureterovesical junction and into the bladder may reduce reflux and irritation and thereby reduce patient discomfort and medical problems associated with ureteral stents.
Other features and advantages of the invention will appear from the following description of the preferred embodiment, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a ureteral stent with a central portion of the tubular segment omitted.
FIG. 2 is a cross-sectional view along line 2 — 2 in FIG. 1 .
FIG. 3 is an enlarged side-view of a portion of the ureteral stent in FIG. 1 .
FIG. 4A is a view of an alternate embodiment of the stent in FIG. 1 , and FIG. 4B is a section taken along 4 B— 4 B of FIG. 4 A.
FIGS. 5A and 5B are schematic representations of another stent according to the invention, depicted in place.
FIGS. 6A-6D depict alternative cross-sections of the tail of a stent according to FIG. 5 .
FIG. 7 is a schematic representation of yet another stent according to the invention, having an extraction thread.
FIG. 7A is an enlargement of a portion of FIG. 7 .
FIG. 8 is a schematic representation of the stent of FIG. 7 shown in position.
FIG. 8A is a detail of the connection between the tail and the extraction thread.
FIG. 8B is a cross-section of threads of differing softness, showing the effect of compression on interstitial space.
FIG. 9 shows an alternative embodiment of the stent.
FIG. 10 is a schematic drawing of the human urinary tract without a stent, showing the renal pelvis, the kidney, the ureter, and the ureteral orifices opening into the bladder.
FIG. 11 depicts a prior art double-J stent outside the body.
FIG. 12 depicts a prior art J indwelling ureteral stent in position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , ureteral stent 100 includes an elongated tubular body 130 connecting coil end 140 to straight end region 120 . Tubular body 130 is designed to extend from the renal pelvis through the ureter to a terminus upstream of the bladder. Tail 110 is attached to straight end region 120 , and tail 110 extends along the ureter, across the ureter/bladder junction and into the bladder.
The two opposing end regions 120 and 140 of elongated tubular body 130 are illustrated in FIG. 1 . Coiled end region 140 is designed to be placed in the renal pelvis of the kidney. For illustrative purposes, coiled end region 140 is shown with a pigtail helical coil although any shape that will retain the stent in place within the kidney will do. Coiled end region 140 includes several openings 125 placed along the wall of the tubular body; the openings may be arranged in various geometries (e.g., axial, circumferential, spiral). The entire tubular segment, including the region between the kidney and the bladder end regions, may include additional openings.
The bladder end region 120 of the tubular stent segment is designed to terminate in the ureter, upstream of the bladder. For purposes of further description, the end region of stent 100 received in the kidney will be designated the kidney end and the opposite end of stent 100 toward the bladder will be termed the bladder end.
FIG. 2 is a cross-sectional view of stent 100 of FIG. 1 . In FIG. 2 , elongated tubular body 130 has annular walls 250 having an inner and outer diameter. The outer diameter of tubular body 130 may be substantially uniform throughout much of the length of the tube, or it may taper from a relatively short region of larger diameter (the site of the repair, where there is a risk that the healing process will substantially restrict flow in the lumen) to a region of generally small diameter. The precise configuration may depend on the ureteral defect being corrected. Just one of the many classes of procedures that can benefit from the stent are endopyelotomies—procedures for treating ureteropelvic junction (UPJ) obstruction by an incision which perforates the ureter at the stricture. In these and other procedures, the stent keeps the ureter lumen open during the healing process, so that the inner diameter of the resulting healed structure is adequate. The section of the tubular segment at the defect is large enough to support growth of repair tissue having an adequate inner diameter. At other sections of the ureter (e.g., sections not being surgically repaired), the outer diameter of the tubular segment may be far smaller, but with an inner diameter adequate for passage over a guidewire. For example, the outer diameter of the bladder end region of the tubular segment typically is 2Fr.-12Fr. Preferably the outer diameter of tubular body 130 is greatest at the ureteropelvic junction obstruction but begins to taper approaching each end. Alternatively, for a patient with an upper ureteral obstruction, the upper (kidney) portion of the tubular member 130 may be uniform in diameter, tapering just in the lower (bladder) portion.
Tubular member 130 defines a central lumen or passageway 260 , extending from kidney end region 140 to bladder end region 120 . The inner diameter of lumen 260 is sufficient to permit passage over a guidewire. Tubular body 130 may also have openings 125 extending through its walls 250 to facilitate the flow of urine from the kidney into central lumen 260 and openings 127 to facilitate flow out of central lumen 260 .
In FIG. 3 , the outer diameter of elongated tubular body 130 tapers near bladder end region 120 . The outer diameter of bladder end region 120 may be made as small as possible while maintaining the ability to pass over a guidewire. Elongated tubular body 130 may (but need not be) substantially straight in bladder end region 120 , i.e. it does not coil or curve in the absence of external force. When tail 110 is a single filament, it typically is thinner than even the smallest portion of bladder end region 120 of the tubular stent segment. Alternatively, it may be desirable to design the tail from multiple filaments, each of which, by itself, is much thinner than the bladder end region of the tubular stent segment. Together, such a multi-filament tail has a larger effective diameter, providing additional bulk while maintaining comfort. Tail 110 may be attached at or near the end of region 120 , and it extends from that attachment into the bladder. Tail 110 is either solid or hollow. It can be generally cylindrical in shape; alternatively, it can be fluted, concave (quarter-moon)-shaped or it may assume other shapes.
The tail can have an outer diameter that is significantly less than the inner diameter of the ureter (typically 2-5 mm) and no greater than the outer diameter of the tubular segment from which it extends. For example the tail diameter is less than 10Fr. and as low as a suture (about 0.5Fr). Preferably the tail diameter is between 2Fr. and 4Fr. The length of tail 110 is preferably between 1 and 100 cm. In one embodiment, the tail is long enough so that at least a portion of it will remain in the bladder, and effectively the entire tail cannot migrate up into the ureter. Preferably the length is between 1 and 40 cm. Tail 110 is flexible and, upon application of force, can be curved, but also has memory such that when the force is removed, it is generally straight.
Stent 100 , including tail 110 and tube 130 , may be a single unit. Thus, tail 110 can be a unified piece, extending from bladder end region 120 with no additional attachment means. Alternatively tail 110 can be secured to elongated tube 130 or bladder end region 120 by physical or mechanical methods.
For example, in FIG. 4A , a suture 415 is inserted through an opening 418 in the tubular member and then threaded through the lumen 417 of tubular member 430 . In FIG. 4B , tail 410 is a hollow member having suture 415 threaded through its inner lumen 412 .
FIG. 5 is a schematic of another stent 510 . The kidney end A of the stent has a pre-formed memory bend, to coil 512 as shown. Kidney end A is larger and more rectangular to help prevent upward as well as downward stent migration. End A may be closed or tapered to accommodate various insertion techniques. For the upper portion (A—B) of the stent, diameter, lumen size, perforations and materials are conventional. The lower end 514 of the tubular stent segment ends at B. The distance A—B could vary depending on the patient's anatomy. At B, the stent is tapered (or at least smooth and constant in diameter).
Two or more monofilament or coated (plastic or silicone) threads 516 exit from the lumen or from the stent wall. These threads only partially fill the ureter and are as flexible (soft) as possible. Typically, they are cut to a length which forces confinement within the bladder.
The portion of the upper segment 512 lying within the renal pelvis (e.g, from the kidney end of the stent to point A) is expanded so that it is larger in section, and it may even be oval or rectangular in cross-section, to help prevent upward as well as downward stent migration. The kidney end of the stent may be closed and/or tapered to accommodate the desired insertion technique. The upper portion 512 is made of a relatively stiff material (among the materials currently used in ureteral stents), and it should be designed to effectively restrict the motion of the stent to prevent proximal as well as distal migration of the catheter during normal physiological activity (required because the lower pre-formed portion is deleted). The length of the straight portion of the upper segment ( FIG. 5A point A to B) will vary with patient size and anatomy. In the preferred configuration, the upper segment extends more than halfway down the ureter when in proper position. The lowest end of the upper segment ( FIG. 5A point B) should be tapered or beveled to facilitate withdrawal. Otherwise, the upper segment is a typical stent in diameter, materials and shape.
The lower segment ( FIG. 5A point B to point C) consists of two or more (e.g four) monofilament, plastic coated or silicone coated threads (shown in section in FIG. 5B ) which extend from the lumen or sidewall of the lower end of the upper segment ( FIG. 5A point B) along ureter 513 into the bladder. These threads are extremely flexible, and their diameter is selected to maintain a passage for urine flow and yet drastically reduce bladder and ureteral irritation. By avoiding distortion of the ureter wall, the threads may inhibit urinary reflux as well. The threads should be long enough to reach well into the bladder ( FIG. 5A point C), but not so long as to wash into the urethra with voiding. One thread 518 (or two or more threads in a loop) may be long enough to exit through the urethra ( FIG. 5A point B to point D) to permit ready removal by pulling (avoiding cystoendoscopy).
These extended threads may also be used for stent exchange, in which a second catheter is exchanged for the catheter already in place. According to that procedure, these extended threads are captured with a snare that has been inserted through the central lumen of a second catheter. The snare is used to pull the threads through the lumen as the second catheter is advanced into the ureter. A guidewire is then inserted through the central lumen of the second catheter to the kidney (outside the first catheter's tubular body). The first stent is then removed by pulling on the threads, leaving the guidewire in position for placement of a new stent using standard techniques.
FIGS. 6A-6D are alternative cross sectional sketches (taken at the same location as FIG. 5B ) of some possible arrays of threads passing within the lower ureter 517 . Multiple threads 516 ( 2 and 4 , respectively) are shown in FIGS. 6A and 6B . A substantially similar conduit could be achieved by fluted type cross sections in a single filament FIGS. 6 C and 6 D). The shapes of FIGS. 6C and 6D could also be effective in reducing stiffness and hence irritability at the bladder end (i.e., lower segment), e.g., in a single filament design. Multiple threads may have the advantage of better surgical manipulability and superior comfort to the patient.
Further refinements are described below and in FIGS. 7 and 7A which deal with: a) proximal or upward stent migration of either the entire stent or individual threads in the lower segment independent of upper segment movement; b) bunching of one or more threads within the ureter so as to obstruct flow or cause ureteral injury or knotting at the time of removal; and c) in multi-thread embodiments, discomfort and/or reduced drainage through the ureter resulting from the use of threads of different lengths. In FIGS. 7 , 6 F (F=French size=circumference in mm) stent is a generally a good size for adult urinary systems. It is large enough to provide good drainage and small enough to minimize local irritation and inflammation of the ureter. In this embodiment, the upper segment need be only a single loop of conventional size because a change in the design of the lower segment (see later discussion and FIG. 8 ) should prevent proximal migration. The upper segment ( FIG. 7 point A to point C) is constructed of a relatively firm material because, during insertion, the pusher tubing should be removed after the guidewire is removed. This means that there will be some drag on the threads during removal of the pusher tubing which could dislodge the stent if the coil ( FIG. 7 point A to point B, about 2.5 cm) does not provide adequate resistance. The coil may be tapered or closed depending on the insertion technique desired (i.e., over a previously placed guidewire.
FIG. 7 point B to point C should have an approximate length of 12 cm. This is long enough to prevent dislocation of the upper segment in a large renal pelvis and short enough to end well above the point where the ureter crosses the common iliac vessels. At the iliac vessels, the ureter takes a fairly sharp turn and the threads will more easily follow the natural curves at this point. This design should reduce the inflammation that is normally seen in this region when a conventional double-J stent is left indwelling on a chronic basis.
The junction of the upper and lower segments at FIG. 7 point C is important. See FIG. 7A , which enlarges this junction. At point C ( FIG. 7 ) the threads are attached to the upper segment in a manner that achieves the following goals: 1) the threads are securely attached to the upper segment and to each other (at least for a short distance of about 0.8 mm) so that their orientation to themselves is maintained (to the maintenance of lower end asymmetry); 2) the threads do not obstruct the lumen of the upper segment and they allow for the easy passage of a standard guidewire (e.g., 0.035 guidewire); 3) the transition diameters in this region closely preserve the 6F standard so that this point can pass in both directions smoothly throughout the instruments used for insertion and through the ureter; 4) there is no cause for a localized ureteral obstruction; and 5) there is an effective abutment for the pusher tubing. For an average size ureter a good starting string diameter for a four string lower segment ( FIG. 7 point C to point E) would be 0.020 inches. A simple monofilament nylon thread is an easy potential solution but may be too stiff. A more supple monofilament or woven thread with silicone or other coating may be required to achieve minimal irritability. However, the threads should be sufficiently resistant to compression so that tissue generated pressures cannot collapse the interspaces of the threads. See FIG. 8B , showing cross-sections of threads (left) which retain interstitial space under some modest compression and of threads (right) which are so soft that they compress into a plug with reduced interstitial space. These threads may have centimeter markings beginning at a point no more than 20 centimeters from point B ( FIG. 7 ) so that functional ureteral and total stent length may be noted.
The portion of the lower segment which lies within the bladder when the stent is in proper anatomic position ( FIG. 7 point D to point E) is important to, both comfort and function. Proximal migration can be controlled by using asymmetrical lengths of the thread pairs, with one pair being 2 cm longer than the other pair, so that the fused junction 810 of these threads tends to intersect with the ureteral orifice 814 at an angle (e.g., ˜90°) with the stiffened area 815 having a length of 6 mm (see detail FIG. 8 A). In the ideally fitted stent of this embodiment, the thread pairs will extend beyond the ureteral orifice ( FIG. 7 point D) by 1 cm at the short limb 820 and 3 cm at the long limb 825 . However, this lower segment configuration allows for considerable tolerance in sizing (unlike unsecured independent threads which must be selected to have a length so as to avoid upward migration of the thread through the ureteral orifice 814 ) and a chosen length which is 1 cm shorter or 2-3 cm longer than the ideal length should be satisfactory. Using this configuration the threads should form a continuous loop 828 of 3.5 cm length to prevent free ends from poking the bladder wall or prolapsing through the urethra. Buoyant threads may add to patient comfort, because they will float away from the trigone region of the bladder, where most of the sensory nerve fibers are located. A typical small gauge filament extraction thread 830 may be attached to the longer limb 825 of the thread pairs, which is a suitable pulling point for removal.
From this embodiment, a small diameter pusher tubing of 4-4.5F should be used to aid insertion. Soft percuflex is near optimal for the lower segment, and firm or regular percuflex is used for the upper segment.
The bladder end should be easily inserted using instruments, and it should prevent proximal migration of the stent. The design of FIG. 7 will avoid tangling and migration of the stent. Alternatively, soft percuflex, for example, has good resistance to extreme flexion at small radii (e.g., even 0.020″ diameter) so that a simple continuous loop extending from the junction of the upper and lower segments (see FIG. 9 ) may be adequate to prevent upward migration. The design of FIG. 9 also has the advantage of relative ease of manufacture and relative ease of insertion, as well as ease and comfort of removal.
Other dimensions that can be used (without limitation) are 12 cm straight portion of the upper hollow shaft, and 12 cm, 14 cm, or 16 cm length of added loops of soft percuflex. For the 0.020″ diameter material, either 2 or 3 loops may be used providing 4 or 6 strings, total. For 0.040″ inch material, either 1 or 2 loops is recommended.
FIG. 9 shows such an alternative embodiment having a simple coil at the kidney end. The lower end is constructed of looped stringlike elements with ends fused at the junction between the lower and the upper end. Therefore, there are an even number of string elements, with no free ends. Circle E in FIG. 9 represents an idealized depiction of the ureteral opening into the bladder. While not shown in FIG. 9 , the loops may be fused over a very short distance at the bladder end in order to prevent tangling of loops and to improve stent handling. Any conventional means of fusion may be used. Optionally, organization of the loops can be maintained by pre-placing them inside the pusher tubing using a long monofilament nylon loop tail, similar to those used for the non-invasive removal stents (i.e. without sensor endoscopy).
Methods for insertion and removal of ureteral stents are known in the art. Generally, stent placement is achieved by advancing the tubular stent segment over a guidewire in the ureter. A pushing catheter passes the tubular segment into the kidney, while maintaining the tail in the bladder. Other methods such as a stiff sheath can be used to position the stent. Once in position, the sheath can be removed.
The tubular portion of the stent may be manufactured by extruding a tube according to known techniques. The elongated tail may be separately manufactured by conventional techniques and attached to the tubular portion, e.g., using biocompatible adhesive materials or heat. Alternatively, the stent may be made by injection molding the tube and the tail as a single piece, using a pin to create hollow segments. The stent may be manufactured from any of a number of biocompatible polymers commonly used inside the body, including polyurethane and polyethylene. In still other embodiments, the entire stent may be solid, so that urine is conveyed entirely on an external stent surface.
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A ureteral stent for assisting movement of urine along a patient's ureter and into the patient's bladder. The stent includes an elongated tubular segment extending toward the bladder from a kidney end region for placement in the renal cavity to a bladder end region. A central lumen connects at least one opening at the first end region to at least one opening in the bladder end region. Thin flexible tail(s) are attached to the bladder end region of the tubular segment at a point outside the bladder so as to receive urine from the opening in the bladder end region of the tubular segment and to transport urine from there across the ureter/bladder junction and into the bladder. The tails include an elongated external urine-transport surface sized and configured to transport urine along the ureter. The urine transporting surface(s) are sized and configured to extend along at least part of the ureter, across the ureter/bladder junction, and from there into the bladder.
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[0001] There are no related patent applications.
[0002] This application did not receive any federal research and/or development funding.
BACKGROUND OF THE INVENTION
[0003] The present invention generally relates to a form for constructing and aligning masonries. The terms “masonry” or “masonries” are general terms representing that which is built by a mason or anything constructed of masonry materials, such as bricks, blocks, stones, tiles or other such materials used by a mason during a building or constructing process. More particularly, the present invention is directed towards a plastic form or gauge that is implanted in a wall for aiding in the laying process of the masonry materials. Thus, an unskilled homeowner may easily construct a masonry wall.
[0004] Masonry walls typically comprise bricks or blocks which are stacked or arranged in layers which are commonly referred to as “rows” or “courses”. Mortar is a limestone-based adhesive that is typically used as a binding or bonding agent to adhere the bricks or blocks together. For purposes of this disclosure, the term mortar shall include any adhesive for securing masonry materials together. When bricks or blocks are laid, the mortar is arranged on the top, bottom, and adjacent ends of each brick or block. A brick or block wall is constructed by first laying a foundation concrete upon which the brick wall is constructed. A foundation of concrete is poured and allowed to cure such that it will support weight. Mortar is spread atop the foundation about one inch deep and eight inches wide, if a block wall is being laid. Preferably, a furrow is created in the center of the mortar to force mortar towards the edges of the brick or block. A narrower layer of mortar is spread when constructing a brick wall since the standard size for American bricks is 8″ long by 4″ wide by 1⅝″ to 2¼″ thick.
[0005] There are two basic shapes of American bricks, cored bricks and solid bricks. A solid brick is devoid of internal openings. Cored bricks are bricks that include removed cores or internal openings extending from one side of the brick through to an opposite side. These internal openings reduce the weight of the brick, as well as the production costs associated with reuse of the recycled material from the internal openings. When cored bricks are laid, mortar enters the internal openings to create a stronger or more durable bond between adjacent bricks that comprise a masonry structure. Likewise, a cinder block comprises core openings.
[0006] There are several prior art devices that have attempted in aiding an individual in laying blocks. Some of these include spacing or forming devices that fasten a brick or block to one another or to a backing panel. U.S. Pat. No. 4,756,136 to Hodges discloses an interlocking spacer apparatus for masonry construction. The apparatus comprises a pair of spaced saw-tooth shaped members with a plurality of bearing surfaces that engage adjacent masonry members. U.S. Pat. No. 4,946,632 to Pollina discloses a method of constructing a masonry structure using a prefabricated wire support structure that has the shape of the structure to be made. In U.S. Pat. No. 4,953,337 to Mills, a method and apparatus for constructing a masonry structure is disclosed. The apparatus includes a rigid backing panel with rows of rectangular openings formed therein.
[0007] U.S. Pat. No. 3,374,589 to Neal discloses a course spacer and mortar barrier. The device includes an elongated, rectangular horizontal sheet of kraft paper. Projections provided along the sheet serve as guides for aligning bricks. U.S. Pat. No. 4,136,498 to Kanigan discloses a block or brick guide. A plastic or metal web of material is provided with upper and lower projecting conical members with a surrounding edge band having a thickness equal to the mortar joint between courses of bricks or blocks. U.S. Pat. No. 5,191,718 to Fox discloses a masonry block spacer tool that includes two opposing base plates having ends that snap fit together.
[0008] Still other alignment devices have been constructed for installing other materials including tiles, glass blocks and block walls. U.S. Pat. No. 2,483,560 to Peterson discloses a bearing and spacing guide for glass block construction. The guide includes spaced flanges connected by a web. Lugs provide stability against tipping of the glass block. U.S. Pat. No. 5,259,161 to Carter discloses a vertical and horizontal reinforcing and spacing guide for panels constructed of blocks. The device comprises a plurality of elongated reinforcing members. U.S. Pat. No. 5,288,534 discloses a tile spacer. The spacer includes a platform and a cross-shaped spacer.
SUMMARY OF THE INVENTION
[0009] The present invention is a device and method for improving the field of masonry by aiding both the skilled and unskilled artisans in laying masonry structures. In a first embodiment, an alignment device comprises a lightweight material preferably of molded, extruded plastic, or composite material. The alignment tool may be formed from plastics including, but not limited to, polyethylene, polypropylene, polystyrene, polyurethanes, and polyvinyl chloride, or any other thermoset materials having a roughened exterior. Moreover, the alignment device may comprise stamped metal pieces.
[0010] The alignment device includes a central support member that connects a plurality of external and internal alignment tools that causes bricks or blocks to be correctly stacked or aligned during the masonry building process. The alignment tools extend from one or more locations along the central support member or at either end thereof. In one embodiment, a pair of block spacers is arranged at an end of a central support member for creating a uniform spacing between adjacent bricks in a tier. The pair of block spacers may extend upward or downward as more fully discussed with respect to the drawings. A pair of horizontal alignment tools extends from the central support member to form an extended support interposed between a bottom surface of an upper brick and a top surface of a lower brick. A pair of external face alignment tools are arranged at an end of the horizontal alignment tools for aligning the front face of each brick as it is laid with the front faces of the bricks laid below. Upper and lower post aligners are provided for either being inserted into a core or being arranged in a mortar joint between adjacent bricks. These external and internal alignment tools align the center of gravity of each succeeding course of bricks atop the previously laid course. In this manner, the masonry structure is always true. A bottom surface of a brick rests on an upper surface of the central support member. The central support member preferably includes at lease one snap-off 21 zone arranged midway between each end of the central support member. Other snap off zones 21 may be provided at various locations along the central support member.
[0011] The horizontal alignment tool extends from a front side of the central support member and is preferably the same height and thickness as that of the central support member. After the masonry structure being constructed and prior to the bonding agent hardening, an end of the horizontal aligner is arranged to be separated from the central support member. The horizontal alignment tool causes the central support member to be properly aligned with the top of the brick arranged beneath the device and the bottom of the brick arranged above the device.
[0012] The horizontal alignment tool includes a flexible snap off member that may be struck with a trowel or twisted in a clockwise or counterclockwise manner to remove the upright after the succeed layer of bricks have been laid and prior to finishing the look of the mortar joints after the masonry materials are laid. Moreover, the horizontal alignment tool is flexible to allow for deviations in the bottom of the brick. The thickness of the snap off member is thinner than that of the either the central support member or the horizontal alignment tool.
[0013] An external surface aligner extends from the front side of the central support member and comprises a vertical upright having a central attachment point that attaches to a flexible snap off member which connects at an opposite end to the horizontal alignment tool which in turn connects at an opposite end to the central support member. The vertical upright serves for aligning the front faces of each tier of laid bricks as well as a grip for twisting the external surface aligner to cause separation from the alignment device. The vertical upright ensures that the face of each brick is aligned with each successive one in elevation to make a straight masonry structure.
[0014] A lower internal vertical aligner extends downward from the central support member and inserts into an opening on a brick arranged below the device to securely fasten the alignment device thereto or alternatively, the lower internal vertical aligner may be arranged in a mortar joint that is arranged below the alignment device. In this manner, each succeeding tier of bricks are laid straight with the bricks below.
[0015] An upper internal vertical aligner extends substantially one inch upward from the upper surface of the central support member and in one embodiment includes a pointed end having two sloped edges. The upper internal vertical aligner provides a post upon which the edges or the ends of a pair of adjacent upper bricks are deposited and is arranged in a mortar joint. Alternatively, the upper internal vertical aligner is inserted into a core opening. Each internal vertical aligner is substantially ⅞″ long; one is inserted into an opening in a brick for aligning each of the bricks by using the other internal vertical aligner as a reference.
[0016] A hoop fastener extends from a back side of the central support member and secures the device to an exterior wall of a building or other structure where necessary. Otherwise, the fastener may include a snap-off zone for easy separation from the central support member.
[0017] Thus, the instant device is a formed spacing member that causes adjacent bricks in one layer of the wall to be properly spaced apart such that the proper amount of mortar is deposited between ends of adjacent bricks or blocks, while aligning the exterior front of the bricks or blocks such that each succeeding tier is properly aligned with the tier below. Moreover, the spacing between adjacent ends of the bricks that are arranged end to end is uniform throughout the masonry structure.
[0018] It is an object of the invention to provide an improved masonry constructing method and devices therefore.
[0019] A further object of the invention to provide a device and method that aids unskilled workers in constructing masonry structures. Moreover, the device can also aid a skilled or master mason by allowing helpers to quickly lay the bricks or blocks thus making the master mason more productive and aiding him in quickly constructing masonry structures.
[0020] An additional object of the invention is to provide a device that reduces labor costs associated with constructing masonry structures.
[0021] It is a further object of the invention to provide a device and method that provides more reliable and straighter walls that other alignment devices or techniques.
[0022] It is another object of the invention to provide a device and method that is easy to learn and to use such that an unskilled laborer may construct a masonry structure.
[0023] The above and further objects, details and advantages of the invention will become apparent from the following detailed description, when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1A is a perspective view of a first embodiment of the form and shown from a front side. FIG. 1B is a back perspective view of FIG. 1A . FIG. 1C depicts a brick being arranged onto the form. FIG. 1D is a perspective view of a masonry structure that is built using a plurality of forms. FIG. 1E is a front elevated view of the masonry structure of FIG. 1D .
[0025] FIG. 2A is a second embodiment of the form and shown from a front side. FIG. 2B is a back perspective view of FIG. 2A . FIG. 2C depicts a brick being arranged onto the form. FIG. 2D is a perspective view of a masonry structure that is built using a plurality of forms.
[0026] FIGS. 3A through 3D depict the steps of using the form shown in FIGS. 1A through 1E to create a masonry structure.
[0027] FIGS. 4A through 4D depict alternative steps of using the form shown in FIGS. 2A-2D to create a masonry structure.
[0028] FIG. 5A is a perspective view of a third embodiment of the form and shown from a front side. FIG. 5B is a back perspective view of FIG. 5A . FIG. 5C depicts a brick being arranged onto the form. FIG. 5D is a perspective view of a masonry structure that is built using a plurality of forms.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The embodiments of the invention and the various features and advantageous details thereof are more fully explained with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and set forth in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and the features of one embodiment may be employed with the other embodiments as the skilled artisan recognizes, even if not explicitly stated herein. Descriptions of well-known components and techniques may be omitted to avoid obscuring the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those skilled in the art to practice the invention. Accordingly, the examples and embodiments set forth herein should not be construed as limiting the scope of the invention, which is defined by the appended claims. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.
[0030] FIG. 1 relates to an alignment device with a cored brick. The alignment device 1 comprises lightweight molded or extruded plastic or composite material from plastics including, but not limited to, polyethylene, polypropylene, polystyrene, polyurethanes, polyvinyl chloride, thermoset resins, polyethylene terephthalate, high density polyethylene, and other mixed resins that preferably includes a roughened exterior surface or exterior surface that allows the mortar to adhere thereto. Otherwise, the alignment device may comprise a composite material that is formed or a metal that is stamped or punched from a much larger sheet.
[0031] Alignment device 1 includes a plurality of alignment extensions (collectively element numbers 5 , 6 , 7 , 9 ) which comprise respective vertical elements. In other words, some of the alignment extensions extend upwards; still others extend downward with respect to the upper and lower surfaces of the central support member 2 . Each alignment extension extends from a central support member 2 . The central support member 2 provides a correct height between succeeding courses of bricks such that when a plurality of the alignment devices are used, the correct amount of mortar is applied between each successive course of bricks. The central support member 2 connects the plurality of alignment tools that causes bricks or blocks to be correctly stacked during the masonry building process. A t-shaped end 10 is arranged at one end of the central support member 2 for providing a platform to which end extensions 9 are fixed. A bottom of a brick or block rests on an upper face of the central support member. At lease one snap-off region 21 may be arranged midway between each end of the central support member 2 . Other snap-off regions 21 may be provided as shown in the drawings.
[0032] One alignment extension 7 , referred to herein as an “internal vertical aligner”, extends from an upper surface of the central support member 2 in FIGS. 1A-E . Another alignment extension 6 , also referred to as an “internal vertical aligner”, extends from a lower surface of the central support member 2 in an opposite direction in FIGS. 1A-E . It should be noted that these alignment extensions 6 , 7 are reversed in FIGS. 2A-2D . These alignment extensions 6 , 7 cause the center of an upper brick to be centered over the mortar joint between adjacent bricks in a course below. In this manner, the successive courses of bricks are correctly aligned in a side-to-side manner as well as a front-to-back manner. Aligning the bricks correctly causes center loading of each successive course of bricks which in turn strengthens the masonry structure.
[0033] A pair of end extensions 9 is provided at one end of the central support member 2 for providing an accurate amount of mortar that should be used to create a mortar joint between adjacent bricks. In FIGS. 1A-1E , the end extensions 9 extend upwards from a plane that is parallel to the upper surface of the central support member 2 . In FIGS. 2A-2D , the pair of end extensions 9 extends downward from a plane that is parallel to the lower surface of the central support member 2 . The pair of end extensions 9 serves as spacing members causing adjacent bricks in one course of the masonry structure to be properly spaced apart such that the proper amount of mortar is deposited between ends of adjacent bricks or blocks. In this manner, vertical mortar joints between adjacent bricks are uniform in size.
[0034] Another pair of alignment extensions 5 , referred to hereinafter as “external surface aligners”, extends from the front of the central support member 2 to align exterior surfaces or front faces of bricks 100 . This in turn aids in centering the successive courses of bricks from front-to-back. A hoop fastener 8 extends from the back side of the central support member 2 to fasten the masonry wall to a solid structure such as a building.
[0035] The preferable dimensions of the devices shown in the figures include an overall length of the central support member 2 including a T-shaped end 10 is substantially seven inches (7″). The preferable length of each spacing block 9 is one-half an inch (½″). Each spacing block 9 has an upper end or a lower end that is respectively elevated above a plane formed by the top surface of the central support member or respectively elevated below a plane formed by the bottom surface of the central support member as more fully discussed hereinafter. The height of the central support member is substantially one half an inch (½″). The preferably thickness of the central support member 2 is substantially within a range of one eighth an inch to one-quarter an inch (⅛″ to ¼″).
[0036] A back end of a horizontal aligner 3 extends from a front side of central support member 2 and is preferably the same height and thickness as that of the central support member 2 . The horizontal aligner 3 causes the central support member 2 to be properly aligned with the top of the lower brick and the bottom of the upper brick.
[0037] A back end of a flexible snap off member 4 extends from a front end of the horizontal aligner 3 . An overall length of the horizontal aligner 3 and the flexible snap off member 4 when added to the thickness of the external surface aligner 5 substantially equals two inches (2″). A length of the flexible snap off member 4 is shorter than that of the horizontal aligner 3 . The thickness of the horizontal aligner 3 is substantially the same as that of the central support member 2 . The flexible snap off member 4 is substantially 1/16″ thick and has a shorter length than that of the horizontal aligner.
[0038] An external surface aligner 5 extends from a front end of the flexible snap off member 4 which intersects it at a center of the back side of the external surface aligner which comes into contact with the faces of two stacked bricks. The overall vertical length or height of the external surface aligner 5 is approximately one and three-quarters and inch (1¾″). The thickness of the external surface aligner 5 is substantially equal to the width of the flexible snap off member 4 , which is preferably one-sixteenth an inch ( 1/16″). The external surface aligner 5 extends from a front side of the central support member 2 via the horizontal aligner 3 and snap off member 4 . It comprises a vertical upright having a central attachment point that attaches to the flexible snap off member 4 which connects at an opposite end to a horizontal aligner 3 . The external surface aligner 5 serves for aligning exterior faces of bricks above and below the device 1 , as well as providing a grip for twisting the external surface aligner 5 to detach it from the central support member 2 , preferably at the snap off member 4 . The external surface aligner 5 may also be easily separated by striking it with an end or edge of a trowel.
[0039] An internal vertical aligner 7 extends from an upper face of the central support member 2 . The internal vertical aligner 7 is formed to be easily separated from the central support member 2 by striking it with a trowel. Alternatively, when the alignment device comprises metal, the internal vertical aligner 7 may be removed by either twisting or snipping it off with pliers or tin snips. The thickness of either internal vertical aligner is substantially one-half an inch (½″) wide and having a height of one and one-quarter an inch (1¼″) and a thickness of one-eighth an inch (⅛″). An end of the internal vertical aligner 7 opposite the central support member 2 is preferably shaped with a peak arranged along its width and having two sloped edges as shown.
[0040] Another internal vertical aligner 6 extends downward from a bottom side of the central support member 2 and inserts into a central or core opening on a lower brick to securely fasten the alignment device 1 to the lower brick. In FIGS. 1A-1E , the internal vertical aligner 7 extends upward from the upper surface of the central support member 2 and provides a post upon which the upper brick is deposited such that the internal vertical aligner 7 extends into an internal opening of the upper brick. When the internal vertical aligner 6 and the internal vertical aligner 7 extend into an opening of a respective brick and between mortar joints of two bricks below, the upper brick is automatically aligned with the mortar joint between the adjacent lower bricks. In this manner, the center of gravity for the upper brick automatically is centered over the center of gravity for the lower brick. The internal vertical aligner 6 is shaped like an arrow as shown. In this manner, the outlying areas 6 A, 6 B easily slide into an opening or between a mortar joint arranged between adjacent bricks. The outlying areas 6 A, 6 B, thereafter resist any forces that tend to displace the internal vertical aligner 6 from within the core opening or mortar joint.
[0041] Hoop fastener 8 secures a brick or block wall to an exterior wall of a building, when necessary. It should be noted that the hoop fastener 8 can be provided in a variety of shapes. The hoop fastener 8 also includes a snap off zone 21 near the central support member 2 .
[0042] As can be readily understood from FIGS. 1C-1E , the internal vertical aligner 6 is inserted into the central core opening 105 of brick 100 . The core opening 105 extends from an upper surface 103 throughout to the brick 100 to exit at the lower surface (not shown). The brick 100 rests atop the upper surface of the central support member 2 , t-shaped end 10 and horizontal extension 3 . The brick includes brick ends 101 and front face 102 . Preferably, the bottom surface of the brick 100 remains above the snap off member 4 without actually coming into contact therewith. This aids in the ease of separating an attached external surface aligner 5 . As can be readily understood from FIGS. 1D and 1E , a plurality of these alignment devices 1 may be intermediately arranged between courses of bricks. In this instance, end extensions 9 extend upward to provide a stop for one end of the brick 100 . Internal vertical aligner 6 extends downward to create an appropriate sized mortar joint between adjacent bricks. Internal vertical aligner 7 extends into a core opening to center an upper brick between two adjacent bricks below. In the device of FIGS. 2A-2D the end extensions 9 extend downward; whereas the internal vertical aligners 6 , 7 are reversed such that internal vertical aligner 6 extends into the core opening while internal vertical aligner 7 extends into the mortar joint between two adjacent bricks. It should be noted that in FIGS. 1 and 2 , mortar is not shown for ease in understanding the invention.
[0043] FIGS. 3A-3E discloses steps for constructing a masonry wall with the device of FIGS. 1A-1E . Initially, footer 150 is poured with concrete and allowed to harden. Next a layer of mortar 110 is spread onto the upper surface of the footer 150 . A first brick 100 is then centered and arranged atop the mortar 110 . An end of a second brick is buttered and the second brick is placed adjacent the first brick. The vertical alignment tools 6 , 7 are removed from the central support member 2 , along with the hoop fastener 8 . The central support 2 is then separated at its center preferably along a snap off zone 21 to create a half-sized alignment device shown as the rightmost device of FIGS. 3B-3D . The half-sized alignment device is arranged on the right side of the first brick. A third brick is then buttered and laid against the second brick.
[0044] Next, the vertical alignment device 6 from a whole alignment device is forced into the mortar joint between the first and second bricks of the first course. Additional bricks are added to the first course along with additional alignment devices as mentioned. After the first course has been laid, and all of the alignment devices are in place, a brick is broken in half. Half of the brick is then buttered on the bottom side with mortar and arranged atop the half-sized alignment device. Alternatively, a layer of mortar may be deposited atop one or more of the alignment devices and leveled with the upper surface of the central support member 2 and horizontal aligners 3 by using a trowel as a screed. The tip of the trowel may be rested on the upper surface of the central support member and gently glided along its length until contact with the vertical alignment tool 7 is made. The tip of trowel may be driven up one side of the vertical alignment tool 7 and down the other side and continued along the remaining length of the upper surface of the central support member 2 .
[0045] Another brick is then buttered on one end and inserted such that the central core rests atop the vertical alignment tool 7 . The buttered end comes into contact with a surface of the end extensions 9 . The contact surface is on a side opposite the t-shaped end 10 . As can be understood, the end extensions 9 provide a preferred one-half inch (½″) between adjacent bricks. Additional bricks are buttered and arranged atop the alignment devices as shown in FIG. 3C . Thereafter and prior to a final dressing of the mortar with a striker, the external surface aligners 5 are removed from the central support member 2 .
[0046] FIGS. 4A-4E discloses steps for constructing a masonry wall with the device of FIGS. 2A-2D . Initially, footer 150 is poured with concrete and allowed to harden. Next a layer of mortar 110 is spread onto the upper surface of the footer 150 . A first brick 100 is then centered and arranged atop the mortar 110 . An end of a second brick is buttered and the second brick is placed into place adjacent the first brick.
[0047] Next, a vertical alignment device 6 is forced into the center core opening of the first brick of the first course. The end extensions 9 are also arranged over an end of the first brick. Additional bricks are added to the first course along with additional alignment devices as mentioned. After the first course has been laid, and all of the alignment devices are in place, a brick is then buttered on the bottom side with mortar and arranged atop the first alignment device.
[0048] Alternatively, a layer of mortar may be deposited atop one or more of the alignment devices and leveled with the upper surface of the central support member 2 and horizontal aligners 3 by using a trowel as a screed as mentioned above. In FIGS. 4A-4D , the end extensions 9 extend downward over an end of the first brick as shown. In the second course, a half brick is then buttered and laid onto the first alignment device. Next, a whole brick is buttered and butted against the vertical alignment device 7 .
[0049] Additional bricks are buttered and arranged atop the alignment devices as shown in FIG. 4C while arranging further alignment devices as discussed above. Thereafter, all of the courses of bricks are laid. Prior to a final dressing of the mortar with a striker, the external surface aligners 5 are removed from the central support member 2 as shown in FIG. 4D . It is important to note that the external surface aligner should be disengaged before the adhesive rigidly bonds the bricks together.
[0050] FIGS. 5A-D relate to an embodiment that may be used with cored and solid bricks alike. In this instance, one of the internal vertical aligners 7 is removed. Also, triangular extensions 19 are provided atop end extensions 9 . As shown in FIGS. 2C and 2D , the triangular extensions 19 extend upward and include a side that is arranged against an end of the brick. These extensions 19 may include snap off zones 21 as shown. The triangular shape is especially useful in that it does not interfere with the internal vertical aligner 6 when a masonry structure is created. In FIGS. 5A-5D , a second pair of external surface aligners 15 are arranged to come into contact with a back face of a brick. A graduated extension 17 extends from one of the external surface aligner 15 , preferably the one distal from the end extensions 9 . The graduated extension is preferably one inch (1″) in length and having graduated marks every seven-eighths (⅞″). It is useful in determining irregular shaped bricks.
[0051] Other snap off zones 21 are preferably arranged within the alignment device 1 and include a structurally or mechanically weakened region that is thinner than surrounding regions on either side thereof for ease in separating a portion of the alignment device. Preferably, snap off zones are provided in several locations between the central support member and any aligners, spacing blocks, fasteners or extensions. A snap off zone may be preferably provided midway between the ends of the central support member such that the alignment device may be easily divided into halves. Scoring or perforations may be provided to implement the snap off zones. In this manner, the snap off zones maintain the structural integrity of the alignment device including resisting either tension or compression forces until such time as a mason removes the desired portion of the alignment device.
[0052] It is to be understood that the invention is not limited to the exact construction illustrated and described above, but that various changes and modifications may be made without departing from the spirit and the scope of the invention as defined in the following claims. While the invention has been described with respect to preferred embodiments, 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 limiting sense. From the above disclosure of the general principles of the present invention and the preceding detailed description, those skilled in the art will readily comprehend the various modifications to which the present invention is susceptible. Therefore, the scope of the invention should be limited only by the following claims and equivalents thereof.
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An alignment tool, for aligning masonry structures, includes at least one pair of upright guides arranged on one side of the alignment tool for centering masonry materials such as blocks or bricks. In a first embodiment for use with laying bricks, other uprights are provided on an opposite sides of the alignment tool for aligning a center of a brick over or under a mortar joint and an additional pair of uprights are provided on one end of the alignment tool. In a second embodiment, an upright is provided along a central rib of the alignment tool for insertion into a hole in a brick. Method steps for using the tool are also disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to optical instruments, and particularly to a Berek compensator having a birefringent crystal, which can be both tilted and rotated by means of adjustment rings which are concentric to the optical path of the device.
2. Description of the Prior Art
In the field of experimental optics there is a frequent need to introduce a variable phase difference in an optical beam. Various devices exist for this purpose, perhaps the best known of which is the Soleil-Babinet compensator. The Soleil-Babinet compensator utilizes a pair of rectangular-shaped crystal elements having their optical axis perpendicular to each other so that the ordinary ray in one is the extraordinary wave in the other. One of the rectangular elements is further divided into two wedge-shaped sections. One of the wedge sections is movable with respect to the other so that the total length of the optical path through the pair of wedges is variable with respect to the length of the optical path in the undivided rectangular element. Thus, the phase shift of the incident ray is proportional to the relative lengths of the optical paths. Such devices are described in Principles of Optics, 6th Edition, Max Born and Emil Wolf at pages 693-694, and are commercially available for example from Melles Griot, Inc., Irvine, Calif. Another type of variable retarder is described in U.S. Pat. No. 3,924,930, and is commercially available from Cleveland Crystals, Inc., Cleveland, Ohio.
While the Soleil-Babinet compensator can provide the requisite optical function of a variable phase shift, it requires the fabrication of two wedge-shaped crystals. It also requires a mechanical mechanism to move one wedge relative to the other while maintaining all elements in precise optical alignment. The device also suffers from the requirement for motion transverse to the optical path, thereby adding to the size of the device. Size is not a trivial aspect since it would be desirable to have a compensator having minimal diameter which would permit mounting in a universal type of optical mount of the type having adjustments facilitating the initial set-up and alignment. Similarly, other commercially available retarders require complex optical and mechanical element fabrication, and are large compared to the usable optical aperture.
Another variable phase shift device, known as the Berek compensator, is described in Principles of Optics at page 694. In this device, the active element is a single crystal of birefringent material positioned so that the optical axis is perpendicular to the parallel faces of the crystal. The variable phase shift is created by tilting the crystal relative to the incident beam. While the Berek compensator is well understood and widely known, it has not found wide application in the laboratory.
The lack of practical application of the Berek compensator may be due, at least in part, to the requirement for tilting the crystal and the attendant mechanical complexity necessary to provide the requisite precision control.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a Berek compensator, or similar device, having a tilt and rotate adjustment.
It is another object of this invention to provide an optical mount of minimal diameter adapted to provide precision tilt and rotational movement to an optical element.
Still another object of this invention is to provide an improved Berek optical compensator of minimal diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 is a side view of the mount of this invention;
FIG. 2 is an end view of the mount of this invention taken from the right side of FIG. 1;
FIG. 3 is a sectional view of the mount of this invention taken along the line III--III of FIG. 2;
FIG. 4 is a sectional view of the optical mount of this invention taken along the line IV--IV of FIG. 2;
FIG. 5 is an exploded view of the optical mount of this invention;
FIG. 6 is a side view of the base of the mount of this invention;
FIG. 7 is an end view of the base of the mount of this invention;
FIG. 8 is a sectional view of the base shown in FIGS. 6 and 7 taken along the line VIII--VIII of FIG. 7;
FIG. 9 is a side view of the axially rotatable cylinder showing the bearing retention plate;
FIG. 9A is a top view of the bearing retention plate illustrated in FIG. 9;
FIG. 10 is an end view of the axially rotatable cylinder;
FIG. 11 is a sectional view of the axially rotatable cylinder taken along the line XI--XI of FIG. 10;
FIG. 12 is a side view of the optical element holder;
FIG. 13 is an end view of the optical element holder;
FIG. 14 is a sectional view of the optical element holder taken along the line XIV--XIV of FIG. 13;
FIG. 15 is a side view of one component of the second axially rotatable cylinder illustrating the axial cam surface;
FIG. 16 is a sectional view of the cylinder component shown on FIG. 15;
FIG. 17 is an end view of the tilt adjustment ring component of the second axially rotatable cylinder;
FIG. 18 is a side view of the tilt adjustment ring component of the second axially rotatable cylinder; and,
FIG. 19 is another side view of the tilt adjustment ring component of the second axially rotatable cylinder showing the calibration indicia.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, optical mount of this invention includes a stationary cylindrical base ring 1 having a first, outer cylindrical surface 1a which is slightly greater in diameter than the rest of the mount to facilitate clamping in a conventional clamp. Base ring I is also fitted with a tapped hole 30 to permit it to be affixed to a conventional threaded post. Base 1 has a rotation scale barrel portion 2 with a vernier scale 3 which co-acts with the degree scale 4 on a first, axially rotatable, rotation cylinder 5. A knurled rim 6 affixed to rotation cylinder 5 assists in positioning the cylinder relative to base ring 1.
Rotation cylinder 5 has a tilt vernier barrel portion 10 containing the tilt vernier scale 11. The second, axially rotatable tilt cylinder 20 has a tilt scale 21 and a knurled rim 22 affixed thereto for ease in adjusting the tilt mechanism.
FIG. 2 is a right end view of the optical mount shown in FIG. 1. The knurled rim 6 is secured to the axially rotatable rotation cylinder 5 by means of screws 7 which pass into tapped holes, not shown, in rotation cylinder 5.
FIG. 3 is a sectional view of the optical mount taken along the line III--III of FIG. 2. Parts shown in FIGS. 1 and 2 are identified with the same reference characters. Base ring 1 has a tapped hole 30 which may be used with conventional mounting posts to secure the mount to a bench or optical table. Alternatively, the outer cylindrical surface 32 of base ring 1 can be clamped in devices adapted to hold round optical elements such as the 2-inch multi-function mount Model No. 9850 offered for sale by New Focus, Inc., 340 Pioneer Way, Mountain View, Calif.
The inner cylindrical surface 33 of base ring 1 abuts the outer surface 34 of rotation cylinder 5. The end surfaces 35 and 36 of base ring 1 abut the shoulder portions 38 and 39 of the groove in rotation cylinder 5 formed by the surfaces 34 38 and 39. Rotation cylinder 5 is thus held in axial alignment with base ring 1, and is restrained form longitudinal movement along the axis of the system while freedom for rotational movement is retained.
Tilt cylinder 20 includes a cam portion 40 described in more detail with reference to FIG. 15. Cam portion 40 has a "V" groove 41 extending about the periphery. This groove is adapted to receive pointed set screws passing through threaded holes in the outer portion 23 of tilt cylinder 20. The pointed set screws provide accurate positioning and locking of the cam portion 40 relative to the outer portion 23 by defining a cylindrical ridge which, in conjunction with the rim 50 on the inner cylindrical surface of rotation cylinder 5, rotatably mounts tilt cylinder 20 within rotation cylinder 5.
The cam portion 40 includes an axial cam surface 52 on the interior end of the cylinder. Cam surface 52 engages the cam follower 55 of optical element holder 60, described in more detail with reference to FIGS. 12, 13 and 14. Optical element holder 60 is positioned within the rotation cylinder 5 by means of first and second bearing elements 61 and 62. Bearing elements 61 and 62 include conical seats 61a and 62a, which are adapted to receive the balls 61b and 62b. A corresponding conical seat 62c at the lower end of rotation cylinder 5 receives ball 62b. The upper ball 61b is seated in hole 61c within the bearing spring plate 64, described in more detail with reference to FIGS. 9, 9A, 10 and 11.
It can therefore be seen that rotational movement of tilt cylinder 20 relative to rotation cylinder 5 causes the axial cam surface 52 to move cam follower 55 and rotate optical element holder 60 about the axis defined by the bearing elements 61 and 62. A spring 72, described with reference to FIG. 4, holds cam follower 55 in engagement with ball 57 and cam surface 52.
FIG. 4, a sectional view taken at 90 degrees to that of FIG. 3, shows optical element holder 60 displaced from the position perpendicular to the optical axis of the system in the broken line view. It will be appreciated that element holder 60 may also be rotated by inserting an object into the interior of rotation cylinder 5 and pressing against the side of holder 60 in a fashion to rotate holder 60 away from axial cam surface 52 against the restraining action of spring 72. FIG. 4 also shows the screw 7 which holds knurled rim 6 to rotation cylinder 5.
FIG. 5 is an exploded view of the major component parts of the optical mount of this invention. Base ring 1 accommodates the rotation cylinder 5, which is inserted through the base ring 1. The rotation cylinder 5 has a reduced diameter portion 14 which, after insertion through the base ring 1, provides a support for vernier barrel portion 10, which is fastened to base ring 1 by means of set screws. Cam portion 40 passes through the interior of rotation cylinder 5, and is retained in place by means of the outer portion 10, which is fastened by means of set screws which bear against the "V" groove 41. Optical element holder 60 is positioned within the rotation cylinder 5, and is supported for rotational movement by bearings previously described. The bearings are held tightly against the element holder 60 by bearing spring plate 64, which has a pair of mounting holes 66a and 67a which accommodate screws 66 and 67. Bearing spring plate is slightly flexed when fastened to the rotation ring 5 to load the bearing elements and prevent other than rotational movement. The cam follower 55 on element holder 60 contains a bearing ball 57 which rides on cam surface 52, causing the element holder 60 to tilt about the axis defined by the bearings. Birefringent crystal 65 is mounted on the element carrier 60. The knurled ring 6 is fastened to the right hand end of the rotation cylinder 5.
FIG. 6 shows stationary base ring 1 in detail. The outer cylindrical surface 1a has a nominal diameter of 2 inches to make the device compatible with other optical devices and permit the use of the same clamps. The inner cylindrical surface 1b, shown in FIG. 7, provides a bearing surface for the rotation cylinder 5.
FIG. 8 is a sectional view along the line VIII--VIII of FIG. 7 showing the tapped mounting holes used with conventional optical mounting posts.
FIG. 9 is side view of a portion of the first axial rotation cylinder 5 showing the upper bearing spring plate 64, having a hole 61c with the upper ball 61b positioned therein. Spring plate 64 is shown in detail in FIG. 9a and is secured to rotation cylinder 5 by means of screws 66 and 67. The knurled rim 6 is not shown in this view.
The end view of rotation cylinder 5 in FIG. 10 illustrates the tapped holes which receive screws 7 to rotation cylinder 5.
The sectional view of FIG. 11, taken along the line XI--XI of FIG. 10 shows the aperture 80 and the slot 81 which accommodate the cam follower 55 of element holder 60 and the bearing spring plate 64. Lower ball 62b is also shown.
Optical element holder 60 is shown in top and end views of FIGS. 12 and 13 and the sectional view of FIG. 14. With reference to FIG. 12, element holder 60 has a conical seat 61a adapted to receive the bearing ball, not shown. A cam follower 55 is positioned on the periphery of optical element holder 60 at a point midway between the conical seats 61a and 62a. The end of cam follower 55 has a conical seat 56 to receive a bearing ball 57 which rides on cam surface 52.
The sectional view of FIG. 14, taken along the line XIV--XIV of FIG. 13 shows the interior groove 63 which is used to retain the birefringent crystal 65 preferably of Magnesium Fluoride approximately 2 mm in thickness and having parallel, optically flat surfaces.
Magnesium Fluoride is a preferred choice for the optical element 65. Alternatively, a Brewster plate may be used as the optical element.
The cam portion of the second, tilt, rotatable cylinder is shown in FIGS. 15 and 16. The outer diameter of cylindrical surface 85 matches the interior diameter 90 of outer portion 20. "V" groove 41 is positioned to accommodate the conical point of set screws passing through outer portion 22 and hold the portions 22 in engagement with cam portion 40. Axial cam surface 52 is adapted to displace the cam follower 55 in the axial direction when it is rotated. The sectional view of FIG. 16 is taken along the line XVI--XVI of FIG. 15. The cam surface is a one turn Buttress thread of 8 pitch with a face normal to its axis.
FIGS. 17, 18 and 19 show the outer portion 23 of tilt cylinder 20. The interior cylindrical surface 90 fits over the outer cylindrical surface 85 of the cam portion 40. Tapped holes 90a, 90b and 90c accommodate set screws with conical points which engage the "V" groove 41 in cam portion 40. FIG. 18 shows the knurled surface 22 which facilitates adjustment. FIG. 19 shows the indicia which provide an indication of the tilt angle.
MODE OF OPERATION
In operation, the optical mount of this invention will be set to the zero tilt position and inserted within a conventional optical mount. Once positioned, the radiation source is energized and the mount is moved to a more accurate position by observing the reflected beam at the source. The rotation cylinder 5 is then rotated by grasping knurled rim 6 to provide the correct axial orientation of the crystal 65. The desired phase shift may then be obtained by rotation of the tilt cylinder by grasping the knurled portion of rim 22.
Various modifications can be made to the present invention without departing from the apparent scope hereof.
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The present invention is a mount for optical instruments, and particularly, for a Berek compensator having a birefringent crystal, which can be both tiled and rotated by structure of adjustment rings which are concentric to the optical path of the device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to archery equipment in which the force to be imparted to an arrow is held by the archer and more particularly to a bow and bowstring release mechanism which optimize the force exerted on the arrow upon release.
2. Description of the Prior Art
Bow designers have from ancient times sought to increase the speed at which an arrow is launched thereby improving the trajectory, range and destructive power of the arrow.
The efforts of the designers have resulted in a progression of bows from the conventional long bow to the recurved bow and, in more recent times, to the compound bow. To shoot an arrow each bow must be held at arms length with one hand while the other hand and arm pulls the bowstring from its resting position to its full draw position. The force exerted on the bowstring by the archer is commonly referred to as the draw weight. Once the bowstring is in the full draw position, the bow must be held in a steady position while the arrow is aimed at a desired target and then released. The limiting factor on draw weight is the strength of the archer's back muscles and particularly the strength of the back muscles associated with the pulling arm.
The compound bow utilizes eccentric wheels or pulleys mounted on the ends of the bow limbs and a pair of cables in addition to the bowstring connected between the wheels to increase the stored energy (and exit velocity) imparted to an arrow over that available with a recurved bow. The compound bow accomplishes this by providing a peak draw weight intermediate the resting and full draw positions and a lower draw weight at the full draw position to increase steadiness while aiming and maximizing the total stored energy stored in the bow limbs. The difference between the peak draw weight and the full draw weight in percent is commonly referred to as let-off. As the let-off increases the full draw weight decreases as compared to the peak draw weight and visa versa. A compound bow with a let-off of say 40-50%, at full draw, may increase the exit velocity of an arrow from the bow by as much as 40% over a recurved bow having the same draw weight at the full draw position. However, the strength of the archer's back muscles associated with the pulling arm still limits the total draw weight which can be designed into the bow.
To accurately shoot an arrow it is necessary to provide a rest (or launcher) for the front of the arrow and a nocking point for the rear of the arrow near the middle of the string. The arrow rest and nocking point define the axis along which the arrow is accelerated from the bow (i.e. shooting axis). Conventional bows carry an arrow rest near the hand grip on the riser or central section. Such rests commonly contact the vanes, feathers or fletches (hereinafter "vanes") affixed to the rear of the arrow and may deflect the arrow either laterally (i.e. out of the true plane of movement of the bowstring) or vertically (i.e. up or down) or both. Since such deflections are inconsistent and unpredictable it is difficult for the archer to make allowances therefore.
The position of the arrow rest on the bow's central section and the draw length of the bow determines the minimum length of the arrow suitable for use with the bow. To shoot shorter (and stiffer) arrows it is necessary to position the arrow rest closer to the bowstring. However, the placement of the arrow rest must accommodate the movement of the bowstring to its post release position (i.e. beyond its resting position toward the central section) after the arrow has been released to prevent the bowstring from striking the arrow rest. This post release movement, which may amount to several inches, adds to the minimum length of an arrow suitable for use with any given bow.
Another problem encountered with conventional bows concerns the accurate alignment of the central bow section and its attendant arrow rest within the plane of the movement of the bowstring. To take the forearm of the arm holding the bow out of the path of the bowstring, it is necessary for the archer to roll or bend the arm and/or wrist. This creates a sideways moment or torque that tends to twist the central section of the bow and the arrow rest out of the plane of the moving bowstring. Many bows have a peep sights affixed to the bowstring and a bowsight with a vertical cross-hair (and horizontal range lines) affixed to the central section. However, the alignment of the peep sight with the vertical cross-hair and the target does not inform the archer that the central section is precisely aligned with the plane of movement of the bowstring. Some skilled archers may be able to compensate for such misalignment (most of the time) by aiming slightly to one side or the other of the desired target while holding the bow so that their forearms are in exactly the same position each time. Others try to shoot with the bow hand open to avoid torque. However, most archers cannot accomplish these feats consistently. This torque factor simply increases the skill level required to place arrows within a desired target at any given range.
Various approaches have been taken in the past to alleviate some of the above problems. To increase an arrow's exit velocity, compound bows have been constructed with increased peak draw weights and let-offs of the order of 30% or less. However, such bows are difficult to hold steady during the aiming process. Even with such decreased let-offs the strength of the archer's back muscles associated with the pulling arm remains the limiting factor on maximum draw weight and energy stored in the limbs.
The arrow rest/vane contact problem has been addressed primarily by building flexibility into the rest so that the portion of the rest in contact with the arrow will move out of the arrow's path (i.e., bend or rotate against a spring) when contacted by the vanes. In each case there is inherently some contact between the vanes and the arrow rest which causes some unwanted deflection of the arrow. See, for example, the arrow rests illustrated on pages 33-35 of the Spring 1988 edition of the Bowhunters Discount Warehouse Inc's catalogue of Wellsville, Pa. The flexibility built into conventional rests is also needed to accommodate flexing of the arrow shaft during acceleration (i.e. arrow paradox).
Another prior approach to the arrow rest/vane contact problem involves the use of a mechanism which attempts to sense the shock to the bow when the bowstring is released to move the arrow rest out of the way. However, this type of mechanism has proven unreliable in retracting the arrow rest at the proper time if at all. If the arrow rest is retracted too soon, the force of gravity will cause the front of the arrow to drop during the acceleration phase and change the desired shooting axis.
Various prior art patents have proposed solutions to some of the above problems. For example, U.S. Pat. No. 3,517,657 describes a sling shot type bow in which a rigid member such as a rod extends between a hand held central member and the bowstring in its full draw position. The archer can hold the remote end of the rod and an arrow release mechanism in the cocking hand to thereby relieve tension on the extended or aiming arm. This type of bow (similar to a cross-bow in operation) while perhaps relieving some pressure on the user's arms would not be tolerated in archery tournaments or by hunting regulations which require that the drawstring force be held by the archer. Furthermore, the maximum draw weight for such a bow is still limited by the strength of the archer's back muscles associated with the pulling arm. A device similar to that shown in the '657 patent (referred to as a vertically oriented crossbow) is described in U.S. Pat. No. 2,714,884. Another device for modifying a conventional bow so that it will shoot like a crossbow has been advertised by The Market Place of Freemont, Wis. on page 69 of the October, 1985 issue of Bow and Arrow.
U.S. Pat. Nos. 2,344,799 and 4,662,344 describe bows which use elastic bowstrings to propel the arrow. U.S. Pat. No. 4,787,361 describes a combination handgrip and forearm protector for bows for reducing the tendency of the bow to twist when the arrow is released. However, there is nothing in the described apparatus which allows the user to determine whether or not the central section of the bow and the arrow rest carried hereby is in fact twisted out of alignment.
U.S. Pat. No. 4,674,469 describes a bowstring release to be held in the hand of the pulling arm. A solenoid actuated by a finger on such hand may be used to release a sear from engagement with the bowstring.
A need exists for an archery apparatus in which (1) the maximum draw weight is optimized for a given archer for any given bow (i.e., longbow, recurved or compound bow), (2) the arrow rest is positioned adjacent the bowstring in its rest position to allow the use of shorter arrows, (3) the arrow rest is retracted at the proper time to eliminate interference with the flight of the arrow and (4) any misalignment of the central section of the bow can be detected and corrected by the archer.
SUMMARY OF THE INVENTION
An archery apparatus in accordance with the present invention comprises a bow having a central section or riser and a pair of resilient limbs extending in opposite directions from the central section. A bowstring is connected between the ends of the limbs and includes a nocking point adapted to engage the nock on an arrow. An arrow rest is carried by the central section and lies in the plane of movement of the bowstring (i.e. central plane). The arrow rest together with the nocking point align the arrow on a shooting axis along which the arrow travels when departing the bow. At least one hand grip (and preferably two) is carried by the central section adjacent the shooting axis. Means such as a harness adapted to be worn by the archer includes a bowstring release mechanism. In operation the archer, after affixing the harness to his or her body, secures the bowstring to the bowstring release mechanism carried by the harness, flexes the bow limbs by forcing the bow central section away from the harness with one and preferably both arms and then activates the bowstring release mechanism to propel the arrow toward the desired target.
A preferred arrow rest in accordance with my invention includes a bracket having an upper surface adapted to support the shaft of the arrow and a lower end pivotally mounted on the central section of a bow. Means responsive to movement of the bowstring are provided to rotate the arrow rest away from the shooting axis when the bowstring is released. Where it is desired to shoot short arrows, the arrow rest bracket may be positioned adjacent the bowstring in its resting position and define an opening in the lower end thereof through which the bowstring may travel in reaching its post release position.
A torque or misalignment detection system in accordance with the invention includes a vertical cross-hair mounted on the central section of the bow in the central plane, a peep sight mounted on the bowstring and a pair of vertical anti-torque lines mounted on the central section on opposite sides of the central plane and between the bowstring and the bow sight so that the archer may align the bow to center the vertical cross-hair between the antitorque lines as viewed through the peep sight.
The features of this invention can best be understood from the following description taken in conjunction with the drawings wherein like reference numerals designate like components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a bow in accordance with this invention;
FIG. 2 is a side elevational view of the bow of FIG. 1;
FIG. 3 is an elevational view of the bow on the opposite side to that shown in FIG. 2;
FIG. 4 is a front elevational view of the bow;
FIG. 5 is a rear elevational view of a harness assembly in accordance with the invention;
FIG. 6 is a enlarged plan view partially broken away of the arrow release mechanism carried by the harness in FIG. 3 showing the bowstring retaining position;
FIG. 7 is another enlarged plan view partially broken away of the release mechanism showing the bowstring release position;
FIG. 8 is an enlarged fragmentary perspective view of the arrow rest bracket carried by the bow of FIG. 1;
FIG. 9 is an enlarged fragmentary view of the arrow release signal transmitter carried by the bow illustrating the light emitting diode therein;
FIG. 10 is a block diagram of a transmitter circuit carried by the bow of FIG. 1 for generating a bow release signal;
FIG. 11 is a block diagram of a receiver circuit carried by the harness assembly of FIG. 5 for sensing the transmitted bowstring release signal and actuating the bowstring release mechanism;
FIG. 12 is a side elevational view of the bow held by an archer in the at rest position with the harness assembly strapped to the archer's body; and
FIG. 13 is a side elevational view similar to FIG. 13 showing the archer pushing the bow away from the harness toward the full draw position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and particularly to FIGS. 1-4, a compound bow 10 includes an elongated central section frame or riser 12. The frame 12 may be made of aluminum or other suitable material. The frame comprises a pair of side plates 14 and 16 which are secured together at their ends via bolts 17 through limb attachment blocks 18 and 20. Flexible limbs 22 and 24, made of conventional materials such as glass fibers and resin (e.g. Fiberglas®), carbon or graphite composites, are secured to each end of the blocks 18 and 20 via bolts and adjustment nuts 26 and 28, respectively in a conventional manner. (Fiberglas is a trademark of Owens Corning). A fulcrum member (not shown) is positioned within each of the blocks 18 and 20 and engages the respective limb adjacent the end of the block to allow the tension on the limbs to be adjusted by the nuts 26 and 28 as is well known.
Conventional eccentric wheels or cammed pulleys 30 and 32 are rotatably mounted on the ends of the limbs 22 and 24, via shafts 33, respectively. A bowstring 34 has its ends connected to the pulleys as illustrated and includes a nocking point 35 adapted to engage the nock on an arrow. See FIG. 2. A short cord (or loop) 37 has its ends secured to the bowstring on each side of the nocking point and cooperates with a bowstring release mechanism to be described. The cord forms part of the bowstring. A pair of cables 36 and 38 have one end connected to a respective shaft 33 and the other end connected to a respective pulley. This arrangement is typical and provides the let-off inherent in compound bows as discussed earlier.
A cable guard 40 in the form of an elongated plate is mounted on the frame 12 via suitable bolts and extends horizontally with respect to the vertically oriented frame 12. The cable guard 40 has a forked end adjacent the bowstring with a pair of legs 42 and 44 extending on each side of a U-shaped opening 46 which opening is centered about the plane of movement of the bowstring, (hereinafter referred to as the "central plane"). A cable guide 48 having a channel 50 on one side thereof is slidably mounted on the leg 44 of the cable guard as is illustrated in FIG. 8. The mid-sections of cables 36 and 38 are secured to the cable guide 40 via grooves 41. The cable guide holds the cables to one side of the central plane so that the cables will not interfere with the path of the arrow shaft and its vanes.
An arrow rest 52 in the form of a U-shaped bracket with downwardly depending legs 54 and 56 and an upwardly extending plate 60 with a V-notch 60a therein is provided to support the shaft of the arrow. The lower ends of the legs are pivotally mounted on the inside of the cable guard legs 42 and 44 as shown and defines a U-shaped opening 57 for accommodating the bowstring in its post release position as will be explained.
The terminal end of leg 56 includes an outwardly projecting shoulder 56a which engages the underside of the cable guard leg 44 when the arrow rest is pivoted upwardly and prevents the rest from being rotated beyond the vertical position. The shoulder 56a also engages the leg 44 when the arrow is pivoted downwardly to stop the rest from moving beyond an angle θ within the range of about 20° to 90° to the vertical position and preferably about 45°. See FIG. 2. The upper plate 60 of the arrow rest includes a slot 60b through which a bolt 60c is inserted. The bolt 60c is threaded into the upper extension 55 of the U-shaped bracket (54,56) to allow the plate 60 and the notch 60a to be aligned with the central plane.
A spring 62 is connected between the arrow rest bracket leg 56 and the cable guide 48 as illustrated so that the position of the arrow rest is controlled by the movement of the cable guide which in turn is controlled by the movement of the cables 36,38 and the bowstring 34.
When the bowstring is in its full draw position, the cable guide is positioned toward the end of the cable guard leg 44 and pulls the arrow rest to its vertical position via spring 62 (as is illustrated by the phantom lines in FIG. 2). In this position the arrow is aligned along the shooting axis. When the bowstring is released the cables and cable guide move toward the frame 12 until the post release position is reached and the arrow rest is retracted to its fully retracted position (via the spring 62), which position it also assumes when the bowstring is at rest.
A pair of downwardly extending hand grips 64 and 66 are mounted on the frame 12 on opposite sides of the central plane via angle plates 67 and suitable bolts (not shown) so that the archer can apply force to the central section of the bow with both arms to move the bowstring to its full draw position as will be explained more fully. The hand grips are preferably positioned at an angle ∝ to the central plane within the range of 30° to 60° and most preferably at about 45°. The centers 64a and 66a of the hand grips preferably lie in a plane which encompasses the shooting axis and is perpendicular to the central plane as is illustrated in FIG. 4. This arrangement allows the archer to apply the draw weight force directly in line with the shooting axis.
A bow sight 68 is mounted on the front of the frame 12 and includes a vertical cross-hair 70 (parallel to the bowstring) aligned with the central plane as well as horizontally oriented range lines 72 as is best illustrated in FIGS. 2-4.
A pair of vertically oriented antitorque sighting lines 74 are mounted on rearwardly extending horizontal brackets 76 (bolted to the frame 14). The antitorque lines are positioned on opposite sides of the central plane and between the bowstring and the bowsight. Preferably the lines are spaced about 1/4 to 1/2 inches apart and positioned about 4 to 12 inches from the bowsight.
A conventional peep sight 80 is carried by the bowstring so that when the bowstring is at its full draw position the archer can by looking through the peep sight position the frame 12 so that the antitorque lines 74 frame the vertical cross-hair 70 and the target to allow the archer to eliminate any twisting of the bow.
A bowstring release signal generating and transmitting unit 82 is also mounted on the frame 12 and includes a light transmitting diode 84 for transmitting a light signal toward the rear of the bow. A manually operated switch 86 (FIG. 4) is mounted adjacent the grip 66 to enable the archer to activate the transmitter as will be explained in more detail.
Referring now to FIG. 5, a harness assembly 90 includes a rigid back plate 92 pivotally connected to a flexible belt or strap 94 via a bar 95, a bolt 96 and rigid channel bracket 98. The belt 94 includes extended arm portions 100 and 102 which are arranged to wrap around the archer's waist and be releasably secured together by a suitable fastener such as velcro strips 104. Shoulder straps 106 and 108, provided with adjustable buckles 110, are suitably secured to the belt extensions 100 and 102 (e.g. by sewing) and the back plate via a rivet 112. The back plate 92 may be curved to conform to the archer's back and padded for the comfort.
An L-shaped extension bar 114 is bolted to the pivoted bar 95 adjacent the back plate 92. A bowstring release mechanism 118 for holding the bowstring in the full draw position is secured to the upper end of the bar 114 via a horizontally oriented arm 122 and horizontally oriented bracket 123. An optic detector 124 in the form of a light sensitive solid state device (forming part of the receiver) is mounted on one side of the bowstring release mechanism 118 for sensing the bowstring release signal from the transmitter carried on the bow. The output of the optic detector is supplied to an electronic circuit module 126 (mounted on back plate 92) which activates the bowstring release mechanism. A battery 128 is also carried on the back plate 92 for supplying power to the receiver. The transmitter and receiver circuits are described in more detail in conjunction with FIGS. 11 and 12.
A bowstring release mechanism is illustrated in FIGS. 6 and 7. The mechanism comprises a body 130 having a cylindrical front section 132 with a V-shaped opening 134 therein for receiving the cord or loop 37 of the bowstring 34. A sear 136 in the form of a notched cylindrical plate is rotatably mounted on pin 137 in the front section 132 and protrudes into the opening 134 as illustrated. The sear includes a bowstring griping or retaining surface 138 which engages the bowstring loop 37 and a latching surface 140 which engages a plunger 142. The plunger 142 is biased by a spring 144 against the sear 136 and prevents rotation thereof in the bowstring retaining position as is illustrated in FIG. 6. The sear 136 extends beyond the outer surface of the cylindrical section 132 so that it may be manually rotated from the release position of FIG. 7 (after the cord 37 is inserted into the opening 134) to its retention position of FIG. 6.
A solenoid 145 is mounted on the body 130 and when actuated by an electrical actuating signal applied to conductors 146 withdraws the plunger from the sear and allows the sear to rotate to the bowstring release position illustrated in FIG. 7. The body 130 is retained on the bracket 123 by a pair of cylindrical bores 148 which slide over cooperating posts (not shown) on the bracket 123. The optic detector 124 is mounted on the body 130 by suitable means such as metal screws.
Manually operated bowstring release mechanisms similar to that illustrated in FIGS. 6 and 7 (without a solenoid or other electrically operating means) have been used with conventional bows prior to my invention.
A bowstring release signal transmitter and receiver are illustrated in FIGS. 10 and 11. The transmitter includes a square wave generator 150 for generating a high frequency signal (e.g. 40 KHz), a light emitting diode 152, the switch 86 and a battery 154 as is shown in FIG. 10. The receiver includes a battery 156, a light detector 158 (preferably sensitive to infrared) and an amplifier 159. The output of the amplifier is applied to a bandpass filter and rectifier circuit 160 which applies an output signal to operate a switch such as transistor 162. The switch 162 in turn operates a relay 164 from the battery (designated B+). The relay when activated closes contacts 166 and 168 to supply current from the B+ supply to a manually operated single pole single throw switch 170. When, the switch 170 is operated to make contacts 172 and 171, a light emitting diode 174 informs the archer that the transmitter and receiver are operating properly. When the switch is operated to make contacts 171 and 172 and the relay 164 operated (i.e. in response to the bowstring release signal from the transmitter) the bowstring release solenoid 144 is actuated to release the bowstring.
The operation of the archery apparatus of FIGS. 1-11 will now be explained in reference to FIGS. 12 and 13. Initially the archer (designated 180) straps the harness 90 around his or her body or torso so that the back plate is positioned along the upper back and the bowstring release mechanism 130 positioned over one shoulder and adjacent the neck. It should be noted that the shoulder straps are not shown in FIGS. 12 and 13.
The archer after confirming that the sear 136 of the bowstring release mechanism is in its release position as illustrated in FIG. 7 (manually rotating the sear while switch 86 is pressed if necessary) positions the bow adjacent the harness and inserts the bowstring cord or loop into the opening 134 and turns the sear to its retention position as is illustrated in FIG. 6. The archer, after placing an arrow on the arrow rest 52 and the bowstring, places both hands on the hand grips and pushes the bow away from the body and harness with both arms as is illustrated in FIG. 13. This action caused the cables 36 and 38 and the cable guide 52 to move rearwardly as the bow limbs arch. The rearward movement of the cable guide moves the spring 62 to the bowstring side of the arrow rest and pulls the arrow rest into a vertical position so that the arrow is aligned along the shooting axis. With the bowstring in its full draw position the archer aligns the bow until the vertical cross-hair 70 is centered between the antitorque lines 74 and in line with a desired target as viewed through the peep sight. The switch 86 is then actuated which causes the transmitter via the light emitting diode 84 to transmit a bowstring release signal (i.e. square wave light signal) toward the optic detector 124 on the harness. The receiver detects the bowstring release signal and applies an actuating signal to solenoid 145 which withdraws the plunger 142 and allows the sear 136 to release the bowstring. Upon release the bowstring accelerates the arrow to a velocity which may be double the velocity achievable with prior art compound bows. During the release operation the bowstring moves toward the frame 12 and the mid-sections of the cables 36 and 38 slide the cable guide 48 along the cable guard causing the spring 62 to pivot the U-shaped bracket counterclockwise (as viewed in FIG. 9) to thereby retract the arrow rest from the path of the vanes on the back of the arrow. In its post release position the bowstring travels forwardly beyond its resting position and enters the opening 57 in the arrow rest bracket 54. The bow may now be prepared to shoot another arrow.
A bow in accordance with my invention may be designed for considerably higher draw weights because both of the archer's arms and body are used to force the bowstring to its full draw position. For example, maximum peak draw weights with compound bows of the order 200 or more pounds with a 50-65% let-off are achievable with my invention as contrasted to peak draw weights of 50 to 80 pounds with conventional adult compound bows. The exit velocity of an arrow can be increased by 50% to 100% with the use of my invention over the use of conventional bows. In shooting a conventional bow an archer utilizes the upper back muscles (of one arm) in a pulling action. An archer shooting my bow utilizes the tricep muscles in both arms as well as the major pectoral and back muscles in a pushing action (e.g. similar to a weight lifting bench press action).
The retractable arrow rest allows the use of shorter arrows (i.e. of the order of 15" to 18" in length) as contrasted with conventional arrows (i.e. 24"-32" in length). Shorter arrows can be designed to be lighter and stiffer than the longer arrows thereby improving their trajectory and range.
There has been described an archery apparatus which provides a significant improvement in the trajectory, range, destructive power and accuracy of the arrow. Various modifications to the described apparatus will be apparent to those skilled in the art without involving any departure from the spirit and scope of my invention as defined in the appended claims.
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An archery apparatus for optimizing the force exerted on the arrow upon release includes a frame or riser and a pair of resilient limbs extending in opposite directions therefrom. A bowstring is connected between the free ends of the limbs and includes a nocking point for engagement with the nock of an arrow. an arrow rest is carried by the frame and together with the nocking point on the bowstring define a shooting axis along with the arrow travels when departing the bow. A hand grip is mounted on each side of the frame adjacent the shooting axis for accommodating the left and right hands of an archer. A harness adapted to be worn by the archer includes a bowstring release mechanism for selectively holding and releasing the bowstring adjacent the nocking point. In operation, the archer after putting the harness on, (1) secures the bowstring to the bowstring release mechanism and flexes the bow limbs by forcing the frame away from his or her body with both arms, (2) aims the arrow toward a desired target and (3) actuates the bowstring release mechanism to propel the arrow toward the target.
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TECHNICAL FIELD
This invention concerns catalytic converters used for treating the exhaust gas of an internal combustion engine.
BACKGROUND OF THE INVENTION
Pending U.S. patent application Ser. No. 08/928,996, entitled "Catalytic Converter", filed on Sep. 12, 1997, and assigned to the assignee of this invention discloses a converter having a housing with a ceramic honeycomb catalyst coated substrate located within the cavity of the housing. The substrate is characterized in that its inlet face and its outlet face are each formed with a concave depression, and the central portion of the substrate is wrapped with a mat of intumescent material which expands radially when heated by the exhaust gas of an internal combustion engine. The mat extends along the length of the substrate up to the deepest point of the depression in order to protect the fragile end portions of the substrate and prevent them from fracturing when the converter reaches operating temperature. In addition, the end portions of the substrate are configured so as have the peripheral ends thereof in close proximity to end members that are sealingly attached to the opposed ends of the housing. As a result, the concave depressions in the substrate not only form a gas inlet chamber and a gas outlet chamber but, in addition, the opposed faces of the substrate are intended to shield the supporting mat from the hot gases of the internal combustion engine.
Although the concave facial design of the substrate does provide a shielding effect for the support mat to a certain extent, it is clear that a perfect seal cannot be obtained between the ceramic end portions of the substrate and its associated metallic end member. As a consequence, the ends of the main support mat can be subjected to exhaust gases at a temperature which can be in excess of 750 degrees centigrade. The exhaust gases at this high temperature can damage the ends of the mat and eliminate the mica's ability to expand. The ceramic fibers and mica in the mat then become relatively loose and erode away and cause the mat to deteriorate and lose its ability to serve as an insulator and support for the substrate within the housing.
SUMMARY OF THE INVENTION
In order to prevent the heated exhaust gases from damaging the ends of the mat, one example of this invention involves the use of an additional mat of intumescent material positioned at opposed ends of the substrate that expands in an axial direction rather than a radial direction. By so doing, the end portions of the substrate are not subjected to radial forces which could cause the fragile ends of the substrate to fracture as the mat is heated and expands. In addition, inasmuch as the mat at each of the end portions of the substrate expands along the length of the substrate, it exerts a high axial force between the radially expandable mat and the end members and thereby maintains pressure on the ends of the radially expandable mat to prevent erosion thereof. Also by doing so the ends of the axially expanding mat that contact the radially expanding mat are protected from the intense heat. This allows the mica material, at this protected location, to retain its ability to apply a force to the reoriented mat. This force holds the axially expanding fibrous mat material under sufficient pressure to resist erosion, even at the exposed end portions.
Accordingly, in one example the present invention to provides a new and improved catalytic converter in which a catalyst coated substrate is positioned within a housing and is wrapped with mats of intumescent material one of which expands in a radial direction and the other of which expands in an axial direction so as to improve the durability of the mats which serve to support the substrate and prevent excessive heat transfer between the substrate and the housing.
Advantageously, according to another example, the present invention to provides a new and improved catalytic converter having a housing provided with a catalyst coated substrate and end portions thereof wrapped with a mat of intumescent material that expands along the length of the substrate when heated.
Advantageously, another example of present invention provides a new and improved catalytic converter having a housing provided with a catalyst coated substrate and in which the housing is sealed at each end by an end member with portions of the substrate that are located in close proximity to the associated end member wrapped with a mat of intumescent material that expands in an axial direction.
Another example of the present invention provides a new and improved catalytic converter having a housing provided with a pair of end members and having a catalyst coated ceramic substrate located therein with the inlet face and the outlet face of the substrate having a concave depression therein and in which the central part of the substrate is wrapped with a mat of intumescent material which expands in a radial direction when heated and the fragile end portions of the substrate are wrapped with a mat of intumescent material that expands in an axial direction when heated.
Advantageously, according to a preferred example, this invention provides a catalytic converter for use in the exhaust system of an internal combustion engine that includes a housing having a cavity formed therein and having a gas inlet end and a gas outlet end. A pair of end members are provided at the opposed ends of the housing and each of the end members has an opening for allowing exhaust gases to pass therethrough. One of the end members is sealingly connected to the gas inlet end of the housing and the other of the end members is sealingly connected to the gas outlet end of the housing. A catalyst coated substrate is located within the cavity of the housing and has a gas inlet face at one end and a gas outlet face at the other end. A first mat of material that is expandable in a radial direction when heated is wrapped around the substrate and extends along the length of the substrate to cover a first portion of the substrate. In addition, a second mat of intumescent material that is expandable in an axial direction when heated is located between the substrate and the housing at a second portion of the substrate.
In a preferred embodiment, the first mat that is expandable in the radial direction covers the central portion of the substrate and the second mat that is expandable in the axial direction covers the end portions of the substrate. This arrangement is such that the first mat serves as an insulator and support for the substrate within the housing and the second mat provides a seal and insulator which prevents the hot exhaust gases from eroding the ends of the first mat.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described by way of example with reference to the following drawings in which:
FIG. 1 is a side elevational view of an example catalytic converter made according to the present invention with some parts broken away to show the interior of the converter;
FIGS. 2 and 3 are sectional views taken on line 2--2 and line 3--3, respectively, of FIG. 1;
FIG. 4 is an enlarged view of the circled area of the converter seen in FIG. 2;
FIG. 5 is an isometric view of a mat of intumescent material used with the converter of FIGS. 1 and 2 that is marked with a plurality of equally spaced parallel lines prior to cutting the mat;
FIG. 6 is an isometric view of the sections of the mat after they are cut from the mat seen in FIG. 5; and
FIG. 7 is a view of the cut sections of the mat seen in FIG. 5 after they are rotated ninety degrees and are combined with the main mat of intumescent material which expands in a radial direction when heated.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and more particularly to FIGS. 1-4 thereof, a catalytic converter 10, made according to the present invention, is shown for use in eliminating the undesirable constituents in the exhaust gases of an internal combustion engine. The catalytic converter 10 has an oval cross-sectional configuration providing a low profile configuration for installation under the vehicle floor or any other space-constrained location of the vehicle. As the description of the invention proceeds, it will become apparent that although all of the examples of the present invention are illustrated and will be described in connection with oval-shaped converters, the converter can have other cross sectional configurations such as round, square, rectangular, or some other cross sectional design and provide the advantages to be discussed hereinafter.
As seen in FIGS. 1-3, the catalytic converter 10 comprises an oval-shaped housing 12 which terminates at each end with an oval-shaped edge 14 defining an oval opening located in a plane extending transversely to the longitudinal center axis 16 of the housing 12. The housing 12 is made from a sheet of stainless steel or other material suitable for operation in a high temperature exhaust environment, and it provides a uniform oval cross-sectional cavity along its entire length. The cavity serves to enclose a monolith or substrate 18 made of a frangible material such as ceramic that is extruded with an identical honeycomb cross-section and an oval periphery. The ceramic substrate 18 is coated with a high surface area material and catalyzed with a precious metal such as platinum and/or palladium and/or rhodium. The catalyst serves to purify the exhaust gases exiting the internal combustion engine by entering the plurality of parallel flow passages 19 within the substrate 18 at the front inlet face 20 thereof and exiting the rear outlet face 22 thereof. The purification of the exhaust gases occurs by reduction and oxidation processes well known to those skilled in the art.
In this regard, it will be noted that the front inlet face 20 and the rear outlet face 22 of the substrate 18 are each formed with a depression for a purpose which will be explained more fully hereinafter. As seen in FIG. 1, the depression is concave in cross section when viewed in elevation. Similarly, the faces 20 and 22 are each generally concave in cross section in plan view as seen in FIG. 2. This configuration of the faces 20 and 22 provides integral portions of the substrate 18 that project outwardly from the body of the substrate 18 resulting in the longest flow passages 19 being located along the outer surface of the substrate 18. From this point, the flow passages 19 progressively decrease in longitudinal length as they approach the center of the depression. Therefore, in effect, both the front inlet face 20 and the rear outlet face 22 each have a portion thereof scooped out to provide the concave depression in each of the faces 20 and 22.
The opposed open ends of the housing 12 are closed by an oval-shaped inlet end member or plate 24 and an identically formed outlet end member or plate 26. The inlet end member 24 cooperates with the depression in the inlet face 20 of the substrate 18 to provide an inlet chamber 28 while the outlet end member 26 cooperates with the depression in the outlet face 22 to provide an outlet chamber 30.
As best seen in FIGS. 2-4, the central part of the substrate 18 is supported within the housing by a first mat 32 in the form of an oval-shaped sleeve. The mat 32, as best seen in FIG. 2, extends from the deepest point of the depression in the front inlet face 20 to the deepest point of the depression in the rear outlet face 22 of the substrate 18. Thus, the longitudinal length of the mat 32 is less than the overall longitudinal length of the substrate 18. A second mat composed of three separate sections each identified by reference numeral 34 is wrapped around the end portions of the substrate and fills the area beginning at the end of the mat 32 and ending at the planar inner surface 35 of the associated end member. Both the mat 32 and the mat sections 34 are made from a resilient, flexible and heat expandable intumescent material such as that known by the trade name "Interam". The mat 32 and the mat sections 34 are manufactured by the Technical Ceramics Products Division of 3M Company of Minneapolis, Minn. and are interposed between the inside surface 36 of the housing 12 and the outer surface 37 of the substrate 18. During assembly of the catalytic converter 10, the combined mat 32 and mat sections 34 as seen in FIG. 7, are wrapped around the circumference of the substrate 18 and stuffed into the housing 12. During the stuffing operation, the mat 32 will be subjected to radially applied pressure about its circumference. In addition, the mat section 34 will be subjected to less radial pressure than the mat 32. As will be explained more fully hereinafter, in order to protect the fragile end portions of the substrate 18 that define the depressions within each face 20 and 22 from fracturing during the stuffing operation, the mat sections 34 are dimensioned so that they do not apply excessive radial forces against the outer surface 37 of the substrate 18 during the stuffing operation or while the converter 10 is at operating temperature.
As seen in FIG. 2, the inlet end member 24 includes a circular inlet opening 38 defined by a radius transition adapted to be rigidly connect to a cylindrical exhaust gas inlet pipe (not shown). Similarly, the outlet end member 26 has a circular outlet opening 40 provided with a radius transition adapted to be secured to a cylindrical exhaust gas outlet pipe (not shown) leading to the muffler (not shown) forming a part of the exhaust system in which the catalytic converter 10 is located. The end members 24 and 26 are essentially planar in configuration providing the flat inner surface 35 for engagement with the associated peripheral edge 14 of the oval opening at each end of the housing 12. Also, as shown, the end members 24 and 26 are located in parallel planes that are perpendicular to the longitudinal center axis 16 of the housing 12 and each of the end members 24 and 26 extends radially outwardly beyond the outside surface of the housing 12 for accepting a weld 42 for securing the end member to the housing 12.
It should be noted that the peripheral end portions of the substrate 18 defining the concave depressions in the inlet and outlet faces 20 and 22 are in very close proximity to the flat inner surface 35 of the associated end member. This then allows the outwardly projecting portions of the substrate 18 to substantially shield the space surrounding the substrate 18 and occupied by the mat sections 34. It has been found, however, that a perfect seal is not provided by the projecting portions of the substrate 18 and, in the absence of the mat sections 34, it is possible for the hot exhaust gases entering and leaving the converter 10 to flow from the inlet and outlet chambers 28 and 30 and cause erosion of the opposed ends of the mat 32. In this instance, however, the area around the end portions of the substrate 18 and between the inner surface 35 of each end member 24 and 26 and the associated end of the mat 32 is sealed by the mat sections 34. As a result, the hot exhaust gases do not impinge upon the mat 32 and , therefore, the mat 32 as well as the mat sections 34 can withstand the high temperatures caused by the hot exhaust gases much longer without deteriorating and losing their ability to serve as an insulator and support for the substrate 18.
In a successful test of a converter made in accordance with the present invention, the concave substrate 18 used was manufactured by Corning Incorporated located in Blacksburg, Virginia and identified as CL100429. The housing 12 was made by Delphi Energy & Engine Management Systems, Flint, Mich. and had an overall length of 162.5 mm. Each of the end members 24 and 26 were 4 mm thick. The housing 12 was designed so as to have a 6 mm uniform gap between the outside surface 37 of the concave substrate 18 and the inner surface 36 of the housing 12. The distance between the deepest point of the concave depression in the inlet face and the deepest point of the depression in the outlet face of the substrate 18 measured 130 mm. The mat 32 of intumescent material made by the aforementioned Technical Ceramics Products Division was identified as 3M Interam 100 having a basic weight of 6200 gram per square meter, a width dimension of 122.5 mm, a length of 430 mm, and a thickness of 10 mm. The mat sections 34 were made from a separate piece of the same 3M Interam 110 sheet 46 of intumescent material which, in this case, measured 430 mm in length and approximately 36 mm in width as seen in FIG. 5. The mat sections 34 were provided by cutting along the parallel lines 48 (shown in FIG. 5) that were spaced from each other by 6 mm. The mat or sheet 46 seen FIG. 5 was then cut along the lines 48 to provide six individual mat sections 34. Each of the six individual mat sections 34 were then rotated ninety degrees so as to have the 10 mm dimension horizontally oriented while the 6 mm dimension is vertically oriented as seen in FIG. 6. Afterwards, three of the mat sections 34 were positioned on opposed sides of the mat 32 as seen in FIG. 7. The mat sections were secured to each other and to the mat 32 by use of a conventional cellophane adhesive tape such as made by 3M or other manufacturers. With the mat sections 34 positioned as seen in FIG. 7, the overall width of the assembled mats was 182.5 mm and the length remained at 430 mm.
It will be noted that, as seen in FIG. 7, the mat 32 has the fibers thereof oriented so that when the mat 32 is subjected to the operating temperature of the converter 10, the mat will expand in the directions indicated by the arrows A and B. On the other hand, inasmuch as each of the mat sections 34 had been rotated ninety degrees prior to being placed in the positions shown in FIG. 7, each of the mat sections 34 will expand in the directions indicated by the arrows C and D. Accordingly, when the mat 32 and mat sections 34 are wrapped around the substrate 18 and stuffed into the housing 12 so as to be located in the positions seen in FIG. 2, the mat 32 will expand radially while the mat sections 34 will expand axially or along the length of the converter 10 when the converter is operating at an elevated temperature. As a result, the mat sections 34 can serve to insulate and seal the opposed ends of the converter and protect the opposed ends of the mat 32 from the high temperature exhaust gases. Moreover, since the mat sections 34 will expand in an axial direction rather than a radial direction, the fragile end portions of the substrate will not be subjected to radial forces which could cause such end portions to fracture. At the same time, the mat 32 serves as a support for the substrate 18 and also serves as an insulator to prevent excessive heat from being conducted to the housing.
In another example of this invention, the inlet and outlet chambers are formed by end plates or end cones and the catalyst substrate faces are not concave but flat. The radially expanding mat covers the central portion of the catalyst substrate periphery and the axially expanding mat covers the end portions of the catalyst substrate periphery. The axially expanding mat prevents excessive mat erosion at the ends of the catalyst substrate by maintaining a high mat density by contacting a radial annular surface of the end plates or cones. The high mat density of the axially expanding mat is made possible by two factors. First the portion of the axially expanding mat next to the ends of the radially expanding mat is protected from the extremely high gas temperatures by the insulated distance from the inlet. This allows this portion of the mat to maintain a high expansion pressure on the remaining axially expanding mat, producing high mat density. Second, the axially expanding mat can be compressed by the end plate or cone during assembly of the converter without concern over applying too much pressure on the substrate, even if a thin wall fragile substrate is used. This is because the compression caused by the end plates or cones is in the axial direction.
In another example, annular end rings can be affixed to the inner periphery of the housing or to the end plates or cones to act as walls holding the axially expanding mat. One annular ring is placed at the inlet end and one annular ring is placed at the outlet end. The annular rings prevent movement of the mat material and provide a surface for the mat to be compressed against.
Various changes and modifications could be made to the above-described catalytic converters without departing from the spirit of the invention. Such changes are contemplated by the inventor and he does not wish to be limited except by the scope of the appended claims.
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A catalytic converter for use in the exhaust system of an internal combustion engine, said catalytic converter including a housing having a cavity formed therein and having a gas inlet end and a gas outlet end, a pair of end members, each of said end members having an opening for allowing exhaust gases to pass therethrough, one of said end members sealingly connected to the gas inlet end of said housing and the other of said end members sealingly connected to the gas outlet end of said housing, a catalyst coated substrate located within said cavity and having a gas inlet face and a gas outlet face, a first mat of material which is expandable in an axially direction when heated positioned between said housing and a first portion of the catalyst coated substrate, and a second mat of material which is expandable in a radial direction surrounding a second portion of the catalyst coated substrate.
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[0001] This invention is directed to a dispensing container and to a method of dispensing a liquid from a container. More particularly, this invention is directed to a dispensing container where the dip tube is provided with a decorative feature which also provides an additional function. The decorative feature may optionally coordinate with a design on the front or rear of the container.
BACKGROUND
[0002] Dispensing containers with dip tubes are used to store and dispense a range of personal care products. These include hand soaps, hand and body lotions, shampoos and body cleansing gels. There is a constant need to enhance the appearance of these containers. Various prior patent specifications disclose structures intended to enhance the appearance of the container, and some exhibit a dynamic, moving feature which is operable during dispensing. A recent example is the Applicant's WO-A1-2013/019207. Furthermore, such personal care products often include fragrance. The fragrance intensity or bloom can be detrimentally reduced as a result of the personal care products being stored in the dispensing container.
[0003] The present invention aims to improve the appearance of a container and its product during use.
[0004] The present invention also aims to provide a simple and reliable structure which can be dynamically operated by the user during product dispensing.
[0005] The present invention further aims to provide a dispensing container for a personal care product which can enhance the fragrance intensity or bloom when the product is dispensed.
BRIEF SUMMARY
[0006] The invention provides a container comprising a body portion and a neck portion, the neck portion having a pump dispenser thereon, the pump dispenser comprising a pump mechanism, a dip tube on one end of the pump mechanism, a pump outlet on another end of the pump mechanism, the dip tube extending downwardly from the pump mechanism into the body portion, the body portion containing a first liquid, the dip tube having a central bore along which the first liquid is pumped from the body portion when the pump mechanism is actuated, and a reservoir containing a second liquid, the reservoir communicating with the dip tube and adapted to introduce the second liquid into the first liquid within the pump mechanism or dip tube under the action of first liquid flowing through the dip tube.
[0007] The invention further provides a method of dispensing of a liquid from a container, the method comprising the steps of:
a. providing a dispensing container including a pump mechanism and a dip tube extending downwardly from the pump mechanism into a first liquid to be dispensed from the container; b. operating the pump mechanism to cause the first liquid to flow upwardly through the dip tube and out of an upper end of the pump mechanism; and c. introducing a second liquid into the first liquid within the pump mechanism or dip tube under the action of first liquid flowing through the dip tube, the second liquid being contained in a reservoir communicating with the dip tube.
[0011] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0013] FIG. 1 is an elevation view of a dispensing container having a dip tube with an integral dropper in accordance with a first embodiment of the invention.
[0014] FIG. 2 is an exploded elevation view of the dispensing mechanism of the dispensing container of FIG. 1 .
[0015] FIG. 3 is an enlarged elevation view of the dropper in the dispensing mechanism of the dispensing container of FIG. 1 .
[0016] FIG. 4 is an elevation view of a dispensing container having a dip tube with an integral basin in accordance with a second embodiment of the invention.
[0017] FIG. 5 is an elevation view of the dispensing container of FIG. 4 after dispensing of an amount of liquid from the basin and shrinkage of the basin.
[0018] FIG. 6 is an exploded elevation view of the dispensing mechanism of the dispensing container of FIG. 4 .
[0019] FIG. 7 is an enlarged elevation view of a dispensing mechanism for a dispensing container in accordance with a third embodiment of the invention, which is a modification of the embodiment of FIGS. 1 to 3 .
[0020] FIG. 8 is an elevation view of a dispensing container having a dip tube with an integral wicking mechanism in accordance with a fourth embodiment of the invention.
[0021] FIG. 9 is an exploded elevation view of the dispensing mechanism of the dispensing container of FIG. 8 .
DETAILED DESCRIPTION
[0022] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0023] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.
[0024] The invention will be disclosed in its preferred embodiments with reference to the Figures in the drawings. The dispensing container has an enhanced appearance before and during use by a consumer to dispense the product contained within the container.
[0025] FIGS. 1, 2 and 3 show a dispensing container 10 with the enhanced appearance. The dispensing container is comprised of a body portion 12 and a neck portion 14 . The neck portion 14 has closure 16 . Mounted in the closure is a pump mechanism 18 with a dip tube 22 at one end and an actuator 20 with a dispensing channel exiting at a pump outlet 24 . The dip tube 22 extends downwardly from the pump mechanism 18 into the body portion 12 which contains a liquid L to be dispensed. The liquid may be, for example, selected from hand soaps, hand and body lotions, shampoos and body cleansing gels. When the pump mechanism 18 is activated by manual depression of the dispensing activator 20 , liquid in body portion 12 travels up a central bore 21 of the dip tube 22 , through the pump mechanism 18 and then through outlet 24 . The pump mechanism 18 is a conventional self-priming pump mechanism well known in the art.
[0026] A dropper 26 is fitted to or integral with the dip tube 22 so as to be coupled to the dip tube 22 . The dropper 26 comprises a transparent vial 28 sealed at one end 30 and provided with a one-way pressure relief valve 27 to permit flow of liquid L into the end 20 of the dropper 26 to displace liquid within the drop[per 26 as that liquid is dispensed from the dropper 26 . A capillary tube 32 extends from the other end 34 of the vial 28 and the lower end 36 of the capillary tube 32 remote from the vial 28 connects with the dip tube 22 via an orifice 42 . The capillary tube 32 is transparent. The dropper 26 is downwardly oriented towards the lower end 36 . A fragrance oil 38 is disposed within the vial 28 which acts as a reservoir 40 for the fragrance oil 38 . The fragrance oil 38 is colored with a dye or pigment so that the fragrance oil 38 is visible from the exterior of the dispensing container 10 . At least a part of the body portion 12 is transparent and the liquid L is typically transparent or translucent. In the embodiment of FIG. 1 , at least a portion of the dip tube 22 adjacent to the orifice 42 is transparent and is visible from an exterior of the container.
[0027] In the illustrated embodiment, the dropper 26 is integral with an upper end part 44 of the dip tube 22 . The upper end part 44 of the dip tube 22 comprises a tubular portion 46 which is fitted, by bonding or a compression fitting, at its upper portion 48 to the pump mechanism 18 and at its lower portion 50 to an elongate tubular lower end part 52 of the dip tube 22 . The upper end part 44 of the dip tube 22 may be a molded section, such as being formed by injection or blow molding. The lower end part 52 of the dip tube 22 is typically flexible and may be formed by extrusion to an elongated form.
[0028] The lower portion 50 may optionally be fitted with a one way valve (not shown) to prevent or inhibit siphoning of liquid fragrance oil 38 from reservoir 40 through the orifice 42 and down into the dip tube 22 .
[0029] A decorative element, not shown, may be fitted to or integral with the vial 28 . The decorative element may have a visual association with the fragrance, for example illustrating a flower when the fragrance is a floral fragrance.
[0030] When the pump mechanism 18 is activated by manual depression of the dispensing activator 20 , this imparts upward liquid flow through the dip tube 22 during the dispensing operation. As the liquid flows past the lower end 36 of the capillary tube 32 , drops of fragrance oil are successively introduced into the liquid flow from the orifice 42 at the lower end 36 of the capillary tube 32 . Depending on the liquid properties and the dispensing mechanism, the liquid flow may generate shear forces to pull a drop out of the capillary tube 32 and/or a reduced pressure in the liquid flow may suck a drop out of the capillary tube 32 . The fragrance oil is gravity fed from the reservoir 40 to the lower end 36 of the capillary tube 32 . This provides a constant supply of fragrance oil at the orifice 42 .
[0031] The orifice 42 typically has a cross-sectional area so as not to exceed the surface tension of the fragrance oil in the liquid L so that drops of fragrance oil only enter the liquid L as a result of liquid flow past the orifice 42 .
[0032] Since the fragrance oil is introduced dropwise into the liquid flow, this effect may be seen by a user. Also, over a period of time, as a result of plural successive dispensing operations, the volume of oil in the reservoir 40 is diminished. The diminishing volume of fragrance oil may also be visible to a user. Accordingly, the dropper and the visible fragrance oil therein provide a decorative effect visible from an exterior of the container 10 .
[0033] Furthermore, the fragrance oil is stored in the reservoir 40 rather than in the liquid to be dispensed. Such separate storage of the fragrance oil in the reservoir 40 provides that the fragrance oil is exposed to a minimum amount or concentration of oxygen or air prior to dispensing. In turn, this provides that the fragrance intensity or bloom is maximized during product dispensing, because the fragrance oil is introduced into the liquid immediately prior to dispensing. Prior to dispensing, the fragrance oil is retained in the reservoir 40 , and the vial 28 seals the fragrance oil against contact with the liquid or air apart from at the narrow bore orifice 42 of the capillary tube 32 .
[0034] The pump mechanism 18 may include a screen or air chamber, or other pump parts, as are known in the art, such as a foamer mechanism, which would function to shear the fragrance and mix together the fragrance oil 38 and the liquid L during dispensing to provide a uniform mixture exiting outlet 24 .
[0035] In an alternative embodiment, not illustrated, the dropper 26 can be vertically oriented so that the orifice 42 is upwardly directed. When the liquid L is pumped, a reduced pressure above the orifice 42 would tend to pump fragrance oil 38 up the capillary tube 32 and into the flow of liquid L. This modification has the advantage that fragrance oil 38 is less likely to be released inadvertently into liquid L as a result of shaking the container 10 because the fragrance oil 38 is held by gravity as well as surface tension in the reservoir 40 .
[0036] A second embodiment of a dispensing container is shown in FIGS. 4, 5 and 6 .
[0037] In this embodiment, the dispensing container 10 is similar to that of the first embodiment. The dispensing container is comprised of a body portion 12 and a neck portion 14 . The neck portion 14 has closure 16 . Mounted in the closure is a pump mechanism 18 with a dip tube 22 at one end and an actuator 20 with a dispensing channel exiting at a pump outlet 24 . The dip tube 22 extends downwardly from the pump mechanism 18 into the body portion 12 which contains a liquid L to be dispensed. The liquid may be, for example, selected from hand soaps, hand and body lotions, shampoos and body cleansing gels. When the pump mechanism 18 is activated by manual depression of the dispensing activator 20 , liquid in body portion 12 travels up a central bore 21 of dip tube 22 , through the pump mechanism 18 and then through outlet 24 . The pump mechanism 18 is a conventional self-priming pump mechanism well known in the art.
[0038] In this embodiment, a flexible bulb 60 is fitted to the dip tube 22 . The flexible bulb 60 defines a basin 62 between the outer bulb wall 64 , which is flexible, and a central tubular element 66 . The outer bulb wall 64 comprises a transparent film, typically composed of a polymer. An upper edge 68 of the outer bulb wall 64 is fitted, by bonding or a compression fitting, to an upper end 70 of the central tubular element 66 and a lower edge 72 of the outer bulb wall 64 is fitted, by bonding or a compression fitting, to a lower end 74 of the central tubular element 66 . The upper end 70 is fitted, by bonding or a compression fitting, to the pump mechanism 18 and the lower end 74 is fitted, by bonding or a compression fitting, to the upper end 76 of an elongate tubular lower end part 78 of the dip tube 22 . The central tubular element 66 may be a molded section, such as being formed by injection or blow molding. The lower end part 78 of the dip tube 22 is typically flexible and may be formed by extrusion to an elongated form.
[0039] At least one capillary orifice 80 is provided in the lower end 74 of the central tubular element 66 , which communicates the basin 62 to the central tube 82 of the central tubular element 66 and thereby connects the basin 62 with the dip tube 22 . The orifice(s) 80 again may be dimensioned so as each to have a cross-sectional area so as to provide drops of fragrance oil into the liquid L only as a result of liquid flow past the orifice(s) 80 .
[0040] A fragrance oil 84 is disposed within the basin 62 which acts as a reservoir 86 for the fragrance oil 84 . As for the first embodiment, the fragrance oil 84 is colored with a dye or pigment so that the fragrance oil 84 in the basin 62 is visible from the exterior of the dispensing container 10 . At least a part of the body portion 12 is transparent and the liquid L is typically transparent or translucent.
[0041] A decorative element, not shown, may be fitted to or integral with the flexible bulb 60 . The decorative element may have a visual association with the fragrance, for example illustrating a flower when the fragrance is a floral fragrance.
[0042] When the pump mechanism 18 is activated by manual depression of the dispensing activator 20 , this imparts upward liquid flow through the dip tube 22 during the dispensing operation. As the liquid flows past the capillary orifice(s) 80 , drops of fragrance oil are successively introduced into the liquid flow from the orifice(s) 80 at the lower end of the basin 62 containing the fragrance oil 84 . Depending on the liquid properties and the dispensing mechanism, the liquid flow may generate shear forces to pull a drop out of the capillary orifice(s) 80 and/or a reduced pressure in the liquid flow may suck a drop out of the capillary orifice(s) 80 . The fragrance oil is gravity fed from the reservoir 86 to the capillary orifice(s) 80 . This provides a constant supply of fragrance oil at the orifice(s) 80 .
[0043] Since the fragrance oil is introduced dropwise into the liquid flow, this effect may be seen by a user if at least the lower part of the central tubular element 66 is transparent. Also, over a period of time, as a result of plural successive dispensing operations, the volume of oil in the reservoir 86 is diminished. FIG. 4 shows the flexible bulb 60 initially full of fragrance oil and FIG. 5 shows the flexible bulb 60 after some amount of fragrance oil has been dispensed, and the corresponding reduction in the volume of the flexible bulb 60 can readily be seen.
[0044] The diminishing volume of fragrance oil may also be visible to a user. Since the bulb 60 is flexible, the bulb volume also is diminished as a result of plural successive dispensing operations, which is visible to a user. Accordingly, the flexible bulb 60 and the visible fragrance oil therein provide a decorative effect visible from an exterior of the container 10 .
[0045] Furthermore, as for the first embodiment, the fragrance oil is stored in the reservoir 86 rather than in the liquid to be dispensed and the fragrance oil is introduced into the liquid immediately prior to dispensing. Prior to dispensing, the fragrance oil is retained in the reservoir 86 , and the flexible bulb 60 seals the fragrance oil against contact with the liquid or air apart from at the capillary orifice(s) 80 .
[0046] A further dispensing mechanism is shown in FIG. 7 , in accordance with a third embodiment of the invention, which is a modification of the embodiment of FIGS. 1 to 3 . The dispensing mechanism 82 is disposed in a dispensing container (not shown) which is the same container as in the other embodiments. The dispensing mechanism 82 comprises a vial 83 containing a liquid, such as a fragrance oil F, to be introduced dropwise into the liquid L in the body of the container, as discussed hereinbefore. The vial 83 is upwardly oriented and a straw-like tube 84 extends downwardly into the vial 83 through a sealed upper surface 85 of the vial 83 . The straw-like tube 84 connects to a side port 86 of a three-way connector 87 at the top of the dip tube 88 and beneath the pump 89 . A one way valve 90 may be provided in the straw-like tube 84 to prevent liquid in the dip tube 88 from flowing back into the vial 83 . The vial 83 may have flexible walls and be compressible, in a manner similar to the basin of the previous embodiment, and/or a one way valve 92 may be provided in the vial 83 to permit pressure equalization between the interior of the vial 83 and the container body.
[0047] In this embodiment, instead of gravity feeding the fragrance oil into the dip tube through capillary orifice(s), a straw-like tube 84 is provided which communicates between the vial 83 and the dip tube 88 . Liquid flow through the dip tube 88 sucks liquid from the vial up the straw-like tube 84 and into the three-way connector 87 where the liquids are blended together.
[0048] In a further embodiment, the basin of FIGS. 4 to 6 incorporates an upwardly oriented straw-like tube therein, similar to the straw-like tube of FIG. 7 , rather than capillary orifices, for controllably delivering the liquid in the basin dropwise into the dip tube or the pump mechanism as a result of liquid flow through the dip tube.
[0049] Referring to FIGS. 8 and 9 , in a further embodiment the dispensing container 10 is similar to that of the previous embodiments. The dispensing container is comprised of a body portion 12 and a neck portion 14 . The neck portion 14 has closure 16 . Mounted in the closure is a pump mechanism 18 with a dip tube 22 at one end and an actuator 20 with a dispensing channel exiting at a pump outlet 24 . The dip tube 22 extends downwardly from the pump mechanism 18 into the body portion 12 which contains a liquid L to be dispensed. The liquid may be, for example, selected from hand soaps, hand and body lotions, shampoos and body cleansing gels. When the pump mechanism 18 is activated by manual depression of the dispensing activator 20 , liquid in body portion 12 travels up a central bore 21 of dip tube 22 , through the pump mechanism 18 and then through outlet 24 . The pump mechanism 18 is a conventional self-priming pump mechanism well known in the art.
[0050] In this embodiment, the dip tube 22 incorporates a wick element 100 which is pre-loaded with a fragrance oil 102 . The wick element 100 typically comprises a tube of transparent or translucent porous material, such as a porous polymeric open-cellular foam, which contains fragrance oil 102 infused therein. The wick element 100 is surrounded by an impermeable layer 104 , for example a transparent polymeric film, which prevents the fragrance oil 102 from leaching out of the dip tube 22 into the body portion 12 which contains the liquid L to be dispensed. The impermeable layer 104 may be provided with a one way valve at the bottom thereof, in order to equilibrate the pressure in the wick element 100 and liquid L, to prevent fragrance oil from leaching into the liquid L. The wick element 100 typically has a thickness dependent upon the desired liquid storage capacity of the wick element 100 .
[0051] The wick element 100 acts as a reservoir 106 for the fragrance oil 102 . As for the previous embodiments, the fragrance oil 102 is colored with a dye or pigment so that the fragrance oil 102 in the wick element 100 is visible from the exterior of the dispensing container 10 . At least a part of the body portion 12 is transparent and the liquid L is typically transparent or translucent.
[0052] A decorative element, not shown, may be fitted to or integral with the wick element 100 . The decorative element may have a visual association with the fragrance, for example illustrating a flower when the fragrance is a floral fragrance.
[0053] When the pump mechanism 18 is activated by manual depression of the dispensing activator 20 , this imparts upward liquid flow through the dip tube 22 during the dispensing operation. As the liquid flows through the wick element 100 , fragrance oil 102 is introduced into the liquid flow from the pores of the wick element 100 containing the fragrance oil 102 .
[0054] The wick element 100 may have a hollow core in order to allow the liquid L to pass freely up the center of the wick element 100 and control fragrance dispensing into the liquid L.
[0055] Over a period of time, as a result of plural successive dispensing operations, the volume of fragrance oil in the wick element 100 is diminished. The diminishing volume of fragrance oil may also be visible to a user, as a result of reduced intensity of the color of the reduced concentration of the fragrance oil in the wick element 100 . Accordingly, the wick element 100 and the visible fragrance oil therein provide a decorative effect visible from an exterior of the container 10 .
[0056] Furthermore, as for the previous embodiments, the fragrance oil is stored in the reservoir 106 rather than in the liquid to be dispensed and the fragrance oil is introduced into the liquid immediately prior to dispensing. Prior to dispensing, the fragrance oil is retained in the reservoir 106 , and the impermeable layer 104 seals the fragrance oil against contact with the liquid or air apart from in the interior tubular bore 106 of the wick element 100 .
[0057] The container may be made of essentially any substantially transparent plastic. Glass may also be used. Useful plastics are polyvinyl chloride and polyethylene terephthalate. The dip tube and the associated parts may be produced from any plastic that can be extruded, and optionally blow-molded, or injection molded. Such polymers include homopolymers and copolymers of ethylene and propylene, vinyl compound homopolymers and copolymers, such as polyvinyl chloride, and polyesters such as polyethylene terephthalate.
[0058] The container may be provided with a label. The label can be shaped or partially transparent to reveal at least the reservoir, for example providing a window through which the reservoir may be viewed. The label may be applied by in-mold labeling or the use of a shrink film.
[0059] Front and/or rear labels may be composed of any substantially clear plastic. The preferred plastics are thermoplastics, such as polyethylene, polypropylene including biaxially oriented polypropylene, polyvinyl chloride and polyethylene terephthalate. The front and rear labels are typically printed. In-mold labels and shrink film labels may be composed of a wide range of monolayer and laminate materials, such as thermoplastic polymers.
[0060] Other modifications to the illustrated embodiments will be apparent to those skilled in the art and are within the scope of the present invention as defined in the appended claims.
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A container comprising a body portion and a neck portion, the neck portion having a pump dispenser thereon, the pump dispenser comprising a pump mechanism, a dip tube on one end of the pump mechanism, a pump outlet on another end of the pump mechanism, the dip tube extending downwardly from the pump mechanism into the body portion, the body portion containing a first liquid, the dip tube having a central bore along which the first liquid is pumped from the body portion when the pump mechanism is actuated, and a reservoir containing a second liquid, the reservoir communicating with the dip tube and adapted to introduce the second liquid into the first liquid within the pump mechanism or dip tube under the action of first liquid flowing through the dip tube.
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PRIORITY
[0001] This application is a Continuation of U.S. application Ser. No. 10/308,756, filed on Dec. 3, 2002, which claims priority to an application entitled “Method for Allocating UATI in a Mobile Communication System for High-Speed Packet Data Transmission” filed in the Korean Industrial Property Office on Jun. 3, 2002 and assigned Serial No. 2002-31188, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a method for allocating an identifier to an access terminal in a mobile communication system, and in particular, to a method for allocating a UATI (Unicast Access Terminal Identifier) to an access terminal in a mobile communication system.
[0004] 2. Description of the Related Art
[0005] In general, a CDMA2000 1x (IS-95C) system can transmit data at 144 Kbps, two or more times faster than an IS-95B system having a maximum data rate of 64 Kbps. Further, the CDMA2000 1x system supports services provided through a radio multimedia platform such as Java, Brew, etc., a multimedia service such as a streaming type of AODNOD (Audio On DemandVideo On Demand) etc., and a text service.
[0006] A CDMA2000 1x EV-DO (Evolution-Data Only) system, which has evolved from the CDMA2000 1x system having a maximum data rate of 144 Kbps, has a maximum data rate of 2.4 Mbps, at least 16 times faster than the CDMA2000 1x system, and can support bidirectional data transmission as well as high-speed Internet search. If the CDMA2000 1x EV-DO technology acknowledged by the ITU (International Telecommunication Union) is used, a large amount of traffics can be transmitted with superior quality by optimizing existing voice and data spectrum.
[0007] However, while the CDMA2000 1x system uses an IMSI (International Mobile Subscriber Identity) permanently allocated to an access terminal (AT), the CDMA 1x EV-DO system uses a UATI temporarily allocated to the AT by an access network controller (ANC), corresponding to a base station controller (BSC), in order to provide a high-speed packet data service. Therefore, in order to provide a high-speed packet data transmission service efficiently in the CDMA 1x EV-DO system, which is a mobile communication system for high-speed packet data transmission, a specific UATI allocation method is needed for determining when the UATI is to be allocated to the AT and which UATI is to be allocated.
SUMMARY OF THE INVENTION
[0008] It is, therefore, an object of the present invention to provide a method for allocating a UATI to an AT in a mobile communication system for high-speed packet data transmission.
[0009] It is another object of the present invention to provide a method for exchanging messages between an AT, an ANC, and a data location register (DLR) in order to allocate a UATI to the AT in a mobile communication system for high-speed packet data transmission.
[0010] According to an aspect of the present invention, there is provided a signaling processing method for allocating a UATI to a given AT (Access Terminal) in a mobile communication system including access networks, each having an ANC (Access Network Controller), for communicating by radio with ATs, and at least one DLR (Data Location Register) connected to ANCs, for storing a plurality of UATIs, which can be allocated to the ATs and managing the remaining UATIs that are not allocated. In the method, upon receipt of a UATI Request message from the AT, the ANC transmits a UATI Allocate Request message to the DLR. Upon receipt of the UATI Allocate Request message, the DLR allocates one of the remaining UATIs to the AT and transmits a UATI Allocate Response message including the allocated UATI to the ANC. Upon receipt of the UATI Allocate Response message, the ANC transmits a UATI Allocate message including the allocated UATI to the AT.
[0011] According to another aspect of the present invention, there is provided a signaling processing method for reallocating a UATI to an AT (Access Terminal) while the AT to which the UATI is allocated by a first DLR (Data Location Register) moves to an AN (Access Network) where a second DLR allocates the UATI in a mobile communication system including a plurality of ANs each having an ANC (Access Network Controller), for communicating by radio with a plurality of ATs, and two or more DLRs each connected to the ANC included in at least one AN, for storing a plurality of UATIs and managing remaining UATIs that are not allocated. In the method, upon receipt of a UATI Request message including an old UATI from the AT, the ANC transmits to the second DLR a UATI Allocate Request message for requesting the second DLR to reallocate the UATI. Upon receipt of the UATI Allocate Request message, the second DLR transmits to the first DLR a Session Information Request message for requesting the first DLR to transmit session information relating to the old UATI. Upon receipt of the Session Information Request message, the first DLR transmits a Session Information Response message including the session information relating to the old UATI to the second DLR. The second DLR reallocates one of the remaining UATIs to the AT and transmits a UATI Allocate Response message including the reallocated UATI to the ANC. Upon receipt of the UATI Allocate Response message, the ANC transmits a UATI Allocate message including the reallocated UATI to the AT.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above and other objects, features, and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
[0013] FIG. 1 illustrates an entire structure of a mobile communication system for high-speed packet data transmission;
[0014] FIG. 2 illustrates a procedure for exchanging messages when the AT is initially driven to open a session for the first time in a mobile communication system for high-speed packet data transmission according to a preferred embodiment of the present invention;
[0015] FIG. 3 illustrates a procedure for exchanging messages when the DLR includes session information while the AT hands off in a mobile communication system for high-speed packet data transmission according to a preferred embodiment of the present invention;
[0016] FIG. 4 illustrates a procedure for exchanging messages when the DLR has no session information while the AT hands off in a mobile communication system for high-speed packet data transmission according to a preferred embodiment of the present invention;
[0017] FIG. 5 illustrates a procedure for exchanging messages when there is no UATI to be allocated in a mobile communication system for high-speed packet data transmission according to a preferred embodiment of the present invention; and
[0018] FIG. 6 illustrates a procedure for exchanging messages when a UATI Complete message transmitted by the AT is loss in a mobile communication system for high-speed packet data transmission according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] A preferred embodiment of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail.
[0020] Unlike a CDMA2000 1x system in which an IMSI is permanently allocated, a CDMA2000 1x EV-DO system temporarily uses a UATI temporarily allocated to an AT by an ANC (BS, Base Station). The present invention newly proposes UATI allocation-related messages exchanged between a DLR, which determines when the UATI is to be allocated to the AT, and which UATI is to be allocated, an ANC, and an AT in the CDMA2000 1x EV-DO system (hereinafter, referred to as a mobile communication system for high-speed packet data transmission), so that the UATI can be efficiently allocated to the AT.
[0021] FIG. 1 illustrates an entire structure of a mobile communication system for high-speed packet data transmission. Access network transceiver systems (ANTSs) 103 , 105 , 113 , and 115 transmit/receive signals to/from ATs 101 and 111 , respectively. ANCs 107 and 117 control the ANTSs 103 , 105 , 113 , and 115 . A general ATM (Asynchronous Transfer Mode) switch network (GAN) 121 connects the ANCs 107 and 117 with peripheral devices. A base station manager (BSM) 123 is connected to the GAN 121 . An access network authentication, authorization and accounting server (AN AAA) 125 connected to the GAN 121 authenticates the ATs 101 and 111 . A DLR 127 connected to the GAN 121 manages a UATI session. A packet data service node (PDSN) 129 connected to the GAN 121 is defined in the CDMA2000 1x system. A home agent (HA) 131 is connected to the PDSN 129 , and an authentication, authorization and accounting server (AAA) 133 is connected to the HA 131 . An Internet protocol (IP) network 135 is connected to the HA 131 . The ANTSs 103 and 105 and the ANC 107 constitute one access network (AN), and the ANTSs 113 and 115 and the ANC 117 constitute another AN. The CDMA 1×EV-DO system, a mobile communication system for high-speed packet data transmission, has a plurality of subnets. The subnet is an area managed by one GAN. The number of ANs constituting one subnet may be variable according to traffic circumstances, and usually one subnet consists of 20 to 30 ANs.
[0022] In FIG. 1 , although the DLR 127 covers one subnet, that is, one GAN area, the DLR may cover a plurality of GAN areas or a plurality of DLRs may be connected to one GAN area. The construction between the DLR and GAN is not directly related to the present invention, so a description thereof will not be provided.
[0023] A description will be made of types and structures of messages exchanged between the ANC and the DLR when the AT requests the ANC to allocate a UATI in a mobile communication system for high-speed packet data transmission with reference to Tables 1 to 6.
[0024] Table 1 below shows fields constituting a UATI Allocate Request message transmitted by the ANC to the DLR when the AT requests the ANC to allocate the UATI.
TABLE 1 Field Type Message Type M Message Length M TID M OldUATI O Authentication Parameter O Paging Parameter O Location Registration M HW ID O
[0025] Referring to Table 1, fields for the UATI Allocate Request message are divided into mandatory fields M when carrying of corresponding information is mandatory and optional fields O when information is optionally carried. The mandatory fields M for the UATI Allocate Request message include a Message Type field indicating the type of a message, a Message Length field indicating the length of a message, a TID (Transaction IDentifier) field for identifying ATs, and a Location Registration field consisting of ANC_ID and ANTS_ID, used for registering the location of an AT. The optional fields O for the UATI Allocation Request message include an OldUATI field for transmitting, if the AT has a previously allocated UATI (OldUATI), an Authentication Parameter field consisting of a Security Layer Packet, a Sector ID, and a Time Stamp, used for authenticating the AT, a Paging Parameter field having a maximum of 20 bytes used during paging, and an HW ID (Hardware Identification) field indicating hardware information. If the UATI Allocate Request message includes the OldUATI field, the Authentication Parameter is included therein, and if the UATI Allocate Request message does not include the OldUATI field, the Paging Parameter is included therein.
[0026] Table 2 below shows fields constituting a UATI Allocate Response message transmitted by the DLR to the ANC in response to the UATI Allocate
TABLE 2 Field Type Message Type M Message Length M TID M RET M UATI O PDSN IP Address O Access Network Address O
[0027] Referring to Table 2, fields for the UATI Allocate Response message are also divided into mandatory fields M when corresponding information is necessarily carried and optional fields O wherein information is optionally carried. The mandatory fields M for the UATI Allocate Response message include a Message Type field indicating the type of a message, a Message Length field indicating the length of a message, a TID field for identifying ATs, and an RET (Return) field indicating the result of a service. A TID received through the UATI Allocate Request message of Table 1 is carried in the TID field, and a return of the UATI Allocate Request message is carried in the RET field. The optional fields O for the UATI Allocation Response message include a UATI field for transmitting, if the AT has an allocated UATI, a PDSN IP Address field indicating an IP address of the PDSN, and an Access Network Address field indicating an address of the AN. Only when the UATI to be allocated exists, corresponding information is carried on the PDSN IP Address field and the Access Network Address field.
[0028] Table 3 below shows fields constituting a UATI Allocate Complete Request message (hereinafter, referred to as a UATI Complete Request message) indicating that the UATI has normally been allocated to the AT, transmitted by the ANC to the DLR.
TABLE 3 Field Type Message Type M Message Length M TID M UATI M Location Registration M
[0029] In Table 3, a UATI value allocated to the AT is carried in the UATI field.
[0030] Table 4 below shows fields constituting a UATI Allocate Complete Response message (hereinafter, referred to as a UATI Complete Response message) transmitted by the DLR to the ANC in response to the UATI Complete Request message shown in Table 3.
TABLE 4 Field Type Message Type M Message Length M TID M RET M MN ID O Paging Parameter O OldUATI O HW ID O
[0031] Referring to Table 4, a return of the UATI Complete Request message is carried in the RET field. In an MN (Mobile Node) ID field, information is carried only when corresponding information exists. Likewise, in an HW ID field, information is carried only when corresponding information exists.
[0032] Table 5 below indicates the RET field among the fields for the UATI Allocation Response message shown in Table 2. The RET field is included in a response message to a request message. That is, a value representing a return of the request is carried in an RET Value field.
TABLE 5 7 6 5 4 3 2 1 0 Octet Element Identifier 1 Length 2 RET Value 3
[0033] Tables 6 and 7 below indicate meanings of values used in the RET Value field shown in Table 5. In Table 6, the meanings of the RET values are classified by an upper 4 bits of the value of the RET Value field. In Table 7, the meanings of the RET values are classified in more detail.
TABLE 6 Class Binary Value Meaning Normal B′0000˜B′0001 Return of message is successful. Resource B′0010 Failure due to shortage of resource etc. Processing B′0011˜B′0101 Failure in service. Message Invalid B′0101 Failure in message transmission due to erroneous message or error in TID. Protocol Error B′0110 Failure due to error in parameter. Authentication B′0111 Failure in Failure authentication. Reserved B′1000˜B′1110 Unused ETC B′1111 Failure due to the other causes.
[0034]
TABLE 7
RET
Class
Value
Name
Meaning
Normal
H′01
SUCCESS
Return of message is
successful.
H′02
DUPLICATED_UATI
Duplicated UATI having
the same MN ID exists.
Resource
H′21
NO_UATI_AVAILABLE
UATI resource to be
allocated is short.
Processing
H′31
UNKNOWN_UATI
Received UATI is not
allocated UATI.
H′32
AUTHEN-
Failure in SHA-1
TICATION_FAILED
authentication
specified in IS-856.
H′33
STAIL_OLDUATI
MN ID or session
information
corresponding to
received OldUATI
does not exist.
H′34
MN_ID-MISMATCHED
Transmitted MN ID
is different from
stored value.
H′35
LOC-Unavailable
Location information
of AT is not clear.
Protocol
H′41
INVALID_MESSAGE-
Message type is
TYPE
unknown.
H′42
MANDATORY-
Mandatory parameter
ELEMENT_OMITTED
has been omitted.
H′43
UNKNOWN_ELEMENT
Unknown parameter
has been received.
H′44
INVALID_ELEMENT
Contents of parameter
are invalid.
H′4F
GENERAL-
Failure in processing
PROTOCOL_ERROR
of other protocol.
PPS
H′51
PPS_Not-OK
PPS(Pre-Paid Service)
subscribers are
unlimited.
ETC
H′FF
GENERAL_ERROR
Failure due to the
other causes.
[0035] In Table 7, NO_UATI_AVAILABLE is used to represent that there is no available UATI when the UATI resource to be allocated is short, UNKNOWN_UATI is used to represent that the received UATI is not the allocated UATI when the OldUATI received from the ANC cannot be found, AUTHENTICATION_FAILED is used to represent failure in authentication for the received OldUATI, and STALE_OldUATI is used to represent that the MN ID or session information corresponding to the received OldUATI does not exist.
[0036] Table 8 below shows the MN ID field among fields for the UATI Complete Response message indicated in Table 4.
TABLE 8 7 6 5 4 3 2 1 0 Octet Element Identifier 1 Length 2 Identity digit 1 Odd/even Type of Identity 3 Identity digit 3 Identity digit 2 4 . . . . . . Identity digit N + 1 Identity digit N N
[0037] Table 9 below indicates meanings of values of the MN ID field shown in Table 8. The MN ID field represents a type of a used identity. Such an MN ID includes an IMSI (International Mobile Subscriber Identity) used to identify international subscribers, an ESN (Electronic Serial Number) assigned as a fixed bit during manufacturing, an MIN (Mobile Identification Number), a broadcast address used for broadcasting.
TABLE 9 Binary Value Meaning 000 No Identity Code 001 MIN 010 Broadcast Address 101 ESN 110 IMSI
[0038] A signaling procedure between the AT, ANC, and DLR, for allocating a UATI in the mobile communication system for high-speed packet data transmission will be described in detail with reference to FIGS. 2 to 6 .
[0039] FIG. 2 illustrates a procedure for exchanging messages between the AT, ANC, and DLR, for allocating the UATI when the AT is initially driven to open a session for the first time in the mobile communication system for high-speed packet data transmission.
[0040] The AT, a CDMA 1x EV-DO terminal, has no UATI therein when power is initially turned ON or a session is initially opened. In this case, the AT transmits to the ANC a UATI Request message for requesting the ANC to allocate a UATI by using a random access terminal identifier (RATI), which is generated at random therefrom, so that the ANC can select any one of a plurality of DLRs existing in a GAN area. A procedure for exchanging messages when the AT initially opens the session will now be described with reference to FIG. 2 .
[0041] In FIG. 2 , the AT transmits the UATI Request message to the ANC using the RATI in step 200 to request the ANC to allocate the UATI. Upon receipt of the UATI Request message, in step 202 , the ANC transmits to the DLR the UATI Allocate Request message illustrated in Table 1, including the Paging Parameter, to request the DLR to allocate the UATI. As described with reference to Table 1, not the Authentication Parameter, but the Paging Parameter is included in the UATI Allocate Request message because the AT has requested the ANC to allocate the UATI by using the RATI rather than the OldUATI. Thus, when the AT transmits the UATI Request message using the RATI to the ANC, the ANC selects any DLR among DLRs within a subnet and transmits the UATI Allocate Request message to the selected DLR. Upon receipt of the UATI Allocate Request message, the DLR checks whether the AT requesting the ANC to allocate the UATI is an AT opening a new session within the subnet of the DLR area or an AT moving from an adjacent subnet. When the RATI is used, the DLR recognizes the AT requesting the ANC to allocate the UATI as an AT opening a new session. Then the DLR stores the Paging Parameter transmitted by the ANC and transmits the UATI Allocate Response message illustrated in Table 2 to the ANC in step 204 . Upon receiving the UATI Allocate Response message, the ANC transmits a UATI Allocate message to the AT in step 206 to allocate a new UATI to the AT. The AT, which has received the UATI Allocate message, transmits to the ANC a UATI Allocate Complete message (hereinafter, referred to as a UATI Complete message) indicating that the new UATI has been allocated in step 208 . Upon receiving the UATI Complete message, the ANC transmits the UATI Complete Request message shown in Table 3 to the DLR in step 210 . Upon receipt of the UATI Complete Request message, the DLR transmits the UATI Complete Response message shown in Table 4 to the ANC in step 212 to terminate a UATI allocating procedure. In this case, since the DLR has no MN ID for the AT, it does not transmit the MN ID to the ANC.
[0042] FIG. 3 illustrates a procedure for exchanging messages between the AT, ANC, and DLRs while the AT hands off in the mobile communication system for high-speed packet data transmission. In FIG. 3 , a first DLR (DLR 2 ) within a subnet to which the AT has belonged before handoff has session information, and the AT is to belong to a second DLR (DLR 1 ) through the handoff. The CDMA 1x EV-DO system includes a plurality of subnets. The subnet indicates an area where information representing that the current AT opens the session for the first time and information on the UATI of the AT or the session is managed. If the AT moves from its subnet to another subnet, the AT recognizes that the subnet is changed through an overhead message and requests the ANC to allocate a new UATI. A description will now be made of a procedure for exchanging messages between the AT, ANC, DLR 1 , and DLR 2 when the DLR 2 has session information while the AT hands off the subnet in the mobile communication system for high-speed packet data transmission with reference to FIG. 3 .
[0043] The AT transmits the UATI Request message to the ANC in step 300 by use of the OldUATI, which has been allocated from the DLR 2 within the subnet before the handoff. Upon receipt of the UATI Request message, the ANC transmits to the DLR 1 the UATI Allocate Request message illustrated in Table 1, including the OldUATI instead of the Paging Parameter in step 302 , to request the DLR 1 to allocate the UATI. Upon receiving the UATI Allocate Request message, the DLR 1 transmits a Session Information Request message to the DLR 2 having the session information of the AT in step 304 to request the DLR 2 to transmit OldUATI-related information. The DLR 2 then transmits a Session Information Response message including the OldUATI-related information to the DLR 1 in step 306 . Upon receiving the OldUATI-related information, the DLR 1 transmits the UATI Allocate Response message illustrated in Table 2 to the ANC in step 308 to allocate the UATI to the ANC. The ANC, which has received the UATI Allocate Response message, transmits the UATI Allocate message to the AT in step 310 to allocate a new UATI to the AT. Upon receiving the UATI Allocate message, the AT transmits to the ANC the UATI Complete message indicating that the new UATI has successfully been allocated in step 312 . The ANC, which has received the UATI Complete message, transmits the UATI Complete Request shown in Table 3 to the DLR 1 in step 314 . Upon receiving the UATI Complete Request message, the DLR 1 transmits the UATI Complete Response message illustrated in Table 4 to the ANC in step 316 to terminate the UATI allocating procedure. In this case, since the DLR 1 has the MN ID, it transmits the MN ID for the AT to the ANC through the UATI Complete Response message.
[0044] FIG. 4 illustrates a procedure for exchanging messages between the AT, ANC, and DLRs while the AT hands off a subnet in the mobile communication system for high-speed packet data transmission. In FIG. 4 , a first DLR (DLR 2 ) within a subnet to which the AT has belonged before handoff has no session information, and the AT is to belong to a second DLR (DLR 1 ) through the handoff.
[0045] Referring to FIG. 4 , the AT transmits the UATI Request message to the ANC in step 400 by use of the OldUATI, which has been allocated from the DLR 2 within the subnet before the handoff. Upon receipt of the UATI Request message, the ANC transmits to the DLR 1 the UATI Allocate Request message illustrated in Table 1, including the OldUATI instead of the Paging Parameter in step 402 . Upon receiving the UATI Allocate Request message, the DLR 1 transmits the Session Information Request message to the DLR 2 in step 404 to request the DLR 2 to transmit the OldUATI-related information. If the OldUATI-related information does not exist or the OldUATI fails in authentication, the DLR 2 transmits a Session Information Reject message to the DLR 1 in step 406 . Upon receipt of the Session Information Reject message, the DLR 1 does not allocate the UATI and transmits a UATI Allocate Reject message to the ANC in step 408 to inform the ANC that the OldUATI-related information does not exist. The ANC, which has received the UATI Allocate Reject message, transmits a Session Close message to the AT in step 410 . Upon receipt of the Session Close message, the AT closes the session and transmits the UATI Request message to the ANC in step 412 by use of the RATI, rather than the OldUATI after a lapse of a prescribed time to request the ANC to allocate the UATI again. The next processes are the same as when the session is opened for the first time.
[0046] FIG. 5 illustrates a procedure for exchanging messages between the AT, ANC, and DLR when the allocation of the UATI fails due to the shortage of the unallocated UATI in the mobile communication system for high-speed packet data transmission.
[0047] Referring to FIG. 5 , the AT transmits the UATI Request message in step 500 . The ANC, which has received the UATI Request message, transmits the UATI Allocate Request message shown in Table 1 to the DLR in step 502 to request the DLR to allocate the UATI. If there is no UATI to be allocated, the DLR, which has received the UATI Allocate Request message, transmits a UATI Allocate Failure message to the ANC in step 504 to inform the ANC of failure in allocation. Upon receipt of the UATI Allocate Failure message, the ANC terminates the UATI allocating procedure without transmitting a response message to the AT. Because the UATI has not been allocated, the AT retransmits, in step 506 , the UATI Request message to the ANC after a prescribed time period from transmission of the UATI Request message, to request the ANC to allocate the UATI. Preferably, the AT attempts to transmit the UATI Request message up to a maximum of 10 times. The number of attempts for requesting the ANC to allocate the UATI may be arbitrarily set.
[0048] FIG. 6 illustrates a procedure for exchanging messages between the AT, ANC, and DLR when the UATI Complete message transmitted by the AT is damaged in the mobile communication system for high-speed packet data transmission.
[0049] Referring to FIG. 6 , the AT transmits the UATI Request message to the ANC in step 600 . Upon receipt of the UATI Request message, the ANC transmits the UATI Allocate Request message indicated in Table 1 to the DLR in step 602 to request the DLR to allocate the UATI. Upon receipt of the UATI Allocate Request message, the DLR transmits the UATI Allocate Response message shown in Table 2 to the ANC in step 604 . The ANC, which has received the UATI Allocate Response message, transmits the UATI Allocate message to the AT in step 606 . While the AT, which has received the UATI Allocate message, transmits the UATI Complete message to the ANC in step 608 , the UATI Complete message may be damaged due to various reasons. If the UATI Complete Request message is not received for a prescribed time, the DLR transmits to the ANC a Session Close Command message for commanding the ANC to close the allocated UATI-related session and to allocate a new UATI again in step 610 . Upon receiving the Session Close Command message, the ANC transmits a Session Close message to the AT in step 612 to request the AT to close the session. The AT, which has received the Session Close message, transmits a Session Close Complete message to the ANC in step 614 . Upon receipt of the Session Close Complete message, the ANC transmits a Session Close Confirmation message to the DLR in step 616 . The DLR, which has received the Session Close Confirmation message, transmits a Session Close Confirmation Acknowledge message to the ANC in step 618 . After a prescribed time from transmission of the Session Close Complete message, the AT retransmits the UATI Request message to the ANC in step 620 to request the ANC to allocate the UATI again.
[0050] As described in the message exchanging procedures illustrated in FIGS. 2 to 6 , upon receipt of the UATI Allocate Request message from the ANC, the DLR implements a function of allocating the UATI and managing the session information. In allocating the UATI, the DLR processes a UATI allocation request of the ANC with respect to the GAN area. The UATI can be allocated and managed irrespective of the defined subnet area. That is, the DLR can simultaneously support several subnets. Moreover, the different ATs should not have the same UATI. To avoid the duplicated UATI, the UATI that has been allocated to the AT should be allocated to another AT after a lapse of a sufficient time. The DLR also supervises the UATI allocating processes. Namely, the DLR determines whether the UATI Complete Request message for the UATI Complete message transmitted by the AT is received from the ANC. If it is not received, the DLR determines that the UATI has been not allocated. Upon receipt of the OldUATI during the UATI allocating processes, the DLR should obtain the OldUATI-related session information from another DLR. Next, in managing the session information, the DLR stores the MN ID for the AT and the session information etc. with respect to the GAN area, and can support several subnets at the same time. If the ANC requests the DLR to send information, the DLR transmits both the MN ID and the session information.
[0051] As described above, messages required to allocate the UATI in the CDMA2000 1x EV-DO system are newly proposed and they are appropriately exchanged between the DLR, the ANC, and the AT, which are a UATI managing system according to circumstances. Therefore, the UATI can be efficiently allocated to the AT. Meanwhile, an AT of the present invention can be referred to a MS (mobile station), and an ANC can be referred to a BS (base station).
[0052] While the invention has been shown and described with reference to a certain preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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A signaling processing method for allocating a UATI (Unicast Access Terminal Identifier) to a given AT (Access Terminal) in a mobile communication system including ANs (Access Networks) each having an BS (Access Network Controller), for communicating by radio with ATs, and at least one DLR (Data Location Register) connected to BSs, for storing a plurality of UATIs, which can be allocated to the ATs, and managing the remaining UATIs that are not allocated. Upon receipt of a UATI Request message from the AT, the BS transmits a UATI Allocate Request message to the DLR. Upon receipt of the UATI Allocate Request message, the DLR allocates one of the remaining UATIs to the AT and transmits a UATI Allocate Response message including the allocated UATI to the BS. Upon receipt of the UATI Allocate Response message, the BS transmits a UATI Allocate message including the allocated UATI to the AT.
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FIELD OF THE INVENTION
[0001] The present invention refers to the subsampler and to a subsampling method that allows for an environmental biomonitoring without the use of large sample volumes, thus ensuring the diversity of the species and a quick analysis.
BACKGROUND OF THE INVENTION
[0002] Biological monitoring is a core element in the water resource management and in the conservation of ecological integrity in water ecosystems (Karr, J. R. 1991. Biological integrity: a long-neglected aspect of water resource management. Ecological Applications, 1: 66-84; Rosenberg, D. M., and Resh V. H. (Eds.). 1993. Freshwater biomonitoring and benthic macroinvertebrates. Chapman and Hall (Eds.), New York, 488p; Karr, J. R., and Chu, E. W. 1999. Restoring Life in Running Waters: Better Biological Monitoring. Island Press, Washington, D.C.).
[0003] Biological water ecosystem monitoring programs were created in the early XX century by KOLKWITZ & MARSSON ([Kolkwitz, R., and Marsson, M. 1908. Ökologie der pflanzlichen Saprobien. Bericht der Deutschen Botanischen Gesellschaft 26a: 505-519. (Translated 1967). Ecology of plant saprobia. In Kemp, L. E., W. M. Ingram & K. M. Mackenthum (eds), Biology of Water Pollution. Federal Water Pollution Control Administration, Washington, D.C.: 47-52.] [Kolkwitz, R., and Marsson, M. 1909. Ökologie der tierischen Saprobien. Beitrage zur Lehre von des biologischen Gewasserbeurteilung. Internationale Revue der gesamten Hydrobiologie und Hydrographie, 2: 126-152.]), which set the conceptual foundations for the construction of biomonitoring methods.
[0004] From their inception to the end of the 1980s, biotic indices predominated as biological monitoring tools ([Metcalfe, J. L. 1989. Biological Water Quality Assessment of Running Waters Based on Macroinvertebrate Communities: History and Present Status in Europe. Environmental Pollution, 60: 101-139.]; [Rosenberg, D. M., and Resh V. H. (Eds.). 1993. Freshwater biomonitoring and benthic macroinvertebrates. Chapman and Hall (Eds.), New York, 488p)].
[0005] More recently, new approaches were set as tools for biomonitoring such as predictive models (RIVPACS—UK; AusRivAs—Australia; BEAST—Canada, New Zealand model) (Wright, J. F. 1995. Development and use of a system for predicting the macroinvertebrate fauna in flowing waters. Australian Journal of Ecology 20: 181-197; Norris, R. H., and Georges, A. 1993. Analysis and interpretation of benthic macroinvertebrate surveys. Chapman and Hall, New York (USA), pp. 234-286. 1993; Reynoldson, T. B.; Bailey, R. C; Day, K. E., and Norris, R. H. 1995. Biological guidelines for freshwater sediment based on Benthic Assessment of SedimenT (the BEAST) using a multivariate approach for predicting biological state. Australian Journal of Ecology 20:198-219; Joy, M. K., and Death, R. G. 2003. Biological assessment of rivers in the Manawatu-Wanganui region of New Zealand using a predicative macroinvertebrate model. New Zealand Journal of Marine and Freshwater Research 37: 367-379).
[0006] The development of multimetric indices has been prioritized in the US since the late 1980s ([Plafkin, J. L.; Barbour, M. T.; Porter, K. D.; Gross, S. K., and Hudges R. M. 1989. Rapid bioassessment protocols for use in sites and rivers: Benthic macroivertebrates and fish. U.S. Environmental Protection Agency, EPA, 444/4-89-001, Washington, D.C.], [Barbour, M. T.; Gerritsen, J.; Griffith, G. E.; Frydenborg, R.; McCarron, E.; White, J. S., and Bastian, M. 1. 1996. A framework for biological criteria for Florida streams using macroinvertebrates. Journal of North American Benthology Society. 15 (2), 185-211]; [Barbour, M. T.; Stribling, J. B., and Karr, J. R. 1995. The multimetric approach for establishing biocriteria and measuring biological condition. Pp: 63-76. In: Davis, W. & Simon, T. (eds). Biological Assessment and Criteria: Tools for Water Resource Planning and Decision Making.] [Lewis Publishers. Ann Arbor, Mich.; Barbour, M. T.; Gerritsen, J.; Griffith, G. E; Frydenborg, R.; McCarron, E.; White, J. S., and Bastian, M. L. 1996. A framework for biological criteria for Florida sites using benthic macroinvertebrates. J. N. Am. Benthol. Soc, 15(2): 185-211)]; [Gibson, G. R.; Barbour, M. T.; Stribling, J. B.; Gerritsen, J., and Karr, J. R. 1996. Biological Criteria. Technical Guidance for Sites and Small Rivers. EPA/822-B-96-001. U.S. Environmental Protection Agency. Office of Science and Technology, Washington, D.C.]). European Union countries recently started to invest in the standardization and use of multimetric indices, following the proposals set by the Water Framework Directive No. 2000/60/EC (EC, 2000 European Commission. The EU Water Framework Directive—Integrated River Basin Management for Europe. Available at: http://ec.europa.eu/environment/water/water-framework/index_en.html accessed on: Feb. 21, 2008.). In this sense the EU produced the AQEM and STAR projects to standardize and inter-calibrate the operating procedures and development of different multimetric indices, based on the fauna of macroinvertebrates (Pinto P.; Rosado, J.; Morais, M., and Antunes, I. 2004). Assessment methodology for southern siliceous basins in Portugal. Hydrobiology, 516: 193-216; Bohmer, J.; Rawer-Jost, C, and Zenker, A. 2004. Multimetric assessment of data provided by water managers from Germany: assessment of several different types of stressors with macrozoobenthos communities. Hydrobiologia, 516: 215-228; Vlek, H. E.; Verdonschot, P. F. M., and Nijboer, R. C. 2004. Toward a multimetric index for assessment of Dutch stream using benthic macroinvertebrates. Hydrobiologia, 516: 173-189; Buffagni, A.; Erba,S.; Cazzola, M., and Kemp, L. L. 2004. The AQEM multimetric system for the southern Italian Alpennines: assessing the impact of water quality and habitat degradation on pool macroinvertebrates in Mediterranean rivers. Hydrobiologia, 516: 313-329; Furse, M. T.; Hering, D.; Brabec, K; Buffagni A.; Sandin, L., and Verdonschot, P. F. M. 2006. The Ecological Status of European Rivers: Evaluation and Intercalibration of Assessment Methods. Hydrobiologia, 566: 3-29).
[0007] The strength of the multimetric approach lies in the ability to integrate data from the various aspects of a community to provide a general classification of the level of degradation in an ecosystem without losing information from individual metrics. The metrics should be based on solid ecological concepts and represent complex ecosystem processes, to allow for the assessment of ecological functions. The use of different nature metrics may allow for a qualitative evaluation, in addition to the quantitative one, as a metrics may, individually, be able to gualify the source of the impact.
[0008] In general, all of the indices were initially formulated considering exhaustive collection and separation work in the surveying of the macroinvertebrate benthic fauna. Therefore, the indices are constructed considering a biological database that is very robust but with limited application in routine procedures.
[0009] From a practical standpoint, following the collection procedure, all the substrates sampled, organic materials (leaves/algae/macrophytes) and minerals (silt, sand, fine rock, stones) are transported to the laboratory and washed and after that the separation and identification of the biological material are initiated; it should be highlighted that the volume of raw material collected can reach up to 15-20 liters. Among the disadvantages of these techniques we could point the large volumes of the samples collected that have to be correctly treated and stored, the time spent in separating the substrate and the sizable amount of hours spent in the identification of all the specimens, apart from the large quantity of alcohol used in the preservation of the material. We should also point that the number of specimens collected frequently reaches thousands of larvae, which considerably increases operating costs and the environmental impact.
[0010] In this context quick evaluation protocols are being developed as simple tools and with low application costs, to assess the health of water ecosystems. These protocols blend simple and cost-effective field equipment with an optimized processing of the samples in the lab.
[0011] Subsampling is a technique currently used in Europe and in the US, consisting of counting and identifying a part of the randomly obtained community in the total sample collected in the field. The goal of subsampling is to generate a faithful and unbiased representation of a larger sample. It should be random and incorporate the heterogeneous character and diversity of the habitats studied in the field. This leads to a reduction of the effort required.
[0012] With this system, all the material collected is taken to the lab, washed and mixed through different techniques, allowing it to become homogeneous. Through a subsampler (tray split into 24 areas) one randomly chooses a portion of the sample
[0013] Quick evaluation protocols produced in the US ([Plafkin, J. L.; Barbour, M. T.; Porter, K. D.; Gross, S. K., and Hudges R. M. 1989. Rapid bioassessment protocols for use in sites and rivers: Benthic macroinvertebrates and fish. U.S. Environmental Protection Agency, EPA, 444/4-89-001, Washington, D.C.], [Barbour, M. T.; Gerritsen, J.; Snyder, B. D.; and Stribling, J. B. 1999. Rapid Bioassessment Protocols for Use in Sites and Rivers: Periphyton, Benthic Macroinvertebrates and Fish, Second Edition. EPA 841-B-99-002. The US Environmental Protection Agency; Office of Water; Washington, D.C.]) traditionally recommend subsampling via counting of a fixed number. In these protocols the minimum number of organisms recommended to ensure efficiency in evaluation is of at least 300 individuals; in order to prevent much instability in the index metrics and provide reliable results for the evaluation. In practical terms, however, there is a big variation in the minimum number of organisms counted, depending on the analysis at hand. Additionally, when comparing the number of subsamples, it is possible to see the frailty in the small amount of samples.
[0014] Another type of subsampling is that done per area which is also the standard procedure suggested by the AQEM. This protocol suggests the use of trays split into quadrats where 25% of the total sample, of a minimum 300 individuals, are sorted. Area subsampling guarantees the random nature of the procedure, making it less subjective and less prone to the variations inherent to team change. However, there are still problems related to the large volume of the samples collected, to their storage, conservation, separation from the substrate, amount of alcohol used, and the quantity of specimens collected, that can reach thousands of individuals, amongst larvae and adults.
[0015] Regardless of the kind of sampling, the existing state-of-the-art methods have been discussed in several studies in countries where biomonitoring programs are already in application (EU, Australia and the US) ([Barbour, M. T.; Gerritsen, J.; Griffith, G. E.; Frydenborg, R.; McCarron, E.; White, J. S., and Bastian, M. 1. 1996. A framework for biological criteria for Florida streams using macroinvertebrates. Journal of North American Benthology Society. 15 (2), 185-211]; [Countermanch, D. L. 1996. Commentary on the subsampling procedures used for rapid bioassessments. Journal of North American Benthological Society 15: 381-385]; [Somers, K. M.; Reid, R. A., and S. M. 1998. Rapid ecological assessment: how many animals are enough. Journal of the North American Benthological Society 17: 348-358.]; [Doberstein, CP.; Karr, J. R.; Conguest, L. L. 2000. The effect of fixed-count subsampling on macroinvertebrate biomonitoring in small streams. Freshwater Biology , Volume 44 (2): 355-371]; [Lorenz, A.; Hering, D.; Feld, C, and Rolauffs, P. 2004. A new method for assessing the impact of hydromorphological degradation on the macroinvertebrate fauna of five German stream types. Hydrobiologia, 516: 107-127]).
[0016] One of the biggest issues associated with biosampling is that of the wealth of species. The number of taxa found in a sample increases asymptotically as a function of the area sampled and of the number of individuals in the sample. Thus, it is always expected that, with the increase in the effort, one would obtain a greater wealth of species. The issue to focus on, in the specific case of subsampling for biomonitoring is that when this increase no longer is significant and, at the same time, provides an explanation for the change in ecosystem integrity. Apart from that, the full processing of this type of sample, with many individuals, is too costly.
[0017] Thus, the state-of-the-art is embedded with the issue is of how to carry out the subsampling and what the optimal effort is, in the sense of speeding the evaluation without impairing the ecological validity of the response ([Barbour, M. T.; Gerritsen, J.; Griffith, G. E; Frydenborg, R.; McCarron, E.; White, J. S., and Bastian, M. L. 1996. A framework for biological criteria for Florida sites using benthic macroinvertebrates. J. N. Am. Benthol. Soc, 15(2): 185-211]; [Countermanch, D. L. 1996. Commentary on the subsampling procedures used for rapid bioassessments. Journal of North American Benthological Society 15: 381-385]; [Doberstein, C P.; Karr, J. R.; Conguest, L. L. 2000. The effect of fixed-count subsampling on macroinvertebrate biomonitoring in small streams . Freshwater Biology , Volume 44 (2): 355-371]; [Nichols, S. e Norris, R. H.2006. River condition assessment may depend on the sub-sampling method: field live-sort versus laboratory sub-sampling of invertebrates for bioassessment. Hydrobiologia, 572: 195-213]). The subsampling should preferably be carried out in the field or, better yet, in the laboratory.
[0018] Clarke and collaborators (2006) (Clarke, R T.; Furse, M T.; Gunn, R. J. M.; Winder, J. M., and Wright, J. F. 2002. Sampling variation in macroinvertebrate data and implication for river quality indices, Freshwater Biology 47: 1735-1751) studied the effect of subsampling directly on the metrics of different types and found that the precision of the measurements based on the wealth of taxa is quite affected by the size of the subsample, which is predictable due to the species-area ratio.
[0019] Apart from the analysis of the sampling effort, it is always necessary to verify if the subsampling apparatus guarantees the randomization of the organisms, that is, that the organisms are in a given quadrat by chance. A trend observed in this stage can lead to errors in determining the minimum evaluation effort and, in the context of a biomonitoring program, errors in the evaluation of ecological integrity. In biological terms, it is necessary to ask whether the organisms are randomly distributed in the space, or in this case, in the subsampling tray. If the random pattern indeed exists, the Poisson distribution is the right statistical descriptor for the data (Krebs, C. J. 1998. Ecological Methodology. Benjamin/Cummings, Menlo Park.). The Poisson distribution assumes that the expected number of organisms of a particular taxon is the same in all the quadrats and is egual to the population average, estimated based on the sampling average.
[0020] In this context, several subsamplers are found in the state-of-the-art. They basically consist of a plastic tray split into 24 areas. This equipment allows for the reduction of relative time in substrate separation and fauna identification, but does not solve the issues related to the large volume of samples collected, their storage, conservation, amount of alcohol used and the number of specimens collected. However, on the other hand, they produce damage to the specimens as a result of the homogenizing process that hamper the separation and identification, apart from not contributing to the preservation of the biota.
[0021] It is important to point that, if time and resource-saving procedures such as subsampling are applied to the biological monitoring with no prior analysis for equipment accuracy and precision, as well as methods used, the data collected could be useless, resulting in waste of resources, or even in the misled application of handling measures. On the other hand, the application of exhaustive procedures that use much lab time and resources, taking long to provide the biological answer are not practical in terms of application of biomonitoring programs that should assess the condition of hundreds of water bodies. Thus, equipment and methodologies are needed that would allow for an ideal cost-benefit ratio, ensuring the applicability of the tool, without the loss of scientific rigor and power to inference and decision.
[0022] This way, the creation of new subsampling equipment and methodologies that gather the usability features for small volumes, random distribution of the fauna, maintenance of their integrity, and environmental respect, are needed.
SUMMARY OF THE INVENTION
[0023] The goal of the present invention is to carry out the biomonitoring of water bodies without the technical limitations of the methodologies and of the subsamplers as found in the state-of-the-art.
[0024] The first achievement of the present invention refers to a subsampler that allows the carrying out of environmental monitoring without the use of large sample volumes, thus ensuring specimen wealth and speed in the analysis. The Subsampler in the present invention consists of a set of independent structures: two trays, a separator, and support legs. The equipment also presents a measurement system for its correct positioning on site and packaging and transport systems. The subsampler, unlike the others, is preferably used directly in the field. As an alternative, the equipment can also be used in the laboratory, fully assembled or on a benchtop if without the legs.
[0025] A second achievement of the present invention relates to the subsampling methodology. It consists of correctly positioning the subsampler of this invention on the surface; adding the substrate collected in the water medium onto the internal tray; removing the large-sized material, draining part of the water through the opening of the water drain system without fully removing it, adding the anesthetic solution so that the organisms found there reduce their moving capacity, homogenizing the substrate, fitting the separator onto the internal tray, opening the water drain flow system to discharge the anesthetic solution, randomly removing the substrate from the chosen quadrats, storing the removed substrate in alcohol and transporting it to the laboratory.
BRIEF DESCRIPTION OF THE FIGURES
[0026] FIG. 1 is a general view of the set that forms the subsampler object of this invention.
[0027] FIG. 2A is a front view of the internal tray and
[0028] FIG. 2B is a front view of the external tray, for the subsampler shown in FIG. 1 .
[0029] FIG. 3 is a perspective view of the lower part of the internal tray shown in FIG. 2A , showing a support system for the internal tray and the water flow system.
[0030] FIG. 4 is a view from the top of the separation system for the subsampler shown in FIG. 1 .
[0031] FIG. 5 —Critical values for the Chi-square test for the Dispersion Index for α=0.05 and n<101.
[0032] FIG. 6 —Curves for environmental effort showing mean and standard deviation for the 6 points sampled: (a) wealth accumulation in UTOs and (b) wealth accumulation in families.
[0033] FIG. 7 —Wealth expected after rarefaction analysis in differently sized communities in the 6 water streams (A, B, C, D, E, and F) and mean values.
[0034] FIG. 8 —Assessment of the variation in values for metrics amongst different subsample sizes: (a) metrics on wealth and diversity, (b) composition metrics, (c) trophic metrics, and (d) tolerance metrics.
[0035] FIG. 9 —Mean similarity values with total sample (24 quadrats) in growing size subsamples.
[0036] FIG. 10 —comparison between measures for impact measures (metrics) using the community found in 6 quadrats in areas minimally affected (REF) with average intensity disturbances (INT) and strongly altered (POB).
DETAILED DESCRIPTION OF INVENTION
[0037] The Subsampler in the present invention consists of a set of independent structures: two trays, a separator, and support legs, represented by the number (10) in FIG. 1 .
[0038] It is worth pointing that the subsampler in the present invention also has a system to measure the correct positioning of the equipment on site and, alternatively, a packaging and transport system as shown in FIG. 1 .
[0039] The construction of the subsampler structures can be done with any feasible material for a technically minded person. Preferably, the more adequate materials are steel, aluminum, resin, or plastic.
[0040] The internal tray ( 22 ), shown in FIG. 2A , of size such as to fit the external tray ( FIG. 2B ), has in its bottom an outlet to discharge water, preferably with holes ( 24 ) equally distributed to allow its flow. The said internal tray ( 22 ) also has a net (not shown) to filter the biota-sediment complex of size that is adequate to the type of study to be undertaken, that can vary, preferably, from, 500 μm to 1 mm. FIG. 3 shows the outer side of the base of the internal tray ( 22 ) where there is a support system ( 26 ) in free form. The free form of the support system ( 26 ) is chosen so as not to prevent the flow of water, and can be S-shaped, albeit not limited to it, set in a direction parallel to the water flow line, thus jointly avoiding the loss of form of the tray and the flow back phenomenon. There can optionally be the presence of algae ( 28 ) in the internal tray ( 22 ) to facilitate its handling. ( FIG. 2A )
[0041] The outer tray ( 32 ) with a size adequate to the size of the sample to be collected, preferably ranging from 60×50×16 to 36×36×10 cm, has a reinforcement edge to assist in supporting the weight and shape of the device. Said outer tray ( 32 ) has: a water outlet ( 34 ) system (such as, but not limited to, a tap or threaded plug). Additionally, the outer tray ( 32 ) has a support system with legs and a system for the correct (horizontal positioning of the device in the field. In the preferred configurations of the present invention, possible positioning systems that can be used are those of the ‘bubble’ or ‘pendulum’ types, but not limited to them. ( FIG. 2 b )
[0042] The separator system ( 42 ) shown in FIG. 4 consists of a set of plates fitted perpendicularly between them with the function of separating the material collected from the substrate. This device is sized according to the inner box in which it should fit snugly, separating the material into 24 quadrats. Optionally, handles can be incorporated to the separation system to facilitate its handling. ( FIG. 3 )
[0043] The support legs ( 11 ) form a set of rods that can vary in number, provided it is not smaller than four, with height according to ergonomics principles, preferably 80 cm long, but without limiting themselves to this, and can also be adjustable or folding to facilitate the transport of the equipment. According to what is proposed in this invention, the use of support legs ( 11 ) is optional and there is no need when the subsampling is done in a laboratory.
[0044] Thus, in a preferred configuration of the invention, the subsampler, unlike the others found in the state-of-the-art is used directly on site.
[0045] For the perfect operation of the subsampler in this invention it is positioned horizontally at the place of collection, adjusting its legs ( 11 ) correctly with the aid of the positioning system. After that, the internal tray ( 22 ) is inserted in the external tray ( 32 ). The biological material from the collected substrate is stored in the internal tray ( 22 ) and covered with the river water. Large-sized sticks, stones, and leaves are manually removed by operators, for a standard length of time that ranges from 10-20 minutes. Following this work, part of the water is removed with the opening of the water outlet ( 34 ) as found in the outer tray ( 32 ); part of the water is removed, and some of it is left still on the bottom of the inner tray ( 22 ).
[0046] After that, the water that remains in the tray is added with an adequate amount of anesthetic in proportion to the box used. The anesthetic used in the present invention should be reversible, to allow the survival of the biota that is not used in the later stages of the subsampling. in a preferred configuration of this invention the anesthetic used is gaseous water. However, other reversible anesthetics known in the state-of-the-art can be used in this invention. To facilitate the understanding, the preferred proportion is of two liters for a 60×50×16 box filled with 10 cm of water. This procedure aims at anesthetizing the animals found in there, thus ensuring a homogeneous distribution of the biota in the subsampler. After the time necessary for the anesthetic to act, all the material is mixed in the inner tray ( 22 ). In the case where gaseous water is used this stage can last from 5 to 15 minutes.
[0047] After the homogenization operation the separator system ( 42 ) is positioned on the tray. The water outlet ( 34 ) is opened until the full removal of the anesthetic solution from the subsampler. By means of a draw, according to the methodology chosen, quadrats from the separator ( 42 ) are selected and the material in them is removed. It is recommended and preferred that a draw is made of 4-6 of the 24 quadrats. After that, the material found in the selected quadrats is removed. The samples collected are stored in proper containers such as, but not limited to, plastic bags and immobilized. The immobilization can be done with the use of organic compounds such as, but not limited to, 70% to 80% concentrated alcohol; 4% to 10% formaldehyde, or a blend of both, for the transport to the laboratory where the identification of the specimens will be made.
[0048] The material remaining in the inner tray is returned to the water environment.
[0049] The subsampler in the present invention has clearly shown to be, through its onsite use, that it allows for a rapid subsampling of the material collected.
[0050] According to what is proposed in this invention, subsampling with the equipment and the use of the methodology described produces, apart from optimizing the time spent, a series of advantages when compared with the equipment and methodologies found in present-day state-of-the-art.
[0051] Considering a river with trees on its banks, with many leaves at its bottom, by using the subsampler of the present invention a considerable reduction in the volume of the material can be achieved. When comparing this point to what is presently the state-of-the-art it is possible to get a ⅔ approximate reduction of the volume of the material washed in the field and, after washing, a ¾ reduction. Apart from that, with the present invention, one avoids the washing stage of the biological material at the laboratory, a stage that requires considerably high investment in time.
[0052] As regards the transportation and preservation under conserving agents, the use of the subsampler in the present invention cuts some 80% of the volume of the material collected when compared to the state-of-the-art, that is, with classical subsampling.
[0053] The use of this equipment and its methodology contribute more effectively for the preservation of the integrity of macroinvertebrates when compared to other subsamplers found in the state-of-the-art, which consequently allows for the execution of better taxonomic separation and tagging. This feature is produced as a result of the homogenizing system for the material found in the inner tray. In the subsampler of the present invention the material is collected along with a large amount of water and with the specimens still alive, unlike other techniques where the homogenizing is done in dry conditions in the laboratory, and with specimens previously fixed in alcohol. This causes the hardening of the muscle tissues, favoring damage to the animals.
[0054] The homogenizing proposed by the present invention also contributes significantly to the randomizing of the organisms, i.e. favoring their random distribution along the quadrats.
[0055] Another difference related to the state-of-the-art is found in relation the biota that is left in the on-site subsampler. This biota usually consists of thousand of larvae and adults from dozens of different taxonomic groups. According to the present invention these organisms are returned to ecosystem while they are alive. Therefore, once in contact with the environment's water (river) the anesthetic effect of the gaseous water, for example, is instantly reversed.
[0056] The invention presented here can be considered environmentally friendly, affecting minimally the location where the collection is made, apart from being very efficient; reducing operating time frames, as well as costs and, on the other hand, maintaining the random nature/wealth of the species, factors that are fundamental in water biomonitoring programs.
[0057] Despite the use of the subsampler in the present invention being preferably of a on-site nature, the scope of the invention includes its use also in a laboratory environment, fully assembled or on a benchtop, without its legs, to allow the subsampling of material previously fixed in the field.
[0058] Below are listed configurations for the present invention, and we point that it is not limited to the examples below but also includes variations and modifications, within the limits of its operation.
EXAMPLES
Example 1
Subsampler Assessment
Organism Collection
[0059] In order to evaluate the efficacy of the subsampling done by the equipment and the methodology in the present invention the data of 6 water streams, considered lightly affected areas, was used. The streams are located in the basins of rivers Macacu and Guapimirim, a dense ombrophilous forest area belonging to the domains of the Atlantic Forest Range, in Sea Range, state of Rio de Janeiro (Table 1). The criteria to define the reference areas were at first: visual habitat evaluation protocol with either excellent or good condition; over 75% of the basin area above the point under forest cover; Dissolved Oxygen over 6 mg/L; Fecal Coliform per 100 mL<10.
[0060] The collection procedure considered samplings of the multi-habitat kind in a collection proportional to the availability of the substrate in the river section studied. A kick sampler was used with a 500-micron mesh, with a total 20 replicas per point where each one consists of 1 (one) m 2 of substrate surveyed. Thus, some 20 m 2 of substrate in the river were collected. The sample was unified and kept in ethanol at 80%. In the 6 water streams studied the collection was done by the same team and the maximum standardization was sought for the procedure.
[0000]
TABLE 1
Characterization of the collection points
Altitude
Visual Evaluation
Rivers
Code
Order
(m)
Protocol
River Andrew
A
2
930
Excellent
River Soberbo
B
3
100
Excellent
River Manoel
C
4
80
Excellent
Alexandre
River Iconha
D
1
1220
Excellent
Macacu Branch
E
1
1100
Good
River (River
Placa)
River Gato
F
3
90
Good
Subsampling Procedure
[0061] In this configuration of the present invention the subsampling was done per area and, for that, a subsampling apparatus was used, split into 24 quadrats sized 64×36 cm.
[0062] The apparatus consists of two plastic trays (inner and outer) fit in such a way as previously described.
[0063] The inner tray ( 22 ) as shown in FIG. 2A has holes evenly distributed at the bottom and a 500 μm mesh (egual to that of the sampler). On its outer side there is a S-shaped support system in a direction parallel to the water flow line.
[0064] As for the outer tray ( 32 ) used in this analysis, it consists of a tray for the water flow with a tap on the side, also with the ‘bubble-type’ correct positioning system, as already demonstrated.
[0065] The separator system used, according to FIG. 4 , consists of a set of plates fitted in a perpendicular manner so to fit snugly into the outer tray ( 22 ), to separate the material into 24 quadrats. The handles found in the separator system facilitated the handling of this part of the equipment.
[0066] The samples were washed in the laboratory, in the internal tray ( 22 ) of the subsampling equipment to remove the coarser material such as large leaves and sticks. After that, the inner tray was filled with some 15 liters of water and the material was homogenized for 5 minutes to ensure the even distribution of the entire sample on the tray surface. The tap ( 34 ) was then opened and the water flowed in a homogeneous way to the outer tray ( 32 ). The separator ( 42 ), with its 24 aluminum quadrats was then fitted onto the inner tray ( 22 ). The material corresponding to each quadrat was removed and individualized in a plastic bag.
[0067] This procedure was repeated for the 6 sampling points, resulting in 144 (24×6) plastic bags, corresponding to 144 quadrats. Each quadrat was then screened to exhaustion and the organisms identified as per genera (except Lepidoptera and Diptera that were tagged as per family) with the aid of a stereoscope microscope. Considering that each river sample represents 20 m 2 of substrate, each quadrat then equals 0.83 m 2 and approximately 4.2% of the total sample. We took into account the processing time (screening and tagging) for each quadrat to ascertain the gain in terms of time and consequently the resources saved in the subsampling procedure.
[0068] The similarity analysis done showed that the communities with 4 quadrats already display high similarity values with the total 24-quadrat sample based on the 3 indices used and the standard deviations under 0.01. For the Morisita Index, even the smaller-size subsample has a 98% similarity with the total sample. The Bray-Curtis Index displayed the smallest similarity values but pointed that a 4-quadrat subsample already has a 70% similarity with the total sample.
[0069] The results of the previous analyses show then that the macroinvertebrate community found in 6 quadrats is similar to that found in the full 24-quadrat sample in terms of structure and composition.
Example 2
Organism Distribution Analysis
Randomness Verification
[0070] In order to test whether the taxa subsampled, as per Example I, have a random distribution in the quadrats, a test was done based on the Dispersion Index (Krebs, C. J. 1998. Ecological Methodology. Benjamin/Cummings, Menlo Park.). The dispersion index is calculated through the ratio between the observed variance and average. A bivariate Chi-square test is then applied, considering the null hypothesis that the data follows the distribution of Poisson. The X 2 is calculated through the multiplication of the value of the dispersion index by the number of freedom degrees (n−1).
[0071] There are two possible directions for deviation. If the organisms are evenly distributed the variance will be much smaller than the average and the Dispersion Index will be close to zero. If the organisms were clustered the variance observed would be greater than the average and the Dispersion Index would be much higher than 1 (one)(Krebs, C. J. 1998. Ecological Methodology. Benjamin/Cummings, Menlo Park) ( FIG. 5 ). Considering α=0.05 and 23 degrees of freedom, the values for X 2 in this case should be between 11 and 37 for the hypothesis of random distribution to be accepted. This test was undertaken for all the taxa on a family level, considering the 24 quadrats in the 6 rivers.
[0072] It was found that most of the subsampled macroinvertebrate families had a random distribution, similar to that of Poisson in the 24 quadrats. The mean Dispersion Index varied in values a little over 1 in the 6 water streams. The summarized results are in Table 2.
[0000] TABLE 2 Distribution of abundances and wealth in quadrats for the 6 rivers surveyed. River River River Manoel River River River Andrew Soberbo Alexandre Iconha Placa Gato Averages Total 2435 2193 2722 2663 1684 1939 2272.667 Abundance Mean 101.4583 91.375 114.125 110.9583 70.16667 80.79167 94.81249 abundance per quadrat Standard 24.92769 20.16845 27.81978 28.95045 20.36977 18.15867 23.39914 Deviation Mean 421 405 485 482 295 319 401.1667 abundance in 4 quadrats Mean 709 595 770 699 434 479 614.3333 abundance in 6 quadrats Mean 890 777 994 926 562 603 792 abundance in 8 quadrats Mean 1332 1117 1413 1345 839 909 1159.167 abundance in 12 quadrats Total 57 52 61 58 45 50 53.83333 wealth (UTOs)
Thus, the subsampling procedure and apparatus in the present invention ensured the random distribution of the organisms. This was driven mainly by the methodology described herein, which avoids to the maximum that the organisms are not sampled due to a flaw in the sample homogenization procedure.
Example 3
Evaluation of Taxa Wealth
Determination of Effort Required
[0073] It is worth pointing out that the on-site sampling should be representative of the heterogeneous character of existing habitats and should be a standard procedure to endure the degree of comparison of the results.
[0074] In order to prove the efficacy of the equipment and of the methodology of the present invention as regards the representativeness of the taxa, work was done to determine the collector curve, using Operating Taxonomic Units (UTOs), that is, the best taxonomic resolution possible. Work was also done to produce the collector curve for the macroinvertebrate fauna identified only on a family basis.
[0075] FIG. 6 shows the curves obtained and shows the averages and the standard deviation for accumulated wealth in each quadrat for the 6 rivers. It is possible to visually verify that, from the sixth quadrat the accumulated wealth starts to display a stabilizing trend, as per FIG. 6 a.
[0076] It was also found that the abundances were different between the points and that implies different wealths with their increase as a result of the number of organisms in the sample— FIG. 6 b.
[0077] The rarefaction curve produced considered communities with 100 to 1,600 organisms in the 6 sampling points. The result of the analysis is in FIG. 2 where it is possible to see the absolute values in the expected wealths, for each water stream, for each sample size. The black circle line shows the averages. Given that the mean abundance of 6 quadrats was of 614 individuals one can consider then that 600 individuals egual 6 quadrats. Another point to highlight is that the adding of 1,200 individuals to the sample (from 400 to 1,600) led to an mean increase of 10 UTOs.
[0078] Thus, for the example at hand, it was determined that the use of 6 quadrats, which add to 25% of the sample and represent around 5 m 2 of substrate from the sampled river, it was enough for the application in biomonitoring programs when using the equipment and the methodology of the present invention. That is, the results showed that the macroinvertebrate community found in 6 quadrats is quite similar to the community found in the total 24-quadrat sample.
[0079] And moreover, the equipment as well as the methodology of this invention were capable of producing robust data for the biological evaluation, comparing different impact intensity areas. Overall, this is the most important test as it directly evaluates the efficiency in sample size as it differentiates the areas affected from the reference areas.
Example 4
Size of Subsample and Metrics
[0080] The analysis done to assess the direct effect of subsample size on the values of biological measurements that might form a multimetric index took place via the definition of sub-communities with 4, 6, 8, 12, and 24 quadrats. The results were presented through Box plots considering the medians and the 25-75% percentiles of the metrics values in the 6 water streams, in each one of these randomly generated sub-communities. A test was then done to compare the value of the metrics for a given subsample size (4, 6, 8, or 12) with the total sample (24 quadrats).
[0081] The metrics chosen for the analysis of the subsampling as done by the equipment and methodology described in Example I were: wealth, relative abundance, trophic groups, and tolerance. FIG. 8 presents the assessment of the values of these metrics in the different subsample sizes.
[0082] As regards the metrics that measure just wealth (family total and of Ephemeroptera/Plechoptera/Trichoptera), these seem to be the most affected by the size of the subsample, as the difference between the value of the metrics to 4 and 24 quadrats is significant through the Mann-Whitney test, as shown in FIG. 8 a . As for Shannon's Diversity it did not seem affected by it, and produced no meaningful difference.
[0083] In the case of the metrics for relative abundance, % EPT, % Diptera, % Choleoptera and % Plecoptera were shown to be stable throughout the different subsample sizes, with no significant variation between them, as it can be seen in FIG. 8 b . This shows, in an indirect manner, that the sample was well distributed along the tray; it once again shows that the equipment and methodology proposed in the present invention can correctly homogenize the material collected.
[0084] FIG. 8 c shows data for the metrics on trophic groupings that correspond to the abundance of theses functional groupings in relation to total abundance (% Filtering Elements and % Fragmenting Elements). Both groupings displayed stability in their values, for the different subsample sizes, demonstrating that the proportion of these organisms is kept, independently from subsample size.
[0085] In the case of the metrics to evaluate tolerance, two were studied: IBE-IOC and the Baetidae/Ephemeropter measurement.
[0086] The first one, IBE-IOC, is a biotic index based on the tolerances of the different genera and families of benthic macroinvertebrates; being, on its own an evaluation tool, providing a classification of the place of collection in categories of different impact levels. A sample error that produces a loss of sensitivity in the index may then mean an error in evaluation and mislead the necessary handling measurements. This index ranges from 0 to 15 and the higher it is the better the biological integrity of the place is, being considered as a measure of integrity. The fact that it was, in the comparative analysis between reference areas, intermediate areas and affected areas, sensitive to a 6-quadrat family points at the fact that this subsample size does not affect a sensitivity of this tool. And, from 6 quadrats on the community already gets grades that are quite similar to those of the index. Only the 4-quadrat subsample produced a significant difference.
[0087] The Baetidae/Ephemeroptera measurement is also a direct measurement for tolerance as it measures the relation between the most tolerant family of the Ephemeroptera and the total abundance of the order. No significant difference was observed amongst all the relative abundance measurements, amongst the different subsample sizes, according to FIG. 8 d.
[0088] This way, it is found that both the equipment and methodology described in Example I have the accuracy and precision needed for the establishment and analysis of the metrics required for the biomonitoring of water systems.
Example 5
Similarity Analysis in Terms of the Composition and Structure in the Different Sizes of Subsamples
[0089] The analysis of similarity done used three assessment indices: Morisita, Bray-Curtis, and Sorensen. FIG. 8 describes the mean similarity with the total sample in growing size subsamples, with standard deviations not being pointed in the graphs of the Figure as they were all under 0.01.
[0090] The communities with 4 quadrats already displayed high similarity values when compared to the total 24-quadrat sample by the three indices used. For the Morisita Index, (Morisita 1959), even the smaller-size subsample has a 98% similarity with the total sample). The Bray-Curtis Index (Bray & Curtis, 1957) displayed the smallest similarity values but pointed that a 4-quadrat subsample already has a 70% similarity with the total sample ( FIG. 8 d ).
[0091] The analysis of the sampling effort curve points that, in operating taxonomic units, the accumulation of wealth is no longer significant in 6 quadrats. All the metrics, including those of taxa wealth, have similar values in samples sized from 6 quadrats. The analysis of similarity pointed that 4-quadrat samples have high similarity values with 24-quadrat samples, as shown in FIG. 9 .
[0092] All this information demonstrates that a community found in 6 quadrats is quite similar to that found in the total 24-quadrat sample, both as regards structure as in wealth and its composition.
Example 6
Subsample Size Validation
[0093] In order to test whether a 6-quadrat can actually serve as a basis for a biomonitoring program a direct comparison was made between the 6 reference areas considered in this evaluation, as per Example I and 6 intermediate and strongly affected areas of independent data sets. The evaluation of the seriousness of the impact was made through a visual habitat protocol modified to attend to the realities of the Brazilian people, assessing the state of conservation of the river bed and of its banks, and of physical and chemical analyses (dissolved oxygen, pH, nitrites, nitrates, phosphates).
[0094] The comparison was made via the calculation of 4 direct impact measurements that are often included in multimetric indexes or represent, on their own, a non-index. A Mann-Whitnney test was undertaken to ascertain the significance of the difference and to confirm if there is a distinction between different impact classes.
[0095] FIG. 10 describes a comparison between values for impact measures (metrics) using the community found in 6 quadrats in areas minimally affected (REF) with average intensity disturbances (INT) and strongly altered (POB). The four assessing measurements considered displayed a high sensitivity to detect the differences between the impact classes. Even in the intermediate class which many times displayed subtle disturbances, it was differentiated by the 6-quadrat community.
Example 7
Subsampling Time
[0096] In this configuration of the invention if only one person undertakes the processing to subsample the sample collected according to Example I, a 6-quadrat subsampling will result in a 12-hour saving in the processing of a sample with a minimally affected area.
[0097] It should be pointed that the loss of a few taxa, inherent to any subsampling technique, in the present invention, brought practically no change to the generation and functioning of the metrics of an index, guaranteeing the scientific robustness of the tool to assess the ecological integrity of the water streams studied.
[0098] All the results presented in the examples above show that the subsampling procedure, done with the equipment and methodology of the present invention allows their application in the biomonitoring of water systems, ensuring especially scientific rigor in the obtaining of the multimetric indices.
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The present invention refers to the subsampler and to a subsampling method that allows for the execution of environmental monitoring without the use of large sample volumes, thus ensuring specimen wealth and expedited analyses.
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BACKGROUND
[0001] Shock waves, i.e. mechanical waves sometimes also named “acoustic”, are presently used in different ways for therapeutic treatment. Shock wave lithotripsy is especially important and has been the starting point of the development in a historical sense, namely the disintegration of concrements in the body, especially stones, using focused shock waves of high amplitude and steep rising edges. Normally, single pulses are directed to the concrement, wherein the first “half wave” corresponding to a compression dominates as regards edge steepness and amplitude whereas already the next succeeding half wave, corresponding to an expansion, is substantially less pronounced. Such pulses are used in a regularly repeated manner.
[0002] Comparable methods using shock waves are also known for other indications, e.g. for treating badly healing bone fractures.
[0003] The essential frequencies of the above-mentioned therapies are above the acoustic threshold; thus, these therapies are ultrasonic methods.
[0004] Although therapies using non-focused shock waves are known, the present invention is related to applications of focused waves (including pulses, compare above). Although the delimitation between focused and non-focused waves can be problematic, in the following, only such therapies shall be meant in which the shock waves are intentionally concentrated to a body region which is more or less extended in order to increase intensities, pressures or edge steepnesses.
[0005] Since in these focusing therapies the localization to the body region to be treated is essential, the adjustment of the respective apparatus for a correct positioning of the focus region in the body is of essential importance. This relates to a preliminary adjustment to the region to be treated, e.g. a stone, on the one hand. In case of too large tolerances, healthy tissue is damaged or unnecessarily much of healthy tissue is subjected to the therapy and, further, the success of therapy in the region to be treated is diminished or endangered. The term “navigation” is used here.
[0006] As a complication, further, the navigation does not necessarily need to be a static operation, i.e. changes during treatment may occur. Movements of the patient or displacements of organs, especially due to respiration, are an essential cause.
[0007] Image producing methods can be used for navigation that render the region to be treated distinguishable from surrounding regions and produce navigation information, i.e. coordinates, for the shock wave apparatus. Particularly known is a running X-ray monitoring during shock wave lithotripsy. Since at least two X-ray projections are necessary for the determination of the spatial position, a substantial technical effort for tilting X-ray axes and corresponding costs are caused. As regards the patient, X-ray monitoring leads to radiation exposure.
SUMMARY OF THE INVENTION
[0008] According to one embodiment of the invention, an apparatus is provided, wherein said apparatus comprises: a shock wave source adapted to produce said shock waves, a focusing device adapted to focus said shock waves onto a focus region in said body to be treated, a locating probe adapted to be inserted into said body to be treated, a magnetic locating element as a part of said locating probe and arranged in said locating probe, and a magnetic locating apparatus adapted to locate said magnetic locating element in said body to be treated and thus adapted for navigation during said treatment.
[0009] Further, the invention is directed to a respective method in which the apparatus is used.
[0010] In addition, the invention also relates to shock wave therapies using proper waves, i.e. continuously oscillating waves. They can be used in a focused manner for heating body tissue, e.g. for the so-called thermal ablation of tumors.
[0011] Preferred embodiments of the apparatus according to the invention and its use are given in the dependent claims. The features therein as well as the disclosure in the description hereunder are to be understood in view of all categories of the invention although differences there between will not be made explicitly as regards the details. The invention also includes navigation methods and treatment methods.
[0012] In one embodiment, the basic idea of the invention is to use a combination of a locating probe and a magnetic locating system. The locating probe is a minimally invasive instrument for insertion into the body, namely near to the region to be treated, however, not necessarily adjacent to this region. Preferably, a catheter or an endoscope can be chosen, wherein the different terms shall mean that a catheter has no optical vision device and an endoscope comprises an optical vision device. Thus, the endoscope can also be flexible and the catheter can also be rigid, at least principally.
[0013] Magnetic locating systems are known and are commonly used as tracking systems. In the body, a locating element is arranged which could be an active or a passive coil or even a permanent magnet. This locating element can be located by an extracorporeal magnetic locating apparatus and its position (i.e. coordinates) can be determined. According to the invention, the magnetic locating system serves to navigate the shock wave apparatus, i.e. the shock wave apparatus is calibrated with reference to the coordinate information of the magnetic locating system.
[0014] According to the invention, the magnetic locating element is arranged within the locating probe, preferably within its tip or near its tip. Thus, it is arranged near the region to be treated. Then, the distance between the magnetic locating element and the region to be treated can be determined or defined in various ways. This includes measuring the distance in case that the magnetic locating element is not adjacent to or in contact with the region to be treated, as well as a minimization of the distance to a quantity without relevance for therapy, i.e. an arrangement of the locating element adjacent to the region to be treated. The criterion for the relevance of the minimized distance is the focus region of the shock waves. Thus, the basic assessment is that in case of a sufficiently close arrangement of the magnetic locating element to the region to be treated, the remaining difference in position is irrelevant for the shock wave therapy so that the position of the magnetic locating element can be used as the “target” for the navigation. In other cases, the remaining distance is measured and considered by means of a calculation.
[0015] The magnetic locating system provides a cost-effective and, as regards the patient, careful and gentle navigation system. The calibration according to the invention using the locating probe is also economic as regards the equipment and cost-effective as well as time-efficient for the therapeutic procedure, practical, and free of radiation exposure. Further, minimally invasive locating probes as catheters and endoscopes are not connected with substantial burden on the patient.
[0016] Thus, one advantage of the invention is that it allows to replace the X-ray navigation with a navigation based on the magnetic locating. However, apparatuses and methods of the invention can also be combined with X-ray imaging in an advantageous manner. Thus, in one embodiment, the invention relates to a combination of the navigation based on the magnetic locating with an X-ray based navigation.
[0017] If a combination of the navigation techniques is used, the X-ray imaging would usually provide a preliminary and thus preferably only single image for calibration purposes together with the locating probe. The invention allows for the running monitoring and especially the consideration of patient movements independently from X-ray monitoring. In certain embodiments of the invention, X-ray technology can be totally dispensed with, thus substantially reducing the expenditure in equipment and substantially simplifying the procedure for the clinic staff. Finally, embodiments of the invention exist in which, although X-ray imaging is used, it is simplified in that only one single imaging axis is used and complicated tilting mechanisms can be dispensed with.
[0018] Thus, the invention provides for an effective, simple and economical shock wave navigation.
[0019] In one embodiment of the invention, the locating probe is an endoscope and thus comprises an optical vision device. Therewith, the approaching of the endoscope, especially the endoscope tip, onto the treatment region can be controlled visually. For example, the endoscope can be introduced via the urethra and pushed forward until a kidney stone to be treated becomes visible in the patient. By means of the guidance of the endoscope due to the visual control, a spatial correspondence between endoscope and stone or between endoscope and the treatment region can be established. In the simplest case, the endoscope can be approached to the stone so that the magnetic locating element, e.g. a coil in the endoscope tip, is directly positioned beside the stone. As soon as the magnetic tracking system detects the position of the magnetic locating element, it can actually monitor the positions of the stone as well, as long as the direct neighborhood between the magnetic locating element and the stone is conserved. This can be certified by visual control. X-ray imaging or other imaging technologies using extracorporeal imaging apparatus are not necessary, however, they can be used preliminary in order to increase the safety of diagnosis.
[0020] Depending on the technical implementation of the endoscope and the precise manner of shock wave treatment, it may be problematic to leave a part of the endoscope in the focus region during the shock wave treatment. For example, the focus regions of shock wave lithotripsy apparatus may damage classical rigid endoscopes. Thus, another embodiment of the invention is provided, in which the endoscope comprises a distance measuring device. Preferred are optical distance measuring methods, i.e. the methods using light. Some examples include stereoscopic, holographic, or propagation time measurement methods allowing a quantitative measurement of the distance between the endoscope, e.g. the endoscope tip, and for example a stone. The distance measured can be accounted for in the navigation and thus provides a correction of the target area as detected by the magnetic locating apparatus.
[0021] A further embodiment of the invention uses a catheter within the measurement endoscope and approaches the endoscope as described above into the neighborhood of the treatment region under visual control. The direct neighborhood of endoscope and treatment region is, however, avoided due to the reasons named. Instead, a catheter comprising the magnetic locating element is pushed out of a working channel of the endoscope and positioned such that the magnetic locating element itself is arranged in direct neighborhood of the treatment region. The catheter can be less sensitive to shock waves and/or be a disposable product. The control of the direct neighborhood between the treatment region and the catheter or, in an embodiment mentioned above, the endoscope in the final phase may also be manual/sensory, naturally beside a visual control, for example by sensing the contact to the stone manually.
[0022] As already mentioned, the invention can be combined in an advantageous manner with an X-ray apparatus. This is true more generally for extracorporeal imaging techniques, e.g. ultrasonic diagnosis.
[0023] In particular, such imaging can verify the approach between magnetic locating element and treatment region already done by visual control, possibly using a distance measurement. In case of a catheter without visual device, an imaging method can replace the visual control. Thus, the catheter can be arranged so that the image shows a direct neighborhood to the treatment region or how large the remaining distance is in order to consider it as a correction.
[0024] In a preferred embodiment, the invention relates to a combination of a catheter as a locating probe with imaging in the following way: An X-ray image or another extracorporeal image having a comparable imaging axis is used for positioning the magnetic locating element in the catheter in a plane perpendicular to the imaging axis. In the direction of the imaging axis itself, the magnetic locating element is located only by the magnetic locating apparatus but not by a separate control of the neighborhood between the treatment region and the magnetic locating element. This is especially reasonable if, for other reasons, such as anatomy, sufficiently precise implications regarding this neighborhood in the direction of the imaging axis are possible. On the one hand, typical shock wave treatments have a lengthy focus region, the longitudinal extension of which is parallel to the main propagation direction of the shock waves. On the other hand, the anatomical situation can already predefine a more precise localization than the extension of this focus region. The localization by the extracorporeal imaging can be done by using a small angle to this shock wave propagation direction, as far as possible therein, so that the localization of the magnetic locating element relative to the treatment region detected with sufficient precision is in a direction in which the focus region is relatively long.
[0025] An essentially coaxial geometry is preferred therein, e.g. having the main axis of shock wave propagation substantially coincident with the X-ray axis. Namely, shock wave sources are preferred that have a hollow construction, e.g. a hollow coil of a lithotripsy source. Then, the X-ray imaging can be done through the hollow space and thus essentially produce an image in the plane of the shortest focus region extension. Therein, a slight inclination between the axes can occur, naturally, as the treatment region imaged by X-ray or generally by an extracorporeal technology need not necessarily be centered precisely in the image. Deviations from the center can be compensated by respective adjustments of the shock wave apparatus without a following adjustment of the X-ray apparatus. Thus, within the imaging region, inclinations of the axes can occur. In this embodiment of the invention the axes can also be coaxially arranged, however.
[0026] Further, the visual control, possibly in combination with the distance measurement described above, can be used for a positioning in the (X-ray) imaging direction itself, namely in the direction not visible by a single X-ray image. The visual control can also be used for the introduction of an endoscope into the relevant region. The additional safety and precision achieved by the extracorporeal imaging can be combined with a renunciation of a multitude of X-ray images.
[0027] However, if an X-ray apparatus providing for several imaging directions is available, the locating probe, especially as a simple catheter without visual device, can also be located by at least two X-ray images within the body in a three dimensional manner. In this localization, a possible residual distance to the treatment region can be measured by the imaging. Usually, such a measurement is superfluous because the catheter is brought into the direct neighborhood, anyway. One advantage of the invention includes the use of the magnetic tracking system for the following navigation, so that X-ray imaging is only necessary preliminarily.
[0028] In the various combinations with extracorporeal imaging techniques, the catheter must be visible for the extracorporeal imaging technique used. For example, inserts (markers) having an increased X-ray absorption can be used. The magnetic locating element itself can serve for this purpose as well. Endoscopes are usually very well visible, at least in case of rigid metal constructions. However, flexible locating probes low in X-ray contrast and having a visual device, e.g. by means of a flexible glass fiber bundle which are named “endoscope” according to the definition used here are considered as well. If this approach is used, a sufficient contrast in the X-ray image should be provided by the magnetic locating element or another marker.
[0029] The shock wave source is preferably extracorporeal. It can be coupled to the body by a liquid volume, e.g. within a bellow. Shock wave lithotripters are an especially important field of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Hereunder, the invention will be explained in more detail by means of exemplary embodiments wherein the individual features can also be relevant for the invention in other combinations and refer to all categories of the invention implicitly, as already mentioned.
[0031] FIG. 1 shows a schematic view of an apparatus according to the invention and a section through a human abdomen.
[0032] FIG. 2 shows a similar view as in FIG. 1 , however of a second embodiment.
[0033] FIG. 3 shows a similar view as in FIG. 1 , however of a third embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIG. 1 shows a schematic section through the abdomen of a human in the upper region of the figure. In the lower region, the spinal column and a respective kidney on the right side and on the left side thereof can be seen. The right kidney in the figure contains a catheter 1 having a so-called double J form. Catheter 1 contains one or several metallic magnetic coils in its most distal portion shown, serving as a magnetic locating element on the one hand and providing a good X-ray contrast on the other hand.
[0035] Particularly in case of urological stones, the introduction of the catheter is advantageous to avoid a blocking of draining vessels by stone fragments and to guarantee a draining of urine through the catheter independently from the transport path of the stone fragments.
[0036] A magnetic locating apparatus 3 shown in the lower right region can detect the position of the magnetic coils. In this exemplary embodiment, it is fastened to a shock wave apparatus 2 known as such having integrated focusing devices and coupled to the body by a liquid-filled bellow 4 . The lines converging from the shock wave apparatus 2 through the liquid volume in bellow 4 to a point in the loop of catheter 1 symbolize the focused shock waves from source 2 . Thereby, a kidney stone shall be disintegrated which is positioned in the focus region indicated.
[0037] Catheter 1 is preliminarily introduced through the urethra and displaced to the relevant region of the kidney in a manner known as such. There, it can be positioned by a conventional series of X-ray images or verified in its position. Hereto, several known methods of fluoroscopy or radiography are adequate. Finally, it is known from the X-ray images that catheter 1 is arranged such that the magnetic coils are adjacent to the stone. Thus, the magnetic coils serve for marking the stone position, namely both in the X-ray image and in the magnetic tracking.
[0038] Since magnetic locating apparatus 3 and shock wave apparatus 2 are mounted in a fixed spatial relationship with reference to each other, the positional data of the magnetic tracking system can be used directly as target coordinate data for shock wave apparatus 2 under consideration of this spatial relationship. Thus, the shock wave focus can be adjusted onto the stone as well, e.g. by turning or displacing a structural unit to which shock wave apparatus 2 and magnetic locating apparatus 3 are mounted. Simultaneously, the spatial relationship between the shock wave focus and the magnetic coil positions can be displayed numerically and/or graphically. As soon as a sufficiently precise coincidence is achieved, the shock wave treatment as such can start.
[0039] During this treatment, magnetic tracking system 3 continuously monitors the position of the magnetic coils. In case of movements of the patient or a change of the magnetic coil positions due to other circumstances, the treatment can be interrupted and can be continued after a recalibration.
[0040] The second embodiment in FIG. 2 differs from the first embodiment of FIG. 1 as regards the locating probe, first. Here, an endoscope 5 is introduced such that the endoscope tip shown in a dark manner in the figure is arranged near the focus region of shock wave apparatus 2 . The endoscope is a rigid tubular construction having an optical vision device for the operator. Therewith, the process of introduction can already be controlled optically, e.g. in choosing the right way when entering a vessel by using a bent endoscope tip. Especially, the endoscope tip can be arranged near a stone in the kidney by using the optical vision device.
[0041] The endoscope comprises an optical distance measuring device not shown in the figure at its tip, e.g. using propagation time measurements of light emitted and reflected at the stone.
[0042] Magnetic tracking system 3 enables a determination of the position of a magnetic coil in the endoscope tip as in the first embodiment. Under consideration of the residual distance to the stone measured, the focus region of shock wave apparatus 2 can be adjusted correctly. It is to be noted herein that magnetic tracking systems do not only deliver three dimensional position information but also direction information so that also the direction in which the distance has been measured by the distance measuring device can be known principally. However, approximations also can be used in case of small residual distances.
[0043] Further, endoscope 5 can comprise a catheter being displaced up to the stone together with a magnetic coil integrated therein. In this case, the distance measuring device is not necessary.
[0044] The third embodiment of FIG. 3 is an advantageous combination with X-ray imaging in a direction as in FIG. 1 . Therein, the fact can be used that the focus region of shock wave apparatus 2 has a lengthy shape, i.e. is, in relation to the drawing, longer in a vertical manner than in a horizontal manner perpendicular to the plane of drawing. Thus, it is preliminarily desired to determine the position of the stone or the magnetic coil in a plane being inclined as minimally as possible relative to a plane perpendicular to the plane of drawing and intersecting this plane horizontally. Especially advantageous is the use of an X-ray apparatus coaxial to shock wave apparatus 2 which X-ray apparatus is shown in FIG. 3 additionally to FIG. 1 .
[0045] Shock wave apparatus 2 , especially the source, is arranged in the path of rays of X-ray system 6 , 7 or arranged around it. The X-ray system is shown only schematically and comprises an X-ray source 7 on the, in relation to the body, distal side of shock wave apparatus 2 and an image amplifier 6 on the side of the body opposed to shock wave apparatus 2 . Shock wave apparatus 2 has a hollow construction showing a central axial hole. This can be achieved by a hollow coil construction of the source. In the hollow hole, crosshair-like X-ray absorbing markers numerated with 8 and only schematically shown in the figure are arranged. Thereby, the complete construction of shock wave apparatus 2 , X-ray apparatus 6 , 7 , and magnetic locating apparatus 3 can be oriented such that the stone and the magnetic coil are arranged in the crosshair or sufficiently near thereto. Alternatively, it can be sufficient to locate the stone in the X-ray image in some manner and to orientate the shock wave apparatus correspondingly, then. Herein, the X-ray apparatus needs not be moved as well.
[0046] This embodiment of the invention is especially adapted for indications in which a certain position of the treatment region, here the stone, and the catheter already results from anatomical conditions. For example, stones in the renal pelvis or at the end of a renal calice leading into the renal pelvis can have a varying position preliminarily in the longitudinal direction of the lengthy renal pelvis. Usually, the treatment is approximately perpendicular to this longitudinal direction. Thus, if it can be ascertained that the stone and the magnetic coil in the catheter are arranged correctly in an X-ray image as made in the above-mentioned direction, a positioning in the “depth” direction can be disposed with due to the anatomical situation. Namely, the renal pelvis can have an extension in this direction in the range of 2 cm whereas a typical focus region length of a shock wave apparatus can be in a range of 4 cm. Here, a two dimensional orientation by the X-ray image is sufficient. In the adjustment of the focus depth, it can be assumed that the magnetic coil is sufficiently near at the stone so that the treatment can be made without an additional reference localization by the magnetic tracking system. By detecting the position of the magnetic locating element in the imaging direction of the first X-ray image, a second X-ray image in a substantially different imaging direction can be avoided. This does not only reduce the X-ray load on the patient but also simplify the X-ray apparatus because tilting mechanisms are not necessary.
[0047] Incidentally, a combination with an ultrasonic imaging can be advantageous especially for the above-mentioned hollow construction of shock wave apparatus 2 . The ultrasonic head can be moved through the hollow space and produce extracorporeal images that are alternative or additional to the X-ray image.
[0048] In addition, combinations of X-ray images with endoscopic visual controls are considered, especially if an X-ray imaging in only one imaging direction in the above-mentioned manner is desired for additional safety or for increasing the precision of the visual control whereas the latter is regarded to be sufficient for the third direction. In many practical cases, the visual control alone will be sufficient so that X-ray technology can be avoided completely.
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The invention generally relates to apparatuses and methods for shock wave treatment of the human body. In particular, the invention relates to navigational aspects of the shock wave treatments, including apparatuses and methods which enable accurate focusing of shock waves.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to body-implantable, medical apparatus, and more particularly to a cardiac rhythm management device (CRMD) having a capability of recording polysomnogram (PSG) data and/or phonocardiogram (heart sound) data upon the detection of pre-programmed conditions or events.
2. Discussion of the Prior Art
State of the art implantable medical devices, such as pacemakers and defibrillators, typically embody a microprocessorbased controller capable of receiving as inputs, digitized signals corresponding to heart depolarization events and other sensor derived outputs and for controlling a pulse generator that generates tissue-stimulating pulses in accordance with a program stored in a memory for the microprocessor-based controller. Such devices also typically include a telemetry link whereby programmed data and operands can be exchanged between the implanted device and an external programmer/monitor.
The memory in the implant may also be used to record, when enabled, electrogram signals for later read-out and analysis by a medical professional.
It is also known that cardiac pacing can be used as a therapy for patients with congestive heart failure (CHF). Algorithms have been developed for establishing a AV-delay interval that optimizes the pumping performance of the sick heart.
In applying cardiac pacing as a treatment for CHF, not only is electrogram data derived from an implanted CRMD of interest, but other physiologic sensor derived data may also prove helpful in treating the patient. For example, heart sound data can prove meaningful.
As is well known, the first heart sound, S 1 , is initiated at the onset of ventricular systole and consists of a series of vibrations of mixed, unrelated, low frequencies. It is the loudest and longest of the heart sounds, has a decrescendo quality, and is heard best over the apical region of the heart. The tricuspid valve sounds are heard best in the fifth intercostal space, just to the left of the sternum, and the mitral sounds are heard best in the fifth intercostal space at the cardiac apex.
S 1 is chiefly caused by oscillation of blood in the ventricular chambers and vibration of the chamber walls. The vibrations are engendered by the abrupt rise of ventricular pressure with acceleration of blood back toward the atria, and the sudden tension and recoil of the A-V valves and adjacent structures with deceleration of the blood by the closed A-V valves. The vibrations of the ventricles and the contained blood are transmitted through surrounding tissue and reach the chest wall where they may be heard or recorded.
In accordance with the present invention, an implanted CRMD may include an accelerometer as a sound transducer and because implanted in close proximity to the heart, may develop a robust electrical signal that can be digitized and stored in the memory of the implant.
The intensity of the first sound is primarily a function of the force of the ventricular contraction, but also of the interval between atrial and ventricular systoles. If the A-V valve leaflets are not closed prior to ventricular systole, greater velocity is imparted to the blood moving toward the atria by the time the A-V valves are snapped shut by the rising ventricular pressure, and stronger vibrations result from this abrupt deceleration of the blood by the closed A-V valves.
The second heart sound, S 2 , which occurs on closure of the semi-lunar valves, is composed of higher frequency vibrations, is of shorter duration and lower intensity, and has a more “snapping” quality than the first heart sound. The second sound is caused by abrupt closure of the semi-lunar valves, which initiates oscillations of the columns of blood and the tensed vessel walls by the stretch and recoil of the closed valve. Conditions that bring about a more rapid closure of the semi-lunar valve, such as increases in pulmonary artery or aorta pressure (e.g., pulmonary or systemic hypertension), will increase the intensity of the second heart sound. In the adult, the aortic valve sound is usually louder than the pulmonic, but in cases of pulmonary hypertension, the reverse is often true.
The third heart sound, which is more frequently heard in children with thin chest walls or in patients with left ventricular failure due to CHF, consists of a few low intensity, low-frequency vibrations. It occurs in early diastole and is believed to be due to vibrations of the ventricular walls caused by abrupt acceleration and deceleration of blood entering the ventricles on opening of the atrial ventricular valves.
A fourth or atrial sound, (S 4 ), consisting of a few low-frequency oscillations, is occasionally heard in normal individuals. It is caused by oscillation of blood and cardiac chambers created by atrial contraction.
When S 3 and S 4 sounds are accentuated, it may be indicative of certain abnormal conditions and are of diagnostic significance. Therefore, the ability to store heart sound information for later playback can prove beneficial to medical professionals following patients in whom cardiac pacemakers and/or defibrillators are implanted.
In addition to heart sound information, benefit can also be derived from the storage and later read out from an implanted CRMD of respiratory related data. While external polysomnograph equipment can be worn for recording respiratory related data over extended time intervals, the ability to derive polysomnograms from an implanted CRMD can prove to be beneficial. Such things as Cheyne-Stokes respiration patterns, Biot's respiration, Epnustic breathing and central neurogenic hypoventilation and hyperventilation can be detected and recorded.
In Cheyne-Stokes respiration, respiratory rate and tidal volume gradually increase, then gradually decrease to complete apnea, which may last several seconds. Then, tidal volume and breathing frequency gradually increases again, repeating the cycle. This pattern occurs when cardiac output is low, as in CHF, delaying the blood transit time between the lungs and the brain. In this instance, changes in respiratory center Pco 2 lag changes in arterial Pco 2 . For example, when an increased Paco 2 from the lungs reaches the respiratory neurons, ventilation is stimulated, which then lowers the atrial Pco 2 level. By the time this reduced Paco 2 reaches the medulla to inhibit ventilation, hyperventilation has been in progress for an inappropriately long time. When blood from the lung finally does reach the medullary centers, the low Paco 2 greatly depresses ventilation to the point of apnea. Atrial Pco 2 then rises, but a rise in respiratory center Pco 2 is delayed because of low blood flow rate. The brain eventually does receive the high Paco 2 signal, and the cycle is repeated. Cheyne-Stokes respiration also may be caused by brain injuries, in which respiratory centers correspond to changes Pco 2 level are damaged.
It is accordingly a principal object of the present invention to provide an implantable CRMD capable of producing and storing in a memory phonocardiograms of heart sounds and polysomnograms reflecting respiratory events for later readout from the device via a conventional telemetry link used in such devices.
It is still another object of the present invention to establish certain triggering mechanisms for enabling the memory to capture certain respiratory patterns such as those related to Cheyne-Stokes patterns by monitoring tidal volume or respiratory rate variations with respect to a pre-determined threshold. Similarly, the system may be enabled to capture heart sound information when, for example, atrial fibrillation occurs or, perhaps, at a certain level of exercise.
SUMMARY OF THE INVENTION
The foregoing objects are achieved in accordance with the present invention by providing an implantable cardiac rhythm management device of a type having a microprocessor-based controller along with a memory. The CRMD may also comprise a pulse generator for producing cardiac stimulating pulses at times determined by the program run on the microprocessor-based controller. Alternatively, the implant may be a purely diagnostic device. The CRMD also incorporates a means for sensing at least one of respiratory related activity and heart sounds. A triggering device is incorporated that is responsive to a predetermined event for initiating storage of data pertaining to the sensed one of respiratory related activity and heart sounds in the memory. As an example, upon detection of a predetermined respiratory pattern, the memory may be enabled for storing polysomnogram data. Alternatively, the occurrence of an event, such as an onset of atrial fibrillation, may be used to trigger the memory so as to store phonocardiogram data. The recording function in the memory of the implanted device can also be manually triggered, using an external magnet.
DESCRIPTION OF THE DRAWINGS
The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment, especially when considered in conjunction with accompanying drawings in which like numerals in the several views refer to corresponding parts.
FIG. 1 is a block diagram of an implantable CRMD incorporating circuitry for capturing phonocardiograms and polysomnograms for subsequent readout to an external monitor;
FIG. 2 represents a polysomnogram recording.
FIG. 3 is a software flow diagram of an algorithm for storing polysomnogram data;
FIGS. 4A through 4D, when arranged as in FIG. 4, is a plot of left atrial, aortic, and left ventricular pressure pulses correlated in time with aortic flow, ventricular volume, heart sounds, venus pulse, and electrocardiogram for a complete cardiac cycle; and
FIG. 5 is a software flow diagram of an algorithm for storing heart sound data.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, an implantable cardiac rhythm management device (CRMD) is shown as being enclosed in a broken line box 10 and, for exemplary purposes only, is represented as a rate adaptive pacemaker in which minute ventilation is the rate controlling parameter. As mentioned above, the implanted device may be purely diagnostic in nature and need not have a tissue stimulating capability.
The device includes a microprocessor 12 having a ROM memory 14 adapted to store a program of instructions, a RAM memory 16 for storing operands and data and an I/O module 18 for controlling a telemetry circuit 20 whereby bi-directional communications can be established between the implanted module 10 and an external monitor 22 via telemetry link 24 . The implanted device 10 is connected to a cardiac site by conductors 26 in a pacing/sensing lead 28 having tissue contacting electrodes 30 and 32 thereon. Those skilled in the art will appreciate that one or more conductors 26 in the lead 28 may be eliminated with the remaining conductors shared between the sense and pace functions. Cardiac depolarization signals, e.g., R-Waves picked up by the electrodes 30 and 32 , are applied by way of a sense amplifier 34 to an input of the microprocessor 12 . Those skilled in the art can also appreciate that the implanted CRMD 10 may also include an atrial sense amplifier adapted to receive atrial depolarization signals (P-Waves) so that both P-Wave events and R-Wave events can be conveyed to the microprocessor 12 .
Operating under control of a program stored in the ROM 14 , the microprocessor 12 is shown in the exemplary embodiment as being connected in controlling relationship, via line 36 , to a pulse generator 38 which is adapted to deliver tissue stimulating pulses, via the lead 28 , to target tissue in the heart.
Being a rate adaptive pacemaker, means are provided for adjusting the rate at which the pulse generator 38 delivers its stimulating pulses to the lead 28 . In the embodiment of FIG. 1, minute ventilation (MV) is provided as the rate controlling parameter. As such, an oscillator 40 is provided for delivering sub-threshold RF pulses, typically at a frequency of about 30 KHz, between an electrode 42 , which may be located on the lead 28 , and an electrode 44 , which may be the metal can comprising the housing for the CRMD 10 . As is well known in the art, respiratory activity (inhalation and exhalation) modulates the 30 KHz carrier signal, which is fed through a sensing amplifier 46 to a demodulator circuit 48 . The demodulator functions to recover the modulating envelope. Changes over time in the trans-thoracic impedance caused by respiratory activity produces an analog signal on line 42 which is then fed through a signal processing circuit 44 and an analog to digital converter 46 before being applied as an input to the microprocessor 12 . Those skilled in the art will appreciate that the A/D converter 46 may itself be implemented in the microprocessor 12 and need not necessarily be a separate module as depicted in FIG. 1 .
In accordance with the present invention, there is also provided an accelerometer type transducer 48 within the CRMD 10 and its output is amplified at 50 and appropriately signal processed at 52 to remove DC baseline shift and signal energy due to body motion before being digitized by the A/D converter 46 and fed to the microprocessor 12 .
FIG. 2 illustrates diagrammatically a polysomnogram illustrating nasal/oral airflow evidencing apnea episodes. As mentioned above, Cheyne-Stokes respiration frequently appears in patients whose cardiac output is low due to CHF.
FIG. 3 is a simplified software flow diagram of an algorithm for triggering the capture (recording) of respiratory pattern information in the event that an abnormal pattern in terms of respiratory rate and/or tidal volume is sensed. At block 54 the microprocessor continues to scan the digitized output from the signal processing circuit 44 to determine whether the trans-thoracic impedance versus time output from the demodulator 48 matches a pre-determined pattern (Block 56 ). If a match is detected, the RAM memory 16 is enabled and the digitized polysomnogram information is stored therein (Block 58 ). The RAM continues to store the polysomnogram data until such time as the test at block 60 determines that a preprogrammed time interval sufficient to capture relevant respiratory data has elapsed.
Once the polysomnogram information is stored in the RAM, it can be later transferred, via I/O module 18 and the telemetry circuit 20 , to an external monitor 22 for print out or display to a medical professional.
Referring next to FIG. 4, the correlation between heart sounds and events in the cardiac cycle is displayed for a patient with a normal heart. Also shown in the diagram of FIG. 4 are plots of left atrial, aortic and left ventricular pressure pulses that are correlated time wise with aortic blood flow, variations in ventricular volume, venus pulse and an electrocardiogram for one cardiac cycle.
FIG. 5 is a software flow diagram for triggering the recording of phonocardiogram data in the random access memory 16 in the CRMD 10 upon the occurrence of a pre-determined event. As indicated at block 70 , the output from the accelerometer 48 is continually scanned by the microprocessor 12 and when a triggering event, such as the detection of atrial fibrillation (block 72 ), the RAM 16 is enabled to store the phonocardiogram data (blocks 74 ). The phonocardiogram data is recorded for a preprogrammed time interval, and when the programmed time interval times out (block 76 ) storage of the data in the memory terminates with control returning to the input of block 70 .
A physician may select to record heart sounds based on criteria other than an episode of atrial fibrillation. For example, the test at block 72 may be based upon the patient reaching a certain level of exercise as determined by measured heart rate. Any other meaningful criteria may also be used as the triggering event for storing the phonocardiogram data.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. For example, the preferred embodiment cardiac rhythm management device has been described for use in a rate adaptive pacemaker, however, it may be used in a defibrillator, an antitachy pacer, a diagnostic-only device or in another type of implantable electronic device where it is desired to monitor polysomnograms and/or phonocardiogram data.
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Currently, brady, tachy and CRT devices all provide stored electrograms that record ambulatory electrograms with programmable trigger mechanisms. The present invention comprises an implantable device with additional capability that can store polysomnograms and phonocardiograms. The polysomnograms can be obtained from an impendent sensor of the type used in minute ventilation-based rate-adaptive pacemakers. The phonocardiograms are obtained from an accelerometer transducer or other type sensors that can detect heart sound.
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BACKGROUND OF THE INVENTION
The present invention relates to the manufacture of refrigeration cabinets and, more particularly, to a cabinet construction which requires a minimum of assembly operations, labor, and number of components for its manufacture.
PRIOR ART
Refrigeration cabinet construction has generally involved the assembly, mostly by hand, of a substantial number of parts and components. Such parts and components have usually required numerous mechanical fasteners and/or welding operations for their final assembly, thereby compounding the necessary number of elements and operations. Besides adding incrementally to the cost of a product, numerous fastening and assembly operations in common use are generally not compatible with prefinished sheet materials. For example, mechanical fasteners and spot welding usually detract from the appearance of preapplied appearance coatings.
Rigid insulating foams of polyurethane or other plastic materials are widely used in recognition of their high insulating qualities. The structural and adhesive properties of such materials have had limited application in the field of refrigeration cabinet construction. Refrigeration apparatus utilizing these properties to some extent is proposed in U.S. Pat. Nos. 3,520,581 and 3,588,214, for example. For the most part, prior efforts using the structural and adhesive properties of insulating foams have not realized the full potential of such materials in eliminating structural components, mechanical fasteners, and assembly operations.
SUMMARY OF THE INVENTION
The invention provides a refrigeration cabinet construction in which panel forming sheet material and rigid insulating foam is structurally integrated in a manner whereby full advantage is made of the structural properties of these materials and whereby the number of elements and assembly operations in the manufacture of the cabinet are minimized.
An outer cabinet shell formed of sheet material preferably is reinforced by only two structural elements. A perimeter frame reinforces one face of the cabinet shell and also provides a convenient mounting for a motor compressor unit. An opposite face of the cabinet shell is reinforced by a thermal breaker collar which also serves to position and support an inner cabinet liner relative to the shell.
According to the invention, the shell, frame, and liner are permanently maintained in their assembled position by applying adhesive at strategic cabinet areas and foaming the rigid insulation in place between the liner and shell. The use of mechanical fasteners and welding operations is thereby eliminated in the assembly procedure. Thus, prefinished sheet material may be employed in the making of the shell without risking damage to its appearance otherwise caused by such fasteners or welding.
In the preferred embodiment, four sides of the outer cabinet shell are formed by a single sheet wrapped into a short rectangular tube. Returned edges of the wrapped sheet are joined at a seam which is self-locking under expansion of the foam insulation. The remaining edges of the sheet define the planes of the other two faces or sides of the box-like liner. The perimeter frame is roll-formed from flat stock to form an angle with one leg of the angle arranged to fit around and provide continuous external support for one of the remaining sheet edges. The other angle leg provides spaced locating tabs stamped from the plane of the leg which cooperate with the first angle leg to properly position the wrapped sheet in the frame prior to foaming of the insulation. Also received in these tabs is an additional panel sheet forming a fifth side of the outer shell. The wrapped sheet and additional panel sheet are secured together and into the frame with a single bead of structural adhesive applied to the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of an outer shell of a refrigeration cabinet constructed in accordance with the principles of the invention.
FIG. 2 is a fragmentary, perspective view, on an enlarged scale, of a portion of a wall seam formed by a sheet from which the outer shell is constructed.
FIG. 3 is a fragmentary, perspective view, on an enlarged scale, of a section of a perimeter frame of the outer shell.
FIG. 4 is a cross sectional view of the perimeter frame illustrating at a typical location a preferred manner of applying a structural adhesive for securing the shell sheets to the frame.
FIG. 5 is a view similar to FIG. 4 showing the assembled condition of the frame and shell sheets.
FIG. 6 is a fragmentary, elevational, sectional view of a finished refrigeration cabinet assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an outer shell assembly 10 for a refrigeration cabinet 11, such as that illustrated in FIG. 6. The shell assembly 10 includes a short, rectangular tube 12, an end wall 13, and a rigid perimeter frame 14. A top opening, domestic chest-type freezer cabinet 11 has been chosen to illustrate the invention. For the sake of convenience, the following description refers to the cabinet 11 in terms consistent with this particular arrangement wherein, for example, the frame 14 is disposed on the lower or bottom side of the shell assembly 10. It is to be understood, nevertheless, that the invention may be applied to other arrangements such as a vertical or upright cabinet.
The rectangular tube or sheet shell 12 is formed by bending up or wrapping an elongated, rectangular sheet such that its original far edges 17 are returned into a seam 18 at a mid-portion of a rear wall 19. As illustrated, this wall 19, an opposite parallel wall 21 and two perpendicular walls 22 are substantially planar and form right corners 16 at their intersections. The walls 19, 21, and 22 form four vertical exterior faces of the finished cabinet 11. Ideally, the seam 18 is mechanically formed by the sheet stock forming the tube 12 itself, preferably without additional parts, such as a channel, frame member, or fasteners, and without welding. The seam 18 is made by reverse folding the ends 24 and 25 of the sheet back on one one another to form interlocking grooves 26 and 27 in a construction commonly referred to as a "Pittsburgh flatlock seam." Remaining peripheral edges 28 and 29 of the shell tube 12 generally define planes of the fifth and sixth faces of the complete cabinet assembly 11.
The sheet forming the shell tube 12 is preferably prefinished metal stock, such as painted or plastic-coated steel or aluminum. Vinyl-coated steel is particularly suited for this application, and may be wrapped into the desired shape without significantly disturbing the appearance or protective effectiveness of the coating where it is stressed at the corners 16 upon bending. Use of such prefinished stock is more economical than the conventional practice of finishingg the cabinet panels after their final assembly. Moreover, a prefinished cabinet generally has a more uniform appearance and greater serviceability than may be had with a cabinet finished after assembly.
A number of spaced plates 31, 32 of steel or other rigid material are secured to the rear cabinet wall 19 by double-sided adhesive tape or other means. These plates 31, 32 are provided with pierced holes (not shown) for receiving screws for externally mounting hinges for a cabinet cover or lid 33 (FIG. 6) and an external condenser coil (not shown). A strip of fiberglass or other porous material 34 is fixed by adhesive tape 36 along the inner periphery of the shell tube 12 adjacent its upper edge 29 to permit air to escape through one or more holes in the rear wall 19 covered by the fiber glass when foam is expanded in the shell as discussed below.
The end wall panel 13, preferably formed of sheet metal, is stepped at right corners 41 and 42 with a riser portion 43 and a platform portion 44. The riser and platform portions 43 and 44 form with the frame 14 a cavity, indicated generally at 46, for reception therein of a motor compressor unit (not shown). A series of corner reinforcing ribs 48 are integrally stamped or otherwise formed on the end wall 13. The end wall 13 includes a peripheral flange 49 depending at right angles to the various planes of the end wall. The peripheral flange 49 serves to stiffen the end wall 13 and, as explained below, provides means for mounting a major portion 50 of the wall in the frame 14. The end wall 13 is dimensioned to fit in the shell tube 12 with a minimum of clearance so that it closes the associated end of the shell tube sufficiently to temporarily contain liquid components during foaming of rigid insulation, as discussed below.
The frame 14 is preferably performed of a continuous length of flat stock rolled into an angle having perpendicular legs or flanges 51 and 52. The angle leg 51 is notched, overlapped, and spot welded at four corners 53. Original ends of the stock are butted on the vertical flange 52 and overlapped on the horizontal or lower flange to form a joint 57 at inconspicuous points, such as the area immediately under the seam 18 of the shell tube 12. A pair of parallel cross members 54 are spot welded on the horizontal flange 51 and provide brackets 55 for mounting a motor compressor unit thereon. Holes 56 are provided adjacent the frame corners 53 for securing support legs or rollers to the lower side of the frame 14.
Referring particularly to FIG. 3, the horizontal frame flange 51 is stamped at spaced locations to form upstanding locating tabs 59. The integral stamped tabs 59 are inclined slightly with respect to the vertical frame flange 52 and cooperate with this flange to provide short grooves 61 (FIG. 4) for reception of the shell tube 12 and, at certain tabs, for reception of the flange 49 associated with the major portion 50 of the end wall. The frame 14 is ideally formed of steel and is painted or otherwise finished after the aforementioned spot welding and punching operations. A pair of vertical legs 63 are dimensioned to rest on the horizontal frame flange 51 and to vertically support the end wall platform portion 44 when the end wall 13 is assembled on the frame 14.
The shell tube 12, end wall 13, and frame 14 are assembled by securing the tube and wall to the frame with a structural adhesive 66 of a commercially available type suitable for the particular materials from which these members are constructed. Ideally, a two-part adhesive is used so that a relatively short set time is achieved. Such adhesive 66 is applied as a continuous bead along the full length of the frame 14, adjacent or in an inner corner 67 (FIG. 4). After the adhesive bead 66 is applied, and before it has set, the lower tube edge 28 and depending flange 49 of the major end wall portion 50 are positioned in the grooves 61 formed by the tabs 59 and are seated on the lower flange 51. As seen in FIG. 5, the sheet edge 28 and flange 49 are thereby embedded in and commonly bonded to the frame 14 by the adhesive 66.
As suggested above, FIG. 6 shows the outer shell assembly 10 in a complete refrigeration cabinet 11. The refrigeration cabinet 11 includes an inner box-like liner 71 having dimensions somewhat smaller than the shell assembly 10. The liner 71 is spaced from the shell tube 12 and the end wall 13 to provide an insulating space therebetween. The liner 71 is positioned horizontally or laterally with respect to the shell assembly 10 by a thermal breaker collar 72. The breaker collar 72 has a channel or inverted U-shaped cross section, with each leg 73 and 74 having a panel receiving groove 75 and 76 for the walls of the liner 71 and the upper edge 29 of the shell tube 12 respectively. The breaker collar 72, ideally, is molded of a plastic material such as vinyl in an integral rectangular piece, with its outer dimensions substantially equal to those of the outer vertical flange 52 of the frame 14.
Rigid foam spacer blocks (not shown) may be set into the shell assembly 10 before the liner 71 is placed so as to support the liner vertically above its end wall 13 at the proper height relative to the shell. The breaker collar 72 is then installed on these components 10, 71. With the shell assembly 10 externally supported in a fixture and a plug internally supporting the liner 71 in accordance with conventional practices, liquid foam components are injected into the space between the shell assembly and liner through a suitable hole in one of these members to react and form rigid insulating foam 79 throughout this space.
The foam 79 is preferably a low density, closed cell polyurethane foam of the type in common use in refrigeration devices. Such foam exhibits relatively high strength for its low density and substantial adhesion to materials such as steel or aluminum. Both the rigidity of the foam 79 and its adhesion to the liner 71 and shell 10 produce a sandwich construction which is surprisingly strong and rigid even when relatively light gauge sheet stock is used in the formation of the liner 71 and/or shell tube 12. The interlocked construction of the shell seam 18 is such that it becomes tightly engaged and self-locking when subjected to tension in the plane of the wall 19. Expansion of the foam 79 in the shell thereby assures a tight seam. Moreover, when the foam 79 solidifies, accidental separation of the seam 18 is prevented, since the foam resists compression forces along the plane of the wall 19.
It is generally not necessary to prefinish the shell tube 12 or liner 71 on their interior surfaces, since these surfaces are not visible and are protected from oxidation by the foam 79. The foam 79 permanently adheres to the breaker collar 72 to prevent its accidental removal from the liner 71 and shell 10. The cabinet door or lid 33 is preferably provided with a balloon-type elastic peripheral seal 81 to the seal on the thermal breaker collar 72.
Although a preferred embodiment of this invention is illustrated, it is to be understood that various modifications and rearrangements of parts may be resorted to without departing from the scope of the invention disclosed and claimed herein. For example, the principles of the invention may be readily adapted to a vertical cabinet construction over the cabinet door provided on a vertical face of the cabinet.
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A disclosed refrigeration cabinet has an integrated construction of sheet material and insulating foam which substantially eliminates the need for mechanical fasteners and welding, minimizes assembly operations, and permits the use of prefinished sheet panels. An outer cabinet shell preferably includes a prefinished sheet wrapped into a rectangular tube. The shell tube is reinforced at one end by a perimeter frame and at the other end by a thermal breaker collar. After the shell tube and frame are assembled, a liner is positioned in the tube and the breaker collar is installed. Rigid insulating foam is then foamed in place between the shell and liner to produce a sandwich construction in which the foam secures and reinforces both the shell and the liner.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT Application No. PCT/US2013/037360 filed Apr. 19, 2013 which claims priority to U.S. Provisional Application Ser. No. 61/635,421 filed Apr. 19, 2012, the entire contents of which are incorporated by reference herewith.
FIELD OF THE INVENTION
[0002] This invention relates to a point of care device, method, and test kit for rapidly detecting cyanide in samples.
BACKGROUND OF THE INVENTION
[0003] Cyanide is a very potent neurological and metabolic poison. House fires generate cyanide gas when materials commonly found in homes and other buildings combust. In addition to traumatic injuries, burns, smoke inhalation, and carbon monoxide poisoning, cyanide is commonly found (after the fact) to have been another element contributing to a patient's morbidity and mortality. In addition to this common source of poisoning, cyanide is also considered to be a weapon of mass destruction and may be used in an act of terrorism or in war.
[0004] Although there are many laboratory methods that can measure cyanide, none can provide a measurement with enough rapidity (i.e., within minutes) to make a clinical difference to a poisoned patient. Often, results are available to physicians only after 2 weeks. Current tests provide a laboratory-based assay only, meaning once blood is drawn from the patient and the appropriate lab is identified, blood must then be shipped to a remote laboratory and the final report may return days to weeks later. Several existing methods that require laborious multistep sample pre-treatment are not amenable for use in the field.
[0005] Since cyanide is a very rapidly acting toxin, it is imperative that physicians and other health care providers have available a rapid test system so that they may provide the best care possible for sick patients because this delay does not allow for an immediate answer and/or treatment for the patient who is suffering from the poisoning. Additionally, empiric treatment for presumed cyanide poisoning is inconsistently used with controversial adverse clinical effects.
[0006] Thus there remains a need for improved devices, assays or test kits for rapidly detecting the presence of cyanide in a sample obtained from a subject, providing a point of care and treatment immediately for such subject if cyanide is detected.
SUMMARY OF THE INVENTION
[0007] The invention provides a point of care device, method, and test kit for rapidly detecting the presence of cyanide in a sample.
[0008] In certain embodiments, the invention provides a device for cyanide detection comprising: a) a sealable container comprising a sample chamber and a sensor chamber, b) a cap for sealing an open end of the container; c) a liquid impermeable and gas permeable membrane anchored to an inner surface of the container separating the sample chamber from the sensor chamber; d) a reagent inside the sample chamber that separates and releases cyanide from the sample; and e) a cyanide detector inside the sensor chamber comprising a conducting polymer that absorbs released cyanide, wherein the conducting polymer can act as a semiconductor to measure cyanide quantitatively from the test sample.
[0009] The inventive device can be used for detecting cyanide in any sample, including but not limited to, environmental fluids, or bodily fluids, such as blood, saliva, tears, and urine obtained from any animals, such as mammals including but not limited to humans, livestock including but not limited to bovine, porcine, and ovine, and companion animals including but not limited to canine and feline. In certain embodiments, the test sample is human blood.
[0010] In certain embodiments, the invention provides a device comprising a cyanide detector comprising a conducting polymer comprising aromatic cycles with or without heteroatoms present. In certain embodiments, the conducting polymer comprises aromatic cycles without heteroatoms present, such conducting polymer includes, but not limited to, polyfluorene, polyphenylene, polypyrene, polyazulene, and polynaphthalene. In other embodiments, the conducting polymer comprises aromatic cycles in which at least one nitrogen atom is present in an aromatic cycle, such conducting polymer includes, but not limited to, polypyrrole, polycarbazole, polyindole, and polyazepine. In yet other embodiments, the conducting polymer comprises aromatic cycles in which at least one nitrogen atom is outside an aromatic cycle, and such conducting polymer includes, but is not limited to, polyaniline (PANI).
[0011] In yet other embodiments, the conducting polymer comprises heteroatoms in which at least one sulfur atom is present in an aromatic cycle, such conducting polymer includes, but not limited to, polythiophene. In yet other embodiments, the conducting polymer comprises heteroatoms in which at least one sulfur atom is outside an aromatic cycle, such conducting polymer includes, but not limited to, poly(p-phenylene sulfide).
[0012] In certain embodiments, the conducting polymer comprises at least one double bond, such conducting polymer includes, but not limited to, polyacetylene. In some other embodiments, the conducting polymer is a copolymer comprising any mixture of a polymer having at least one aromatic cycle and a polymer having at least one double bond. Such conducting copolymer includes, but not limited to, poly(p-phenylene vinylene).
[0013] In certain embodiments, the conducting polymer in the cyanide detector can be formed into nanotubes or serve as a coating to carbon nanotubes or in any other form. In one embodiment, the cyanide detector in the inventive device is formed into test strip, such as the CYANTESMO test strip. In certain embodiments, the cyanide detector in the inventive device may be anchored to the bottom surface of the cap, or to a projection from the bottom surface of the cap, or the sides of the tube.
[0014] The invention further provides that the sensor chamber of the inventive device further comprises a signal processor wherein the cyanide detector is operably coupled therewith. In some embodiments, the processor in the inventive device further comprises a power or energy supply source, which may be embedded within or attached to the cap.
[0015] The invention further provides that the sensor chamber of the inventive device further comprises a display for cyanide measurement readout. In some embodiments, the display includes, but not limited to, an LCD or LED display, which may be embedded within or attached to the cap, as well.
[0016] The invention further provides that the sample chamber has an internal pressure less than atmosphere pressure for drawing a volume of the test sample into the sample chamber through a re-sealable cap on the sample chamber end of the container.
[0017] The invention provides that the sample chamber of the inventive device comprises reagents capable of separating and release cyanide from the sample. Exemplary reagents include, but are not limited to, acids. In certain embodiments, the reagents may comprise at least one acid able to denature the test sample, including but not limited to, phosphoric acid, sulfuric acid, and ascorbic acid. The reagents in the sample chamber can be in any form including, but not limited to, a liquid, gel, or solid form.
[0018] Methods for rapid cyanide detection using the device of the invention are also provided. The invention method comprises the steps of: a) placing a sample in the sample chamber, and b) reviewing the detector or display for an indication of the presence or amount of cyanide. In certain embodiments, the inventive method comprises: a) mixing the sample with at least one reagent to separate and release cyanide from the sample; b) absorbing the released cyanide by the cyanide detector comprising the conducting polymer; c) quantifying the cyanide concentration with the cyanide detector; d) processing the quantified cyanide concentration into a signal by a processor; and e) transmitting the signal to the display for cyanide measurement readout.
[0019] The invention further provides a rapid cyanide detection kit comprising the device of the invention and instructions on how to use the device. In certain embodiments, the cyanide test kit may have reagents already installed in the device or provided separately. The kit may include a phlebotomy needle and holder for obtaining a blood sample. The invention provides that the cyanide test kit is appropriate for a point of care test system for cyanide detection and subsequent treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 illustrates one embodiment of the inventive device comprising a tube container, a cap, a LED display, a cyanide detector, and a liquid impermeable, gas permeable membrane.
DETAILED DESCRIPTION OF THE INVENTION
[0021] In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments which may be practiced. These embodiments are described in detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical changes may be made without departing from the scope of the present invention. The following description of example embodiments is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims.
[0022] The Abstract is provided to comply with 37 C.F.R. §1.72(b) to allow the reader to quickly ascertain the nature and gist of the technical disclosure. The Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
[0023] The invention provides a point of care device, method, and test kit for detecting the presence of cyanide in a sample. The sample may be obtained from the environment or from a subject who is suspected of having cyanide poisoning. In certain embodiments, the invention provides a device for cyanide detection comprising: a) a sealable container comprising a sample chamber and a sensor chamber, b) a cap for sealing an open end of the container; c) a liquid impermeable and gas permeable membrane anchored to an inner surface of the container separating the sample chamber from the sensor chamber; d) a reagent inside the sample chamber capable of releasing cyanide from the sample; and e) a cyanide detector inside the sensor chamber. In certain embodiments, the cyanide detector is a conducting polymer that absorbs the released cyanide, wherein the conducting polymer acts as a semiconductor to measure cyanide quantitatively from the test sample.
[0024] The inventive device can be used for detecting cyanide in any samples, such as environmental or biological samples, including but not limited to, blood, saliva, tears, and urine obtained from any mammal including but not limited to humans, livestock including but not limited to bovine, porcine, and ovine, and companion animals including but not limited to, canine and feline. In certain embodiments, the test sample is human blood.
[0025] The container of the inventive device comprises a sample chamber with a sample inert therein and a sensor chamber. In certain embodiments, the sample chamber within the container can be a self-contained unit that is able to access standard sample draw systems, such as VACUTAINER system for blood collection (available from Becton Dickinson, Franklin Lakes, N.J.). As used herein, a container refers to an item suitable for use to contain, hold, store, and transport a biological sample. Such containers can have sealable stoppers or caps on the sample chamber side of the container configured for blood sample collection with a phlebotomy needle and holder, which are well-known in the art. The container can be, but is not limited to, a tube, bottle, jar, and any other items now known or later developed in the art that can be used for holding a biological sample. In certain embodiments, the container can be clear glass or plastic and marked, for instance, with a fill line for the desired volume of sample, e.g., blood.
[0026] In certain embodiments, the inventive device also comprises a cap for of an sealing at least one or both of an open end of the container on the sensor side or the sample side of the container. As used herein, a cap refers to an item suitable to seal or close an open end of a container. The cap may be any cap now known or later developed in the art that can be used for sealing or closing an open end of a container holding a biological sample. The cap can be made of any materials, including but not limited to, plastic, rubber, and metal, and may be colored or otherwise marked.
[0027] The bottom of the cap can be attached to any projections for certain usage. In certain embodiments where the cap is on the sensor chamber side of the container, certain elements, such as the signal processor, the energy source, and the display within the sensor chamber of the inventive device may be embedded within or attached to the cap or any projections from the cap. In certain embodiments where the cap is on the sample chamber side of the container, the cap is made of a re-sealable polymer or rubber material which can be punctured with a phlebotomy needle.
[0028] In certain embodiments, the inventive device may be packaged with the container capped with most or some of the air removed from the interior of the container. A perfect vacuum need not be created as the desired effect is negative pressure with respect to the surrounding air, in order facilitate the sample draw, as is well-known in the art.
[0029] The inventive device also comprises a liquid impermeable, gas permeable membrane anchored to the inner surface of the container, which separates the sample chamber from the sensor chamber. In certain embodiments, this membrane is located between the sample level fill line on the container and the bottom of the cap or any projections from the cap for separating the sample chamber from the sensor chamber. Any suitable liquid impermeable and gas permeable membrane, now known or later developed in the art, which allows released gaseous cyanide to pass from the sample chamber and maintains the fluid sample in the sample chamber, is encompassed by the invention.
[0030] The inventive device also comprises a cyanide detector located inside of the sensor chamber. Any suitable cyanide detection technologies now available or later developed in the art, are encompassed in the invention. Exemplary cyanide detectors and detection methods are described in Ma and Dasgupta (2010), Anal Chim Acta. 673(2): 117-125; Rella et al. (2004), J Toxico Clin Toxicol. 42(6): 897-900; Ma (2011), Anal Chem. 83(11):4319-24; Murphy et al. (2006), Clin. Chem. 52(3):458-467; and US Publication No. 2013/0005044 to Boss et al., each of which is herein incorporated by reference in its entirety.
[0031] In certain embodiments, the cyanide detector within the sensor chamber of the inventive device comprises a conducting polymer, which can be a copolymer. As used herewith, the term “conducting polymer” refers to any polymers that are able to conduct electricity and acts as a semiconductor to measure cyanide quantitatively from the sample. Conducting polymers are well-known in the art, and the invention is not limited in scope to any particular conducting polymers being used in the cyanide detector. When a conducting polymer is used, the released hydrogen cyanide (HCN) protonates or dopes the conducting polymer proportional to the concentration of the HCN. The conductance of the copolymer varies directly with the degree of HCN doping.
[0032] In certain embodiments, the main chain of the conducting polymer comprises aromatic cycles. In some embodiments, the aromatic cycles have no heteroatoms present. Exemplary conducting polymer in this group includes but not limited to, polyfluorene, polyphenylene, polypyrene, polyazulene, and/or polynaphthalene. In other embodiments, the main chain of the conducting polymer can comprise heteroatoms, in which at least one nitrogen atom is present in an aromatic cycle. Exemplary conducting polymer in this group includes but not limited to, polypyrrole, polycarbazole, polyindole, and/or polyazepine. In other embodiments, the conducting polymer can comprise heteroatoms, in which at least one nitrogen atom can be outside an aromatic cycle. Exemplary conducting polymer in this group is polyaniline (PANI). In some embodiments, the main chain of the conducting polymer comprises heteroatoms, in which at least one sulfur atom is present in an aromatic cycle. An exemplary conducting polymer in this group is polythiophene. In other embodiments, the main chain of the conducting polymer comprises heteroatoms, in which at least one sulfur atom can be outside an aromatic cycle. An exemplary conducting polymer in this group is poly(p-phenylene sulfide).
[0033] In certain embodiments, the main chain of the conducting polymer can comprise at least one double bond. Exemplary conducting polymer in this group is polyacetylene. In yet other embodiments, the main chain of the conducting polymner used in the cyanide detector comprises any mixture of any conducting polymers, now known or later development in the art. Such conducting copolymer may comprise at least one aromatic cycle and at least one double bond. Exemplary conducting copolymer in this group is poly(p-phenylene vinylene).
[0034] In certain embodiments, the cyanide detector of the invention can be present in any useful form. For example, a conducting polymer may be formed into nanotubes or serve as a coating to carbon nanotubes or in any other form. In one embodiment, the cyanide detector in the inventive device is formed into test strip, such as the CYANTESMO test strip or paper (available from Machery-Nagel GmbH & Co., Duren, Germany). In certain embodiments, the cyanide detector may be anchored directly to the inside of the container, to the bottom surface of the sensor cap, or a projection from the bottom surface of the sensor cap, or may be anchored to the sides of the container.
[0035] In certain embodiments, the cyanide detector within the inventive device is operably coupled to a signal processor, which may further comprise a power or energy supply. When a conducting polymer is used within the cyanide detector, a small current is supplied within the device and conducted through the conducting polymer. The change in signal is then read by the signal processor which in turn transmits a signal to the display, such as an LCD or LED display for cyanide measurement readout, thus providing the patient or healthcare provider with a cyanide concentration measurement in the sample. In certain embodiments, the signal processor, the energy source for the processor, and the LCD or LED display may be embedded within or attached to the cap.
[0036] The sample chamber within the inventive device comprises reagents that are capable of separating and releasing cyanide from the test sample. In certain embodiments, the reagent includes at least one acid that is able to denature the test sample and release gaseous cyanide from the test sample. Exemplary acids include but are not limited to phosphoric acid, sulfuric acid, and ascorbic acid. The reagent may be pre-installed in the sample chamber within the device, and can be provided in any form including but not limited to, liquid, gel, solid, or any other forms known in the art. In certain embodiment, the reagent is in a solid form as pellet.
[0037] The sample chamber within the inventive device can have an internal pressure less than atmosphere pressure for drawing a volume of the test sample into the sample chamber. In certain embodiments, the internal pressure is generated by a vacuum embedded inside the sample chamber.
[0038] A non-limiting embodiment of the inventive device is depicted in FIG. 1 , which is referenced herein. The inventive device depicted in FIG. 1 comprises a tube container ( 100 ) comprising a sample chamber ( 105 ) and a sensor chamber ( 110 ). A cap ( 115 ) for sealing the end of the container on the sensor side is provided. Another cap ( 150 ) is provided on the opposite sample collection side. A liquid impermeable and gas permeable membrane ( 120 ) is anchored to an inner surface of the container separating the sample chamber ( 105 ) from the sensor chamber ( 110 ). An acid reagent (not shown) is included inside the sample chamber ( 105 ) with blood ( 108 ) capable of separating and releasing cyanide ( 125 ) from the sample. A cyanide detector ( 130 ) is inside the sensor chamber ( 110 ) comprising a conducting polymer ( 135 ) that absorbs the released gaseous cyanide ( 125 ).
[0039] The invention further provides a method for rapid cyanide detection using the device of the invention. The inventive method comprises the steps of: a) placing a sample in the sample chamber, and b) reviewing the detector color change or electronic display for an indication of cyanide detection. In certain embodiments, the inventive method comprises: a) mixing the sample with at least one reagent to separate and release cyanide from the sample; b) absorbing the released cyanide by the cyanide detector comprising the conducting polymer; c) quantifying cyanide concentration with the cyanide detector; d) processing the quantified cyanide concentration into a signal by a processor; and e) transmitting the signal to the display for cyanide measurement readout.
[0040] In one embodiment, the inventive device depicted in FIG. 1 is used for detecting cyanide concentration from a human blood sample. Blood is drawn up into the sample chamber ( 105 ) through a resealable membrane stopper cap ( 150 ) to a volume of about 3 mL. The blood sample is then mixed with an acid inside the sample chamber ( 105 ), wherein the blood is denatured and the bound cyanide is released. The hydrogen cyanide (HCN) gas ( 125 ) is released, passing through the liquid impeameable and gas permeable membrane ( 120 ) into the sensor chamber ( 110 ) wherein the conducting polymer ( 135 ) of the cyanide detector ( 130 ) absorbs the released HCN gas, resulting in the change in signal, which is read by a signal processor ( 140 ) which is operably coupled with the cyanide detector ( 130 ) in the sensor chamber ( 110 ). The processor ( 140 ) then transmits the signal to the display ( 145 ) wherein the cyanide measurement readout is displayed.
[0041] Depending on the detection polymer used, the results may be apparent through colorimetric change, or a display reading, within several minutes or hours.
[0042] The invention further provides a rapid cyanide detection kit comprising the device of the invention, a needle and hub holder for collecting blood in the device, and instructions on how to use the device. In certain embodiments, the cyanide test kit may have reagents already installed in the device. The invention provides that the cyanide test kit is appropriate for a point of care test system for cyanide detection and subsequent treatment. For instance, at the bedside, a patient's blood is drawn into the system, similar to other standard blood tubes used for routine blood sampling (e.g., a VACUTAINER), where it uniquely mixes with a reagent to release gaseous cyanide. The inventive cyanide detector within the inventive device then measures the cyanide concentration released from the sample blood and reports that number via a numerical readout to the healthcare provider, who can then make an informed decision of whether or not to treat the patient further such as with the use an antidote.
EXAMPLE
[0043] The present description is further illustrated by the following example, which should not be construed as limiting in any way. The contents of all cited references (including literature references, issued patents, or published patent applications as cited throughout this application) are hereby expressly incorporated by reference.
[0044] This example illustrates the inventive device and method of use thereof, for detecting cyanide in blood. The ability to detect cyanide in blood is based on previous work, where the presence of cyanide was determined spectrophotomically. It was previously demonstrated that CYANTESMO test strips, used by water treatment facilities and medical examiners, accurately and rapidly detected, in a semi-quantifiable manner, concentrations of cyanide greater than 1 mg/L in water. CYANTESMO test strips or papers are known to allow the quick and easy detection of hydrocyanic acid (HCN) and cyanides in aqueous solutions and extracts.
[0045] This example demonstrates an effective method for rapid detection of clinically important concentrations of cyanide in blood using CYANTESMO test strips as a cyanide detector in the inventive device. Varying standardized dilutions of KCN ranging from 0.5 mg/L to 30 mg/L were added to pooled, discarded blood that had been warmed to 37° C. in a water bath for 30 minutes. Test samples were then acidified with 100 μL of sulphuric acid in a closed system under a ventilation hood at room temperature. CYANTESMO registered test strips were placed into the test tubes just above the fluid level where liberated HCN gas interacted with the test strip to effect a color change. Color changes were compared to negative controls and to each other. The test strips demonstrated an incrementally increasing deep blue color change over a progressively longer portion of the test strip in less than 5 minutes for each concentration of KCN including 3, 10, and 30 mg/L. The concentrations of 0.5, and 1 mg/L did not demonstrate any color change in less than 2 hours. The CYANTESMO test strips accurately and rapidly detected, in a semi-quantifiable manner, concentrations of CN greater than 1 mg/L contained in each test sample of human blood.
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A device, method, and test kit for rapidly detecting cyanide in a sample. The inventive device comprises a container comprising a sample chamber and a sensor chamber separated by a selectively permeable barrier. The sample chamber contains a reagent for releasing cyanide from the sample, and the sensor chamber contains a cyanide detector comprising a conductive polymer which absorbs the released cyanide, generating a change in signal. Signals can be viewed colorimetrically or transmitted to a LCD/LED panel wherein the cyanide measurement readout is displayed.
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FIELD OF THE INVENTION
[0001] In general, the present invention relates to computer implemented systems and methods for providing services to a network of customers, more specifically to services enabled by methods comprising the collection, aggregation, and analysis of data in a central database from a plurality of systems that are not otherwise associated with one another to provide performance metrics and most particularly to the establishment and improvement of various performance metrics related to the execution of customer activities and the initiation of specific actions related to performance in comparison with such metrics. More specifically, the present invention relates to computer implemented services enabled by systems and methods comprising the collection, aggregation, and analysis of data related to the installation and operation of renewable energy systems comprising solar energy, wind turbine energy, tidal energy, geothermal energy, and the like, or to distributed energy generation systems comprising waste-to-energy generation systems, fuel cells, microturbines, diesel generators, and the like.
BACKGROUND OF THE INVENTION
[0002] There is increased interest in the development and deployment of renewable energy systems comprising solar energy, wind turbine energy, tidal
[0003] energy, geothermal energy, and the like, or to distributed energy generation systems comprising waste-to-energy generation systems, fuel cells, microturbines, diesel generators, and the like. This interest is being driven by a number of factors including a limited supply of fossil fuels, increased pollution from the acquisition and use of fossil fuels, global warming considerations, rising costs of fossil fuels, the loss of natural lands due to the construction of fossil fuel power plants, continued utility grid degradation and blackouts, unpredictable energy prices, the need for local power generation in disaster recovery situations, the need to move away from centralized power plants to distributed energy systems for homeland security, and the like. Advancements in the development of renewable energy and distributed energy generation technologies have overcome earlier impediments such as poor efficiency, installation difficulty, high cost, high maintenance, and the like and are presently offering increasingly attractive alternatives to fossil fuel power systems in the generation and delivery of electric power.
[0004] One of the issues faced by the renewable energy and distributed energy generation industries is that the adoption and deployment of such systems is often sporadic and not well coordinated. The decision to invest in and install a renewable energy or distributed energy generation system is typically made at the individual entity level rather than as a planned activity for an entire community. For economy of language, in this context, an “entity” may comprise an individual, a company, an office building, a shopping mall, a shopping center, a sports complex, or other such organization, business, or group investing collectively in a source of energy. Consequently, the renewable energy and distributed energy generation industries often lack the coordinated, integrated infrastructure that is typically common in other industries. The lack of infrastructure inhibits the adoption and installation of new renewable energy and distributed energy generation systems and does not allow these industries to gain advantages due to cooperation or economies of scale to lower costs, increase acceptance and deployment, and attract additional investment capital.
[0005] Accordingly, there is a need for further developments in methods and systems to facilitate the connection and cooperation of the wide variety of entities and individual implementations of renewable energy or distributed energy generation systems to improve efficiencies, lower costs, facilitate new services, facilitate management and improvement of the energy production and distribution system as a whole, facilitate and improve training and education, facilitate energy commerce, and the like. In particular, there is a need for improved systems and methods to measure the performance of such energy generation and delivery systems (“performance metrics”) and to improve such performance metrics as more data are collected and more experience is gained in the design, installation, operation, maintenance, repair, replacement and use of such systems.
BRIEF SUMMARY OF THE INVENTION
[0006] Advancements in the development of renewable energy and distributed energy generation systems have overcome, to a large extent, earlier impediments such as poor efficiency, installation difficulty, high cost, high maintenance, and the like. Specifically, advancements in the technology associated with the capture and conversion of solar energy into useable electricity has led to an increased adoption and deployment rate of solar energy generation systems. However, the infrastructure associated with collecting and analyzing data associated with the distribution infrastructure, system performance, system response, system efficiency, costs, savings associated with the system, and the like has not grown at the same pace as the implementation of solar energy generation systems. Systems and methods for the collection, aggregation, and analyzing of this data and providing services based on the results of the analysis have been developed as part of some embodiments of the present invention.
[0007] In some embodiments of the present invention, the data collection systems and methods cited above may use a local communications device installed at the site of the renewable energy generation or distributed energy generation system to collect data on the system comprising system ID, location, performance, calibration, ambient conditions, efficiency, temperature, wind speed, wind direction, solar irradiance, energy generation, device status flags, and the like. Typical data collection systems comprise embedded sensors, external sensors, embedded computers, and the like. Typical local communications devices comprise modems, routers, switches, embedded computers, wireless transmitters, and the like. The data may be transmitted via a wireless or hardwired network or other communication means to a secure, central database where the data is aggregated with data from other systems and analyzed to provide value added services to the members of the renewable energy or distributed energy generation supply chain. Examples of suitable networks comprise the Internet, a Local Area Network (LAN), a Wide Area Network (WAN), a wireless network, cellular networks (e.g., GSM, GPRS, etc.), combinations thereof, and the like. Various embodiments of the present invention include security features such that proprietary or business-sensitive data is not accessible among different business entities, thereby providing all entities access to aggregated information while compromising the security of none.
[0008] Various embodiments of the present invention relate generally to systems and methods that utilize the secure, centrally collected, aggregated, and analyzed data to provide a number of beneficial services. The services may be desirable and useful to many “Supply Chain Entities” within the renewable energy or distributed energy generation system supply chain. For economy of language, we use the term, Supply Chain Entity or Entities to refer to one or more of the “Installation Technician”, the “Value Added Reseller (VAR)”, the “System Integrator”, the “Original Equipment Manufacturer (OEM)” component supplier, the “local energy utility”, various local government agencies, the Project Financier or Investor, the Distributed Utility provider, among others. These labels have been used for convenience in the context of the present teaching. It will be clear to those skilled in the art that those entities or parties that provide similar functions and services within the supply chain may use a wide variety of names and labels. These labels do not limit the scope of the present invention in any way.
[0009] In some embodiments of the present invention, the aggregated data may be used to offer services to the VARs that improve the use and performance of the various Installation Technicians in their employment. Data across the network may be used to establish benchmark metrics for Installation Technician performance. Typically, data from new installations are collected, analyzed, and compared to the benchmark metrics. The services may typically highlight Installation Technicians that are deserving of additional recognition because their performance metrics exceed the benchmark metrics. The services may also typically highlight Installation Technicians that would benefit from additional training because their performance metrics fall below the benchmark metrics. Typically, new data may be aggregated into the database and the benchmark metrics for Installation Technician performance may continue to rise over time. Typically, the VARs may enjoy the benefits of shorter installation times, lower installation costs, increased efficiency in the use and deployment of Installation Technician resources, increased End User satisfaction, and the like.
[0010] In some embodiments of the present invention, the aggregated data may be used to offer services to the System Integrators that improve the use and performance of the various VARs in their various distribution channels. Data across the network may be used to establish benchmark metrics for VAR performance. Typically, data from new installations are collected, analyzed, and compared to the benchmark metrics. The services may typically highlight VARs that are deserving of additional recognition because their performance metrics exceed the benchmark metrics. The services may also typically highlight VARs that would benefit from additional training because their performance metrics fall below the benchmark metrics. Typically, new data may be aggregated into the database and the benchmark metrics for VAR performance may continue to rise over time. Typically, the System Integrators may enjoy the benefits of shorter installation time, lower installation costs, increased efficiency in the use and deployment of Installation Technician resources, increased End User satisfaction, and the like.
[0011] In some embodiments of the present invention, the aggregated data may be used to offer services to the System Integrators and VARs that improve the use and performance of the various OEM components used their installed systems. Data across the network may be used to establish benchmark metrics for OEM component performance. Typically, data from new installations are collected, analyzed, and compared to the benchmark metrics. The services may typically highlight OEM components that are deserving of additional attention and selection because their performance metrics exceed the benchmark metrics. The services may also typically highlight OEM components that would benefit from additional development or exclusion from future designs because their performance metrics fall below the benchmark metrics. Typically, new data may be aggregated into the database and the benchmark metrics for OEM component performance may continue to rise over time. Typically, the System Integrators and VARs may enjoy the benefits of shorter installation time, lower installation costs, increased efficiency in the use and deployment of installation resources, increased End User satisfaction, increased reliability, and the like.
[0012] In some embodiments of the present invention, the aggregated data is used to offer services to the System Integrators and VARs that improve the performance of their installed systems. Data across the network may be used to establish benchmark metrics for system performance. Typically, data from systems are collected, analyzed, and compared to the benchmark metrics. The services may typically highlight systems that are deserving of additional attention and scrutiny because their performance metrics exceed the benchmark metrics. The services may also typically highlight systems that would benefit from a service call or troubleshooting activity because their performance metrics fall below the benchmark metrics. Typically, new data may be aggregated into the database and the benchmark metrics for system performance may continue to rise over time. The System Integrators and VARs may enjoy the benefits of improved system performance, improved system efficiency, shorter reaction/service time, lower costs, increased efficiency in the use and deployment of resources, increased End User satisfaction, increased reliability, and the like.
[0013] The methods of some embodiments of the present invention may be implemented on a plurality of systems. The systems may comprise one or more energy systems, sensors contained within the energy systems to monitor various settings and performance attributes of the energy system, sensors associated with the energy systems to measure various environmental conditions, a communications device for managing two-way communications between the sensors, the energy systems, and a network, a network for transmitting the data to a centralized database, a centralized database for receiving and storing data from a plurality of systems, user interfaces for interacting with the centralized database, procedures for acting upon the data, and a plurality of output means for displaying the results of the procedure treatments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other aspects, embodiments and advantages of the invention may become apparent upon reading of the detailed description of the invention and the appended claims provided below, and upon reference to the drawings in which:
[0015] FIG. 1 is a schematic representation of a portion of a typical renewable energy or distributed energy generation system supply chain.
[0016] FIG. 2 is a flow chart of some embodiments of the generic benchmarking, collection, analyzing, comparison, and recommendation steps of the present invention.
[0017] FIG. 3 is a schematic representation of a system pertaining to some embodiments of the present invention.
[0018] FIG. 4 depicts an illustrative computer system pertaining to various embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] In general, various embodiments of the present invention relate to systems and methods that utilize secure, centrally collected, aggregated, and analyzed data to provide a number of beneficial services. The services may be desirable and useful to many Supply Chain Entities within the renewable energy or distributed energy generation system supply chain.
[0020] In some embodiments of the present invention, the systems and methods provide services to the various Supply Chain Entities in the renewable energy or distributed energy generation system supply chain. As an illustration, consider the supply chain structure illustrated in FIG. 1 wherein, large national Systems Integrators, 101 , market and sell the renewable energy or distributed energy generation systems to End Users, 104 . Typically, the System Integrators may design and oversee the installation and commissioning of the renewable energy or distributed energy generation systems. The System Integrators may contract with VARs, 102 , who are local to the End Users and who may perform services comprising installation, service, upgrades, retrofits, and the like on behalf of the System Integrators. Furthermore, the VARs may employ a plurality of Installation Technicians, 103 , who may perform services comprising installation, service, upgrades, retrofits, and the like on behalf of the VARs. OEM component suppliers, 100 , may supply components to the System Integrators, 101 , or the VARs, 102 . These labels have been used for convenience in the context of the present teaching. It will be clear to those skilled in the art that those entities or parties that provide similar functions and services within the supply chain may use a wide variety of names and labels. These labels do not limit the scope of the present invention in any way.
[0021] In an exemplary embodiment of the present invention, the systems and methods may be applied to a solar energy generation system. However, the solar energy example does not limit the scope of the present invention in any way. The systems and methods described herein may be applied to any general system. Specifically, the systems and methods described herein may be applied to any general energy system such as an energy consumption system, an energy generation system, an energy storage system, combinations thereof, and the like. More specifically, the systems and methods described herein may be applied to any renewable energy generation comprising solar energy, wind turbine energy, tidal energy, geothermal energy, and the like, or distributed energy generation technology comprising waste-to-energy generation technologies, fuel cells, microturbines, diesel generators, and the like or any combination thereof. In the context of the present teaching, a system comprising more than one type of system as listed above will be designated a “hybrid” system.
[0022] Typically, the solar energy system may be installed by an Installation Technician following an established installation checklist. The system may be connected to a central database via a network. Examples of suitable networks comprise the Internet, a Local Area Network (LAN), a Wide Area Network (WAN), a wireless network, cellular networks (e.g., GSM, GPRS, etc.), combinations thereof, and the like. In this exemplary embodiment, System Identification Data are collected at the point of sale by the System Integrator or the VAR, said System Identification Data comprising, End User identification, system warranty information, system performance guarantee commitment information, expected system power output, and the like. The System Identification Data are static in time meaning that they may not generally change once established. The System Identification Data may be entered into the central database and serve as a unique identifier for the system. System Configuration Data are collected during the manufacture and testing of the system, said System Configuration Data comprising, system configuration with OEM component identification, system wiring details, system tracking features, system tracking capabilities, and the like. The System Configuration Data are generally static in time meaning that they may not generally change once established. However, the System Configuration Data may change during periods of service, upgrades, or enhancements to the system. The System Configuration Data may be entered into the central database and associated with the unique System Identification Data previously entered. System Installation Data are collected at the time of installation, said System Installation Data comprising, VAR identity, Installation Technician identity, installation location and region, system orientation, system tilt angle, expected shading, time to complete the system installation, number of errors during the system installation, an End User satisfaction index (EUSI), firmware revision, system parameter settings, and the like. In the context of the present teaching, “expected shading” may be associated with the area and time that the system is covered by shadows due to neighboring trees, building, structures, etc. It may be expressed in units of % coverage per hour for each time period of interest comprising months, seasons, years, billing periods, and the like. This quantity may be useful in estimating the performance of the system. The System Installation Data are static in time meaning that they may not generally change once established. The System Installation Data may be entered into the central database and associated with the unique System Identification Data previously entered. System Performance Data and ambient condition data are collected continuously at a predefined intervals after start-up of the system, said System Performance Data comprising, system response, system performance, ambient temperature, solar irradiance, conversion efficiency, current tilt angle, shading, system energy output, current firmware revision, current system parameter settings, device fault and error codes, power, voltage, cumulative energy generated, and the like. The System Performance Data change with time and are entered into the central database as a time series with associated date and time stamps. The temporal System Performance Data are associated with the unique System Identification Data previously entered. The data correlated to the installation region may be aggregated to several levels of granularity, said levels comprising country, time zone, state or province, county, postal code, Global Positioning System (GPS) coordinates, and the like. Additionally, System History Data may be associated with each unique System Identification Data record. The System History Data captures changes in the System Configuration Data over time. Examples of System History Data comprise time-to-first-service-call, details of the service calls, steps taken to resolve the issues in the service calls, upgrades to the system configuration, new firmware revisions, new parameter settings, and the like. Entries in the System History Data typically contain date and time stamps so that changes may be tracked over the life of the system.
[0023] Through the services provided, the data may be manipulated and parsed by the various Supply Chain Entities subject to various security measures as discussed below. A plurality of standard procedures exists to aid in the manipulation of the data. Examples of suitable procedures comprise methods for calculating typical statistical values such as mean, median, average, standard deviation, maximum value, minimum value, variance, and the like. These procedures are listed as illustrations only and do not limit the scope of the present invention in any way. Alternatively, the Supply Chain Entities may develop and generate custom procedures to extract and manipulate the data for their specific purpose. Examples of custom procedures are discussed below.
[0024] The systems and methods may include a number of security measures to protect the intellectual property and confidential information for the various Supply Chain Entities of the renewable energy system supply chain. The security measures may comprise software passwords, tokens, smart cards, biometric identification means, and the like. The security measures ensure that any specific System Integrator, VAR, or OEM manufacturer is only allowed access to the detailed data generated by systems under their specific responsibility. However, the System Integrators, VARs, or OEM manufacturers may request results based on the analysis of the aggregated data across the database so that they may compare their data to the larger population of systems.
[0025] The database may contain data from systems installed worldwide by a large number of Supply Chain Entities. The different pattern fill of the circles representing systems, 300 , illustrated in FIG. 3 is meant to convey that these systems are associated with different Supply Chain Entities. Comparisons and analyses may be completed by aggregating data from systems with similar features comprising one or more of System Integrator ID, VAR ID, Installation Technician ID, expected system power output, system configuration with OEM component identification, system wiring details, system tracking features, system tracking capabilities, installation region, system orientation, system tilt angle, firmware revision, system parameter settings, system response, system performance, ambient temperature, solar irradiance, conversion efficiency, current tilt angle, shading, system energy output, device fault and error codes, power, voltage, cumulative energy generated, and the like. Advantageously, the database enables the Supply Chain Entities to compare detailed data across systems under their responsibility or to compare their data to benchmark or aggregated data across the entire database. For example, a System Integrator may compare detailed data for his systems installed across a large region such as North America. Alternatively, the same System Integrator may compare data for one or more of his systems with benchmark or aggregated data for systems installed in a completely different region such as Europe.
[0026] The aggregated data may be used to offer services to the VARs that improve the deployment and performance of the various Installation Technicians. An exemplary list of data categories is shown in Table 1 for a solar energy system. Similar steps and tables may be envisioned for other renewable energy systems comprising wind turbine systems, tidal energy systems, geothermal energy systems, and the like, or distributed energy systems comprising waste-to-energy systems, fuel cells, microturbines, diesel generators, and the like. Tables 2-6 list similar exemplary data categories for some other energy systems respectively. Tables 1-6 are for illustrative purposes only and are not meant to limit the present invention to the specific data or systems listed. Those skilled in the art will be able to apply the teachings of the present invention to appropriate data categories and systems not specifically listed herein.
[0000]
TABLE 1
Illustrative data categories for an exemplary
solar energy system
System
System
System
Data Type
System ID
Config.
Install
Performance
History Data
Time Scale
Static
Static
Static
Temporal
On Changes
Data Types
System
System
VAR ID
System
Time to 1 st
Integrator
Config.
Response
Service Call
ID
End User ID
OEM
Installation
System
Service
Components
Technician
Performance
Calls
ID
Warranty
System
Install
Ambient
Resolution
Wiring
Region
Temperature
Performance
Tracking
System
Solar
Upgrades
Guarantee
Features
Orientation
Irradiance
Planned
Tracking
System Tilt
Conversion
New Firmware
System
Capability
Angle
Efficiency
Revision
Power
Output
Location
Shading
Install Time
Current
New
Information
Tilt Angle
Parameter
Settings
Region
# of Errors
Energy
Component
Output
Replacements
Utility
End User
Current
Maintenance
Satisfaction
Firmware
Activities
Index
Revision
Utility
Firmware
Current
End User
Tariff
Revision
Parameter
Satisfaction
Information
Settings
Index
Regional
System
Energy Mix
Parameter
Settings
[0000]
TABLE 2
Illustrative data categories for an exemplary
wind turbine energy system
System
System
System
History
Data Type
System ID
Config.
Install
Performance
Data
Time Scale
Static
Static
Static
Temporal
On Changes
Data Types
System
System
VAR ID
System
Time to
Integrator
Config.
Response
1 st
ID
Service
Call
End User ID
OEM
Installation
System
Service
Components
Technician
Performance
Calls
ID
Warranty
System
Install
Ambient
Resolution
Wiring
Region
Temperature
Performance
Fixed or
System
Barometric
Upgrades
Guarantee
Variable
Orientation
Pressure
Direction
Planned
Turbine
Blade Tilt
Wind
New
System
blade size
Angle
Direction
Firmware
Power
Revision
Output
Location
Install Time
Wind
New
Speed/Blade
Parameter
RPMs
Settings
Region
# of Errors
Conversion
Avian
Efficiency
and/or Bat
impacts
Utility
End User
Blade Tilt
Satisfaction
Angle
Index
Utility
Firmware
Energy
Tariff
Revision
Output
Information
Regional
System
Current
Energy Mix
Parameter
Firmware
Settings
Revision
Current
Parameter
Settings
Noise
Measurements
[0000]
TABLE 3
Illustrative data categories for an exemplary
tidal energy system
System
System
System
History
Data Type
System ID
Config.
Install
Performance
Data
Time Scale
Static
Static
Static
Temporal
On Changes
Data Types
System
System
VAR ID
System Response
Time to 1 st
Integrator
Config.
Service Call
ID
End User ID
OEM
Installation
System
Service
Components
Technician
Performance
Calls
ID
Warranty
System
Install
Water
Resolution
Wiring
Region
Temperature
Performance
System
Wave Height
Upgrades
Guarantee
Orientation
Planned
Water depth
Conversion
New
System
Efficiency
Firmware
Power
Revision
Output
Location
Install Time
Energy
New
Output
Parameter
Settings
Region
# of Errors
Current
Firmware
Revision
Utility
End User
Current
Satisfaction
Parameter
Index
Settings
Utility
Firmware
Water Flow
Tariff
Revision
Rate
Information
Regional
System
Pressure
Energy Mix
Parameter
Drop
Settings
[0000]
TABLE 4
Illustrative data categories for an exemplary
geothermal energy system
System
System
System
History
Data Type
System ID
Config.
Install
Performance
Data
Time Scale
Static
Static
Static
Temporal
On Changes
Data Types
System
System
VAR ID
System
Time to
Integrator
Config.
Response
1 st
ID
Service
Call
End User ID
OEM
Installation
System
Service
Components
Technician
Performance
Calls
ID
Warranty
System
Install
Working
Resolution
Wiring
Region
Temperature
Performance
System Depth
Conversion
Upgrades
Guarantee
Efficiency
Planned
Install Time
Energy
New
System
Output
Firmware
Power
Revision
Output
Location
# of Errors
Current
New
Firmware
Parameter
Revision
Settings
Region
End User
Current
Satisfaction
Parameter
Index
Settings
Utility
Firmware
Revision
Utility
System
Tariff
Parameter
Information
Settings
Regional
Energy Mix
[0000]
TABLE 5
Illustrative data categories for an exemplary
waste-to-energy system
System
System
System
History
Data Type
System ID
Config.
Install
Performance
Data
Time Scale
Static
Static
Static
Temporal
On Changes
Data Types
System
System Config.
VAR ID
System
Time to
Integrator
Response
1 st
ID
Service
Call
End User ID
OEM
Installation
System
Service
Components
Technician
Performance
Calls
ID
Warranty
System
Install
Feedstock
Resolution
Wiring
Region
Volume
Performance
System
Conversion
Upgrades
Guarantee
Orientation
Efficiency
Planned
Feedstock
Energy
New
System
Composition
Output
Firmware
Power
Revision
Output
Location
Install Time
Current
New
Firmware
Parameter
Revision
Settings
Region
# of Errors
Current
Parameter
Settings
Utility
End User
Satisfaction
Index
Utility
Firmware
Tariff
Revision
Information
Regional
System
Energy Mix
Parameter
Settings
[0000]
TABLE 6
Illustrative data categories for an exemplary
energy storage system
System
System
System
Data Type
System ID
Config.
Install
Performance
History Data
Time Scale
Static
Static
Static
Temporal
On Changes
Data Types
System
System
VAR ID
System
Time to 1 st
Integrator
Config.
Response
Service Call ID
End User ID
OEM
Installation
System
Service
Components
Technician
Performance
Calls
ID
Warranty
System
Install
Charge
Resolution
Wiring
Region
State
Performance
Storage
System
Charge
Upgrades
Guarantee
Type
Orientation
Capacity
Planned
Discharge
Feedstock
# of
New Firmware
System
Rate
Composition
Charge/
Revision
Power
Discharge
Output
Cycles
Location
Discharge
Install Time
Total
New
Behavior
Energy
Parameter
vs Life
Stored/
Settings
Expectancy
Released
Region
# of Errors
Current
Equalization
Firmware
Information
Revision
Utility
End User
Current
Satisfaction
Parameter
Index
Settings
Utility
Firmware
Tariff
Revision
Information
System
Parameter
Settings
[0027] The system and methods of some embodiments of the present invention provide tools and services to the Supply Chain Entities for accessing and analyzing the data in the central database. Referring now to FIG. 2 , in some embodiments of the present invention, data from the database are used to establish benchmark metrics for Installation Technician performance. The Installation Technician performance benchmark metrics can be established from aggregated data based on parameters selected by the VARs. The VARs will only have access to the detailed data for systems that they are authorized to access, typically systems they have designed, commissioned, installed or serviced. The database security features mentioned previously will prevent the various Supply Chain Entities from accessing site-identifiable, proprietary, confidential, or competitive detailed data that are not associated with their systems. The VARs may organize or parse the data in meaningful categories. For example, the VARs may compare data based on factors such as expected system power output, system integrator identification, OEM component identification, installation region, system configuration, Installation Technician experience, and the like. The aggregated data may be used to establish a number of installation performance benchmark metrics. The VARs may select the population of data from the database that is of interest. For example, the VARs may choose to establish the benchmark metrics from data that is collected only from their region, or their direct involvement, or the like. Alternatively, the VARs may choose to establish the benchmark metrics from data that is collected from the entire database. Examples of said benchmark metrics include time required for system installation, installation cost or cost index, system performance, number of errors reported during system installation, time-to-first-service-call after system installation, service call history including complaint, time and cost, End User Satisfaction Index (EUSI), and the like. The VARs may select acceptable values that may form the benchmark metrics. The VARs may also be able to compare their benchmarks to similar global benchmarks that are established by analyzing the entire database, although they will not have access to the detailed data for systems outside their security clearance (that is, those they are authorized to access).
[0028] Referring again to FIG. 2 , the systems and methods of some embodiments of the present invention may collect the data as previously described in step, 200 , and aggregate the data into the central database in step, 201 . The systems and methods of the present invention may then compare data from new installations to the benchmark metrics in step, 202 . The methods of the present invention may follow the decision tree exemplified by steps, 203 , 204 , and 205 . The methods may highlight Installation Technicians that are deserving of additional recognition because their performance metrics exceed the benchmark metric in step, 204 . The VARs may use this data to drive a number of corporate improvement programs such as incentive programs, bonus programs, employee recognition programs and the like. Similarly, the methods may highlight Installation Technicians that are deserving of additional training or attention because their performance metrics fall below the benchmark metrics in step, 205 . The VARs may use this data to drive a number of corporate improvement programs such as training programs, mentoring programs, employee improvement programs and the like. The services may provide data to the VARs for use in the training programs to highlight common errors, problems, mistakes, and proper corrective actions. Alternatively, common or repetitive errors may indicate poorly designed procedures rather than the need for employee improvements, and appropriate corrective actions can be implemented. Additionally, the new data may be used to improve the benchmark metrics over time as indicated in Step, 209 .
[0029] The system and methods of some embodiments of the present invention provide tools and services to the Supply Chain Entities for accessing and analyzing the data in the central database. Referring now to FIG. 2 , in some embodiments of the present invention, data across the database are used to establish benchmark metrics for VAR performance. The benchmark metrics may be established from aggregated data based on parameters selected by the System Integrators. The System Integrators will only have access to the detailed data for systems that they have designed, and commissioned. The database security features mentioned previously will prevent the various Supply Chain Entities from accessing proprietary, confidential, or competitive detailed data that are not associated with their systems. The System Integrators may parse the data in meaningful categories. For example, the System Integrators may compare data based on factors such as expected system power output, VAR identification, OEM component identification, installation region, system configuration, Installation Technician experience, and the like. The aggregated data may be used to establish a number of installation performance benchmark metrics. The System Integrators may select the population of data from the database that is of interest. For example, the System Integrators may choose to establish the benchmark metrics from data that is collected only from their region, or their direct involvement, or the like. Alternatively, the System Integrators may choose to establish the benchmark metrics from data that is collected from the entire database. Examples of said benchmark metrics comprising time required for system installation, installation cost or cost index, system performance, number of errors reported during system installation, time-to-first-service-call after system installation, service call history including complaint, time and cost, End User Satisfaction Index (EUSI), and the like. The System Integrators may select acceptable values that may form the benchmark metrics. The System Integrators may also be able to compare their benchmarks to similar global benchmarks that are established by analyzing the entire database, although they will not have access to the detailed data for systems outside their security clearance.
[0030] Referring again to FIG. 2 , the systems and methods of some embodiments of the present invention may collect the data as previously described in step, 200 , and aggregate the data into the central database in step, 201 . The systems and methods of the present invention may then compare data from new installations to the benchmark metrics in step, 202 . The systems and methods of the present invention may follow the decision tree formed by steps, 203 , 204 , and 205 . The methods may highlight VARs that are deserving of additional recognition because their performance metrics exceed the benchmark metrics in step, 204 . The System Integrators may use this data to drive a number of corporate improvement programs such as incentive programs, bonus programs, employee recognition programs and the like. Similarly, the methods may highlight VARs that are deserving of additional training or attention because their performance metrics fall below the benchmark metrics in step, 205 . The System Integrators may use this data to drive a number of corporate improvement programs such as training programs, mentoring programs, employee improvement programs and the like. The services may provide data to the System Integrators for use in the training programs to highlight common errors, problems, mistakes, and proper corrective actions. Additionally, the new data may be used to improve the benchmark metrics over time as indicated in Step, 209 .
[0031] The system and methods of some embodiments of the present invention provide tools and services to the Supply Chain Entities for accessing and analyzing the data in the central database. Referring now to FIG. 2 , in some embodiments of the present invention, data across the database are used to establish benchmark metrics for OEM manufacturer component performance. The benchmark metrics may be established from aggregated data based on parameters selected by the System Integrators or VARS. The System Integrators or VARs will typically only have access to the detailed data for systems that they have designed, commissioned, installed, and serviced. The database security features mentioned previously will prevent the various Supply Chain Entities from accessing proprietary, confidential, or competitive information. The System Integrators or VARs may parse the data in meaningful categories. For example, the System Integrators or VARs may compare data based on factors such as expected system power output, OEM component identification, installation region, system configuration, Installation Technician experience, and the like. The aggregated data may be used to establish a number of installation performance benchmark metrics. The System Integrators or VARs may select the population of data from the database that is of interest. For example, the System Integrators or VARs may choose to establish the benchmark metrics from data that is collected only from their region, or their direct involvement, or the like. Alternatively, the System Integrators or VARs may choose to establish the benchmark metrics from data that is collected from the entire database. Examples of said benchmark metrics comprising time required for system installation, installation cost or cost index, system performance, number of errors reported during system installation, time-to-first-service-call after system installation, service call history including complaint, time and cost, End User Satisfaction Index (EUSI), and the like. The System Integrators or VARs may select acceptable values that may form the benchmark metrics. The System Integrators or VARs may also be able to compare their benchmarks to similar global benchmarks that are established by analyzing the entire database, although they will not have access to the detailed data for systems outside its security clearance.
[0032] Referring again to FIG. 2 , the systems and methods of the present invention may collect the data as previously described in step, 200 , and aggregate the data into the central database in step, 201 . The systems and methods of the present invention may then compare data from new installations to the benchmark metrics in step, 202 . The systems and methods of the present invention may follow the decision tree formed by steps, 203 , 204 , and 205 . The systems and methods may highlight OEM manufacturer components that are deserving of additional attention and selection because their performance metrics exceed the benchmark metrics in step, 204 . The System Integrators or VARs may use this data to drive a number of corporate improvement programs such as incentive programs, bonus programs, OEM manufacturer recognition programs and the like. Similarly, the systems and methods may highlight OEM manufacturer components that are deserving of additional development or exclusion from future designs because their performance metrics fall below the benchmark metrics in step, 205 . The System Integrators or VARs may use this data to drive a number of corporate improvement programs such as training programs, mentoring programs, OEM manufacturer improvement programs and the like. The services may provide data to the System Integrators or VARs for use in the training programs to highlight common errors, problems, mistakes, and proper corrective actions. Additionally, the new data may be used to improve the benchmark metrics over time as indicated in Step, 209 .
[0033] The system and methods of some embodiments of the present invention provide tools and services to the Supply Chain Entities for accessing and analyzing the data in the central database. Referring now to FIG. 2 , in some embodiments of the present invention, data across the database are used to establish benchmark metrics for system performance. The benchmark metrics may be established from aggregated data based on parameters selected by the System Integrators, VARs, or OEM manufacturers. The System Integrators, VARs, or OEM manufacturers will typically only have access to the detailed data for systems that they have designed, commissioned, installed, or serviced. The database security features mentioned previously will prevent the various Supply Chain Entities from accessing proprietary, confidential, or competitive detailed data that are not associates with their systems. The System Integrators, VARs, or OEM manufacturers may parse the data in meaningful categories. For example, the System Integrators, VARs, or OEM manufacturers may compare data based on factors such as expected system power output, OEM component identification, installation region, system configuration, system compass settings, system azimuthal angle, and the like. The aggregated data may be used to establish a number of system performance benchmark metrics. The System Integrators, VARs, or OEM manufacturers may select the population of data from the database that is of interest. For example, the System Integrators, VARs, or OEM manufacturers may choose to establish the benchmark metrics from data that is collected only from their region, or their direct involvement, or the like. Alternatively, the System Integrators, VARs, or OEM manufacturers may choose to establish the benchmark metrics from data that is collected from the entire database. Examples of said benchmark metrics comprising energy generation, energy efficiency, cost or cost index, system performance, number of errors reported, time-to-first-service-call after system installation, service call history including complaint, time and cost, End User Satisfaction Index (EUSI), and the like. The System Integrators, VARs, or OEM manufacturers may select acceptable values that may form the benchmark metrics. The System Integrators, VARs, or OEM manufacturers may also be able to compare their benchmarks to similar global benchmarks that are established by analyzing the entire database, although they will not have access to the detailed data for systems outside their security clearance.
[0034] Referring again to FIG. 2 , the systems and methods of some embodiments of the present invention may collect the data as previously described in step, 200 , and aggregate the data into the central database in step, 201 . The systems and methods of the present invention may then compare data from selected systems to the benchmark metrics in step, 202 . The systems and methods of the present invention may follow the decision tree formed by steps, 203 , 204 , and 205 . The systems and methods may highlight systems that are deserving of additional attention and selection because their performance metrics exceed the benchmark metrics in step, 204 . The System Integrators, VARs, or OEM manufacturers may use this data to drive a number of corporate improvement programs such as incentive programs, bonus programs, recognition programs, component selection decisions, public relations, and the like. Similarly, the systems and methods may highlight systems that are deserving of a service call or troubleshooting activity because their performance metrics fall below the benchmark metric in step, 205 . The System Integrators, VARs, or OEM manufacturers may use this data to drive a number of corporate improvement programs such as training programs, mentoring programs, employee improvement programs, component selection decisions, and the like. The services may provide data to the System Integrators, VARs, or OEM manufacturers for use in the training programs to highlight common errors, problems, mistakes, and proper corrective actions. Additionally, the new data may be used to improve the benchmark metrics over time as indicated in Step, 209 .
[0035] Table 7 illustrates a subset of the data that might be contained in the central database. The first two rows illustrate the benchmark metrics for exemplary solar energy systems of various sizes, in this case, 20 kilowatt (kW) and 100 kW. These benchmark metrics may be established from the entire population of solar energy installations included in the database. This scope of data collection, aggregation, and analysis is not currently typical since the various Supply Chain Entities in the solar energy supply chain do not typically collect data or share any detailed data with each other. Table 7 contains exemplary data from various Supply Chain Entities comprising three System Integrators (A, B, C), three VARs (I, II, III), three Installation Technicians (1, 2, 3), and three OEM component manufacturers (X, Y, Z). Exemplary installation performance data are included that illustrates the Time, Cost, and Number of Errors for each installation to be used as metrics to evaluate performance metrics of the exemplary Supply Chain Entities.
[0036] Table 8 illustrates an exemplary result of one possible procedure used to analyze the data contained in Table 7. For illustrative purposes, if the performance metric exceeded the benchmark metric, it was given an arbitrary value of “+1”, if the performance metric was equal to the benchmark metric it was given an arbitrary value of “0”, and if the performance metric fell below the benchmark metric, it was given an arbitrary value of “−1”. The data for each Supply Chain Entity was then established by calculating the arithmetic summation across those installations where that Supply Chain Entity was involved and the resulting metric entered into Table 8.
[0037] It is clear from the data in Tables 7 and 8 that Installation Technician “1” is highly skilled and may be deserving of additional recognition because the performance metric results are positive in each of the three categories. Likewise, Installation Technician “2” shows poor performance in both the areas of Cost and Errors and may need additional training or mentoring due to the negative performance metric results in these areas. Installation Technician “3” is not meeting the benchmark performance metrics for Time and may benefit from acquiring tips from his peers on more efficient installation techniques. This procedure for treatment of the data is for illustration purposes only. For example, other procedures comprising other analytical techniques may comprise calculating a weighted average based on several performance metrics, calculating a performance trend based on the last several installations, use of simple “pass/fail” criteria, and the like. It will be clear to those skilled in the art that there are many procedures comprising many analytical methods that can be used to analyze the original data. The use of these particular examples in no way limits the scope of the present invention.
[0038] It is clear from the data in Tables 7 and 8 that VAR “I” is highly skilled and may be deserving of additional recognition because the performance metric results are positive in each of the three categories. Likewise, VAR “II” shows poor performance in the area of Cost and may need additional training or mentoring due to the negative performance metric results in this area. VAR “III” is not meeting the benchmark for Time and may benefit from acquiring tips from his peers on more efficient installation techniques. This procedure for treatment of the data is for illustration purposes only. For example, other procedures comprising other analytical techniques may comprise calculating a weighted average based on several performance metrics, calculating a performance trend based on the last several installations, use of simple “pass/fail” criteria, and the like. It will be clear to those skilled in the art that there are many procedures comprising many analytical methods that can be used to analyze the original data. The use of these particular examples in no way limits the scope of the present invention.
[0039] It is clear from the data in Tables 7 and 8 that OEM manufacturer components “X” perform well and may be deserving of additional consideration and use on future projects because the performance metric results are positive in each of the three categories. Likewise, OEM manufacturer components “Y” show poor performance in both the areas of Cost and Errors and may need additional development or exclusion from future projects due to the negative performance metric results in these areas. OEM manufacturer components “Z” are not meeting the benchmark for Time and may benefit from development to enable more efficient installation techniques. This procedure for treatment of the data is for illustration purposes only. For example, other procedures comprising other analytical techniques may comprise calculating a weighted average based on several performance metrics, calculating a performance trend based on the last several installations, use of simple “pass/fail” criteria, and the like. It will be clear to those skilled in the art that there are many procedures comprising many analytical methods that can be used to analyze the original data. The use of these particular examples in no way limits the scope of the present invention.
[0000]
TABLE 7
Illustrative installation data for a solar
energy system
System
Install
OEM
System
Size
Integrator
VAR
Tech
Comp
Time
Cost
Errors
Benchmark
20 kW
2
$5K
4
20 kW
weeks
Benchmark
100 kW
4
$20K
6
100 kW
weeks
1
20 kW
A
I
1
X
1
$3K
2
week
2
20 kW
B
I
1
X
2
$5K
3
weeks
3
100 kW
A
II
2
Y
4
$20K
5
weeks
4
20 kW
C
I
1
X
1
$5K
4
week
5
100 kW
B
II
2
Y
3
$25K
6
weeks
6
100 kW
C
II
2
Y
6
$30K
10
weeks
7
100 kW
A
III
3
Z
5
$18K
5
weeks
8
20 kW
B
III
3
z
3
$7K
5
weeks
9
100 kW
C
III
3
Z
4
$15K
3
weeks
10
20 kW
A
II
1
Z
1
$4K
1
week
[0000]
TABLE 8
Illustrative installation data analysis for a solar energy system
Entity
Time
Cost
Errors
A
1
3
4
B
0
−2
−1
C
0
0
0
I
2
1
2
II
1
−1
0
III
−2
1
1
1
3
2
3
2
0
−2
−1
3
−2
1
1
X
2
1
2
Y
0
−2
−1
Z
−1
2
2
[0040] Table 9 illustrates a subset of the data that may be contained in the central database. The first three rows illustrate the benchmark metrics for exemplary solar energy systems of various sizes, in this case, 20 kW, 50 kW, and 100 kW. These benchmark metrics may be established from the entire population of solar energy installations included in the database. This scope of data collection, aggregation, and analysis is not currently typical since the various Supply Chain Entities in the solar energy supply chain do not typically collect or share any detailed data with each other. Table 9 contains exemplary data from various systems installed in a similar region having similar compass and tilt angle settings. Sample System Performance Data are included that illustrate the energy generated and energy efficiency for each system to be established as metrics to compare the performance of the systems.
[0041] Table 10 illustrates an exemplary result of one possible analysis of the data contained in Table 9. For illustrative purposes, if the performance metric exceeded the benchmark metric, it was given an arbitrary value of “+1”, if the performance metric was equal to the benchmark metric, it was given an arbitrary value of “0”, and if the performance metric fell below the benchmark metric, it was given an arbitrary value of “−1”.
[0042] It is clear from the data in Tables 9 and 10 that systems “3”, “4”, and “5” perform well and may be deserving of additional consideration and investigation because the performance metric results are positive in each of the categories. Likewise, systems “1”, “2”, “7”, and “9” illustrate poor performance in both areas and may need a service call or troubleshooting activity due to the negative performance results in these areas. This procedure for treatment of the data is for illustration purposes only. For example, other procedures comprising other analytical techniques may comprise calculating a weighted average based on several performance metrics, calculating a performance trend based on the last several installations, use of simple “pass/fail” criteria, and the like. It will be clear to those skilled in the art that there are many procedures comprising many analytical methods that can be used to analyze the original data. The use of these particular examples in no way limits the scope of the present invention.
[0000]
TABLE 9
Illustrative installation data for solar
energy systems
Compass
Tilt
Sun
Energy
System
Size
Region
Angle
Angle
Exposure
Energy
Efficiency
Benchmark
20 kW
CA
South
45°
10 hrs
18 kW
20.0%
20 kW
Benchmark
50 kW
CA
South
45°
10 hrs
45 kW
20.0%
50 kW
Benchmark
100 kW
CA
South
45°
10 hrs
90 kW
20.0%
100 kW
1
20 kW
CA
South
45°
10 hrs
16 kW
17.8%
2
20 kW
CA
South
40
10 hrs
10 kW
11.1%
3
50 kW
CA
South
45°
10 hrs
55 kW
24.4%
4
100 kW
CA
South
35°
10 hrs
92 kW
20.4%
5
50 kW
CA
South
40°
10 hrs
46 kW
20.4%
6
20 kW
CA
South
45°
10 hrs
18 kW
20.0%
7
100 kW
CA
South
35°
10 hrs
85 kW
18.9%
8
100 kW
CA
South
40°
10 hrs
90 kW
20.0%
9
50 kW
CA
South
45°
10 hrs
40 kW
17.8%
[0000]
TABLE 10
Illustrative installation data analysis for solar energy systems
System
Energy
Energy Efficiency
1
−1
−1
2
−1
−1
3
+1
+1
4
+1
+1
5
+1
+1
6
0
0
7
−1
−1
8
0
0
9
−1
−1
[0043] The services and methods may compare new installation system performance metrics to the benchmark metrics and highlight systems whose performance metrics exceed the benchmark metric. Similarly, the services and methods may highlight systems whose performance metrics fall below the benchmark metric. This may highlight systems that may need attention and may also serve as input into the performance of the various Supply Chain Entities as mentioned previously.
[0044] Referring now to FIG. 3 , the methods of some embodiments of the present invention may be implemented on a plurality of systems. The systems may comprise one or more energy systems, 300 , sensors contained within the energy system to monitor various settings and performance attributes of the energy system, sensors associated with the energy system to measure various environmental conditions, 302 , a local communications device for managing two-way communications between the sensors, the energy systems, and a network, 303 , a network for transmitting the data to a centralized database, 304 , a centralized database for receiving and storing data from the plurality of systems, 305 , user interfaces for interacting with the centralized database, 306 - 309 , procedures for acting upon the data, and a plurality of output devices for displaying the results of the procedure action, 306 - 310 .
[0045] Continuing to refer to FIG. 3 , in some exemplary embodiments comprising solar energy generation systems, the sensors contained within the system may monitor various settings and performance attributes comprising, system response, system performance, conversion efficiency, current tilt angle, shading, system energy output, current firmware revision, current system parameter settings, device fault and error codes, power, voltage, cumulative energy generated, and the like. Sensors associated with the system, 302 , may measure various environmental conditions comprising ambient temperature, solar irradiance, and the like. The data may be communicated onto a network, 304 , by a local communications device, 303 . Examples of suitable networks comprise the Internet, a Local Area Network (LAN), a Wide Area Network (WAN), a wireless network, a satellite network, cellular networks (e.g., GSM, GPRS, etc.), combinations thereof, and the like. The data may be received and stored on a centralized database, 305 . The data in the centralized database may be accessed by a plurality of user interfaces comprising computer terminals, 307 , personal computers (PCs), 306 , personal digital assistants (PDAs), 308 , cellular phones, 309 , interactive displays, and the like. This allows the user to be located remotely from the centralized database. As mentioned previously, the centralized database contains a variety of security features to prevent sensitive detailed data from being viewed or accessed by users without the proper security clearance. Procedures may be used to act on the data to generate results of various inquires. The procedures may be part of a standard set of calculations or may be developed and generated by the user. The results of the action by the procedures may be displayed to the user on a number of output means. Examples of suitable output means comprise computer terminals, 307 , personal computers (PCs), 306 , printers, 310 , LED displays, personal digital assistants (PDAs), 308 , cellular phones, 309 , interactive displays, and the like.
[0046] FIG. 4 depicts an illustrative computer system pertaining to various embodiments of the present invention. In some embodiments, the computer system comprises a server 401 , display, 402 , one or more input interfaces, 403 , communications interface, 406 , and one or more output interfaces, 404 , all conventionally coupled by one or more buses, 405 . The server, 401 , comprises one or more processors (not shown) and one or more memory modules, 412 . The input interfaces, 403 , may comprise a keyboard, 408 , and a mouse, 409 . The output interface, 404 , may comprise a printer, 410 . The communications interface, 406 , is a network interface that allows the computer system to communicate via a wireless or hardwired network, 407 , as previously described. The communications interface, 407 , may be coupled to a transmission medium, 411 , such as a network transmission line, for example, twisted pair, coaxial cable, fiber optic cable, and the like. In another embodiment, the communications interface, 411 , provides a wireless interface, that is, the communication interface, 411 uses a wireless transmission medium. Examples of other devices that may be used to access the computer system via communications interface, 406 , comprise cell phones, PDAs, personal computers, and the like (not shown).
[0047] The memory modules, 412 , generally comprises different modalities, illustratively semiconductor memory, such as random access memory (RAM), and disk drives as well as others. In various embodiments, the memory modules, 412 , store an operating system, 413 , collected and aggregated data, 414 , instructions, 415 , applications, 416 , and procedures, 417 .
[0048] In various embodiments, the specific software instructions, data structures and data that implement various embodiments of the present invention are typically incorporated in the server, 401 . Generally, an embodiment of the present invention is tangibly embodied in a computer readable medium, for example, the memory and is comprised of instructions, applications, and procedures which, when executed by the processor, causes the computer system to utilize the present invention, for example, the collection, aggregation, and analysis of data, establishing benchmark metrics for performance, comparing performance data to the benchmark metrics, displaying the results of the analyses, and the like. The memory may store the software instructions, data structures, and data for any of the operating system, the data collection application, the data aggregation application, the data analysis procedures, and the like in semiconductor memory, in disk memory, or a combination thereof.
[0049] The operating system may be implemented by any conventional operating system comprising Windows® (Registered trademark of Microsoft Corporation), Unix® (Registered trademark of the Open Group in the United States and other countries), Mac OS® (Registered trademark of Apple Computer, Inc.), Linux® (Registered trademark of Linus Torvalds), as well as others not explicitly listed herein.
[0050] In various embodiments, the present invention may be implemented as a method, system, or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof. The term “article of manufacture” (or alternatively, “computer program product”) as used herein is intended to encompass a computer program accessible from any computer-readable device, carrier or media. In addition, the software in which various embodiments are implemented may be accessible through the transmission medium, for example, from a server over the network. The article of manufacture in which the code is implemented also encompasses transmission media, such as the network transmission line and wireless transmission media. Thus the article of manufacture also comprises the medium in which the code is embedded. Those skilled in the art will recognize that many modifications may be made to this configuration without departing from the scope of the present invention.
[0051] The exemplary computer system illustrated in FIG. 4 is not intended to limit the present invention. Other alternative hardware environments may be used without departing from the scope of the present invention.
[0052] The foregoing descriptions of exemplary embodiments of the present invention have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications, embodiments, and variations are possible in light of the above teaching.
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Systems and methods are provided for collecting ( 200 ), aggregating ( 201 ), and analyzing data ( 202, 203 ) associated with the installation and deployment of systems. Energy systems, specifically renewable energy generating systems, are used as examples. The aggregated data ( 201 ) serve as the basis for a variety of services that improve the system performance metrics ( 209 ), improve the installation metrics, lower the cost, and provide monitoring and service to improve performance. Finally, services are provided that facilitate the improvement of the performance metrics of various Supply Chain Entities in the supply chain as well as overall system performance metrics.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. national stage of International Application No. PCT/EP2015/0008887, filed Apr. 30, 2015 and claims the benefit thereof. The International Application claims the benefit of German Application No. 102014008200.8 filed on May 30, 2015, both applications are incorporated by reference herein in their entirety.
BACKGROUND
[0002] Described below is an operating element for a motor vehicle, the operating element having a touch-sensitive operating surface provided by a surface of a glass panel. The surface of the glass panel further has a surface structure formed by deep-drawing of the surface in the heated state of the glass panel. Also described is a method for producing a glass panel for a touch-sensitive operating element. Here, a glass panel and a deep-drawing tool with a first tool part and a second tool part are provided, the glass panel is introduced into the deep-drawing tool between the first tool part and the second tool part, and a surface structure of a first surface of the glass panel is formed by deep drawing the glass panel in the heated state of the glass panel using the deep-drawing tool.
[0003] The related art has disclosed touch-sensitive operating elements, such as e.g. touchpads and touchscreens, which may have a glass panel as an operating surface. Here, such glass panels should be as hard and as scratch-resistant as possible, which is facilitated, for example, by specific glass compositions and tempering methods.
[0004] By way of example, DE 11 2010 004 720 T5 describes a glass composition which should have high-strength, fracture toughness and high scratch-resistance. Glass panels, which are particularly suitable for touchscreens, may be produced from this glass by floating or a deep-drawing process.
[0005] Furthermore, U.S. 2013/0189486 A1 describes a glass composition suitable for fast 3D press forming and tempering in order thereby likewise to be able to provide great hardness, scratch resistance and high resistance to fracturing, in particular for planar and non-planar or bent touchscreen surfaces. Here, it is also possible to generate surface structures during the press forming which have a decorative effect or optical function.
[0006] However, in the case of touch-sensitive operating elements, it is not only the robustness and optics of the operating surface that play a role, but also the operating comfort which should be provided with such operating elements in order, for example, to facilitate operation which is as simple and comfortable as possible.
[0007] Under this aspect, DE 10 2012 020 609 A1 for example suggests a generic operating element and method, in which a three-dimensional, tactile structure on the glass surface is generated by deep drawing of a heated glass surface for a touchscreen. Here, these structure elements serve to subdivide the operating surface into different segments which may be felt by a user such that a user, for example, may feel a specific operating region formed by the elevated structure elements without having to gaze at the touchscreen. Improved and simplifying operating options of an operating element therefore also have a positive effect on the safety in traffic.
SUMMARY
[0008] Described below are an operating element for a motor vehicle, and a method for producing a glass panel for a touch-sensitive operating element for a motor vehicle, which facilitate a further increase in the use and operating comfort by the operating element.
[0009] The operating element described below is distinguished by the surface structure having a wave-shaped embodiment and at least one overall touchable part of the surface of the glass panel being embodied with the surface structure. In particular, the whole surface of one side of the glass panel may also be embodied with a surface structure in this case. Here, advantages have been discovered in relation to the usability and, in particular, in relation to the haptics of an operating device that may be obtained not only by macroscopic structures of the surface which may be felt, but also by a surface-covering formation of a wave-shaped surface structure, like, for example, by fine structuring or microstructuring of the surface. In particular, these advantages are obtained by virtue of the touchable surface not having any plane surface sections as a result of this configuration of the surface of the glass panel. As a result, the sliding properties of the surface may be greatly improved because plane glass surfaces have a very high coefficient of static friction in comparison with an uneven, wave-shaped structured surface. During operation, high values of static friction are expressed, in particular, by virtue of a high resistance being felt initially when reversing the direction of a touching operating movement, or else when briefly resting a finger on the surface, until the desired movement may be carried out, which has a disadvantageous effect on the operating comfort of touch-sensitive operating elements such as touchscreens or touchpads and may very easily lead to incorrect operations. By contrast, a wave-shaped structured surface ensures controlled touching movements on the whole touchable surface of the glass panel and therefore simplifies the operation in a particularly advantageous manner. Moreover, advantages in relation to sliding noises may be obtained, since the surface structure also affects the acoustics of such sliding noises. This is because, advantageously, acoustic damping, in particular of high frequencies, may also be brought about by the roughening of the surface caused by the wave-shaped surface structure, and so, for example, unpleasant squeaking and scratching noises, as often occur in the case of plane, smooth glass surfaces, may be avoided. Moreover, the surface provides huge reductions in the visibility of dirt, such as fingerprints, finger grease, etc. This is brought about, firstly, by the whole surface area of a finger not being placed onto the surface as a result of the wave-shaped surface structure and, secondly, predominantly by the undirected light reflection in contrast to smooth surfaces caused by the wave structure. Hence, only a small fraction of dirt on the surface is even visible at a specific viewing angle. This is advantageous, particularly in the case of the embodiment of the operating element as a touchscreen, as this facilitates a significantly improved identifiability of depictions and displays on the touchscreen. However, another effect, which may be obtained, also contributes to the improved identifiability of depictions and displays displayed through the glass panel. The output coupling efficiency of light radiated into the glass panel may be increased by the wave-shaped surface structure, and so, overall, the degree of transmission of light by the glass panel, and hence of depictions of the operating element displayed through the glass panel, may be increased.
[0010] Moreover, glass panels for touch-sensitive operating elements for motor vehicles may be provided with a semi-transparent color coating so as to match the color appearance of the operating element to the color design of the vehicle interior. Now, as a result of the wave structure, the optical properties of the glass panel may be modified in such a way that such a coating is perceived as significantly more intensive, and hence darker, in terms of the color thereof. In turn, this leads to significantly brighter hues, and hence coatings with a higher light transparency, being able to be used as a coating. Hence, this additionally also contributes to a higher degree of transmission of the glass panel and therefore facilitates a more distinct, clearer and, in particular, more light-intensive display of depictions on the operating element. Moreover, improvements in relation to the thermal properties of the glass panel may be obtained. The enlarged surface of the glass panel on account of the wave-shaped surface structure improves the thermal decoupling of the glass panel and the heat of the operating element may thus be dissipated to the surroundings in an improved manner, this being expressed for a user in terms of a significantly cooler operating surface, which is therefore perceived to be more pleasant, and moreover also being accompanied by a positive effect in relation to reduction of too strong heating of the operating device itself. Moreover, the contact surface area of the finger when touching the surface is reduced in relation to a plane surface as a result of the wave-shaped surface structure, and so less friction arises when moving the finger due to the reduced contact surface area and so less frictional heat is transferred to the glass panel as well. This also advantageously allows a reduction in the heating of the glass panel as a result of using the operating element. Hence, significant advantages overall may be obtained in view of the provision of use and operating comfort which is as high as possible.
[0011] In an advantageous configuration, the surface structure is embodied as a microstructure. Thus, the wave-shaped surface structure should therefore be wherein wavelengths of the wave structure which are significantly shorter than 1 mm. What such a fine structure may advantageously bring about is the different surface curvatures caused by the wave-shaped surface structure not being accompanied by an optically perceivable distortion of a depiction displayed through the glass panel. Moreover, a particularly pleasant operating sensation may be provided by such fine structuring and, moreover, the aforementioned advantages may be implemented particularly effectively. Moreover, forming the surface structure by a deep-drawing process particularly advantageously provides the option of also implementing such a fine structure. The formation of the surface structure by a deep-drawing process is particularly advantageous, precisely when forming a glass panel with such fine structuring. In contrast to directly processing the glass surface, the surface structure may, firstly, be generated very sparingly without straining or damaging the glass panel in the process. Secondly, it is also possible to use the discovery here that fine structuring may be implemented in a particularly simple manner by virtue of a corresponding pattern being able to be introduced into a tool part of the deep-drawing tool, e.g. by CNC milling, the pattern transferring to the surface of one side of the glass panel during deep drawing and it being possible to introduce arbitrary fine structures into the tool part, and hence into the glass surface, in this manner.
[0012] A wave-shaped microstructure may advantageously be implemented by virtue of the surface structure having elevations and depressions, a distance between two closest elevations in each case and between two closest depressions in each case respectively measuring between 80 and 130 micrometers. Particularly homogenous haptics and optics of the glass surface may be achieved macroscopically by way of a wave-shaped surface structure at this small length scale and, moreover, it is possible to optimize the properties of the glass surface in relation to sliding capability, sliding noises, visibility of dirt and degree of transmission. In particular, this optimization may only be provided in combination with the surface structure being embodied in such a way that a structure height of the surface structure measures between 5 and 20 micrometers. Here, structure height is understood to mean the height difference between an elevation and a depression of the surface structure in relation to a reference plane extending parallel to the macroscopic extent of the glass surface. Hence, the structure height is smaller than the structure width by one order of magnitude, as a result of which a very small local surface curvature is provided. This renders it possible to avoid the wave-like structure being felt by a user in an uncomfortable and pronounced manner, or even at all. Moreover, such a small structure height may be implemented particularly easily and quickly by deep drawing of the surface, as only a small change in form in the direction perpendicular to the glass panel needs to be obtained. Moreover, the small surface curvature may ensure that there are no optical distortions of depictions displayed through the glass panel as a result of the surface structure. Furthermore, the surface structure per se is not perceivable optically by a user.
[0013] In a further advantageous configuration, the elevations and depressions are respectively formed to be elongate in a direction of longitudinal extent, in particular so that contour lines of the surface structure mainly extend in the same direction. By way of example, this may be implemented by virtue of a pattern of grooves extending in parallel being introduced into the deep-drawing tool part. These grooves may be milled into the tool part in a particularly simple manner, as a result of which the production of such a glass panel with a wave-shaped, in particular periodic microstructure was found to be particularly simple and cost-effective.
[0014] However, it is particularly advantageous if the elevations and depressions are arranged in a grid-shaped manner such that an elevation is surrounded by four depressions, and vice versa, in particular such that contour lines of the surface structure mainly extend along a closed, in particular circular or elliptical, line. From a production engineering point of view, this may likewise be implemented very easily by virtue of further second grooves being milled into the tool part in addition to the first grooves extending in the first direction, the second grooves extending perpendicular, or at least in a range between 85° and 95°, to the first grooves. This results in a crossing pattern of grooves which is transferred to the glass surface during the deep drawing in such a way that the described grid of elevations and depressions emerges. Here, such a cross structure is advantageous, in particular in combination with the aforementioned dimensions of the structure, in that the surface structure hence has no preferred direction. Hence, this allows a particularly high degree of homogeneity to be achieved over the entire surface in terms of the haptic properties, and also in terms of optical, thermal and acoustic properties of the surface.
[0015] The method for producing a glass panel as described herein is distinguished by virtue of the fact that, when a deep-drawing tool is provided, a deep-drawing tool is provided, the first tool part of which has a pattern formed at least by the introduction of a plurality of groove-shaped first depressions. Furthermore, the glass panel is introduced into the deep-drawing tool between the first tool part and the second tool part in such a way that the pattern is transferred as a wave-shaped surface structure on the first surface of the glass panel when deep drawing the glass panel.
[0016] Hence, the method is designed for producing a glass panel of an operating element, in a particularly cost-effective and efficient manner. Here, the pattern may be introduced e.g. by milling, in particular CNC milling, in order to be able to transfer arbitrary small microstructures onto the glass panel in a simple manner. Moreover, this allows the whole surface of one side of the glass panel to be provided with a surface structure in a particularly simple manner. No restrictions are placed on the design of these microstructures in this manner; however, the groove patterns are distinguished by their particularly simple and effective implementation and, in particular, a pattern with a diagonal cross structure with the effect of an additional optimization and homogenization of the haptic, optical, thermal and acoustic properties of the resultant glass panel is therefore particularly advantageous.
[0017] Hence, in an advantageous configuration, the first depressions are introduced into the first tool part extending in a first direction and adjoining one another in a second direction perpendicular to the first direction, a respective first depression having a width in the second direction which is less than 130 micrometers. This allows a simple generation of the microstructure which is ultimately transferred to the glass panel. The widths of such grooves may, in the process, be predetermined in a simple manner by setting the milling parameters such as milling distance and milling radius. Moreover, the resultant structure height of the surface structure of the glass panel may also be predetermined in a simple manner by these parameters.
[0018] It is particularly advantageous if the pattern of the first tool part is additionally formed by introducing a plurality of groove-shaped second depressions extending in a third direction, the third direction extending at an angle not equal to zero, and may be perpendicular or at least 85° to 95°, to the first direction. In other words, a cross structure is therefore introduced into the tool part, which is then reflected in the cross-structure-like arrangement of the elevations and depressions in the glass surface.
[0019] Moreover, the deep drawing may be carried out in such a way that a second surface of the glass panel lying opposite to the first surface has a plane embodiment. Hence, only one side of the glass panel is provided with a wave-shaped surface structure, which is particularly advantageous, in particular in relation to the sensor system for the touch-sensitive operating element, coatings yet to be provided and also in relation to the stability of the glass panel.
[0020] Moreover, the glass panel may still be subject to further processing. In particular, the side of the glass panel with the surface structure may still be subject to an etching process in one, for example final, processing operation. The etching process may, for example, bring about rounding-off of possible edges of the surface structure by etching. This also allows the surface structures to be embodied in a more defined manner and, for example, the depressions of the surface structure to be made deeper and hence the structure height to be increased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Further advantages, features and details will emerge from the following description of exemplary embodiments and the drawings. In the drawings:
[0022] FIG. 1 a is a schematic and magnified perspective view of a glass surface with a wave-shaped microstructure in accordance with one exemplary embodiment;
[0023] FIG. 1 b is a graph of the course of the surface structure in section through the glass panel along the cut line segment P 1 -P 2 in FIG. 1 a ;
[0024] FIG. 2 is a schematic illustration of a diagonal cross structure of a milling pattern for introduction into a tool part of a deep-drawing tool for the purposes of generating a wave-shaped surface structure on a glass panel in accordance with one exemplary embodiment;
[0025] FIG. 3 is a schematic cross section through a groove-shaped milling pattern in a deep-drawing tool part for elucidating the milling distance and milling radius milling parameters; and
[0026] FIG. 4 is a schematic perspective view of a wave-shaped surface structure of a glass panel with elevations and depressions arranged in a grid-shaped manner in accordance with one exemplary embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0028] FIG. 1 a shows a schematic and magnified illustration of a glass surface 10 a with a wave-shaped microstructure 12 a in accordance with one exemplary embodiment and FIG. 1 b shows the illustration of a course of the surface structure 12 a in a section through the glass panel along the cut line S, plotted in FIG. 1 a , between the points P 1 and P 2 . Here, this surface structure 12 a may be generated by a deep-drawing process of the glass panel by virtue of a milling pattern in the form of grooves, which are adjacent to one another, extend in parallel in one direction and have the same shape, being introduced into one of two tool halves of a deep-drawing tool, between which the glass panel is inserted, such that this pattern is transferred as a corresponding negative form onto the glass surface 10 . As a result, it is therefore possible to generate a periodic wave structure 12 a with elevations 14 a and depressions 14 b extending on the glass surface 10 a in the longitudinal direction. Furthermore, in this example, this pattern 12 is translation invariant in terms of the shaping thereof in the direction of longitudinal extent thereof, in this case in the z-direction, at least when seen within a specific tolerance range which, in particular, is smaller than the structure width B itself since such a fine structure 12 a is firstly subject, in terms of the shaping thereof, to random variations and deviations, as may be gathered from the different shapes of the individual waves in FIG. 1 b . Secondly, such variations and differences may also be generated in a targeted manner, e.g. by final etching of the glass surface 10 with the surface structure 12 a , such that the structuring of the glass surface 10 may not be felt, or may be felt significantly less strongly, by a user as a result of such irregularities generated in a targeted manner, causing a more pleasant operating sensation.
[0029] As the scale on the x-axis in FIG. 1 b further shows, the points P 1 and P 2 are spaced apart by 875.5 μm. The wavelengths of this structure, referred to here as structure width B, which are measured from the distance between two depressions 14 b or elevations 14 a in a direction, in this case the x-direction, perpendicular to the direction of longitudinal extent, in this case the z-direction, of the depressions 14 b and elevations 14 a , i.e., in particular, the distances between two respectively adjacent minima and maxima depicted in FIG. 1 b , in this case may lie in the range between 80 μm and 130 μm and measure between 96 μm and 120 μpm in this example. The structure height H, which is likewise subject to certain variations, may be in the range between 5 μm and 20 μm in this case. In principle, it is also possible to realize structures with significantly smaller dimensions or larger dimensions. However, particularly great advantages in relation to haptics, operating sensation, optics, acoustics, the thermal properties of the glass panel, sliding properties on the surface, and hence, overall, the operability and usability of the operating element per se, may be obtained by a microstructure 12 a with these dimensions.
[0030] In order to further optimize these properties and provide these over the whole glass surface 10 in a particularly homogeneous manner, provision may be made of a diagonal cross structure 16 , as depicted schematically in FIG. 2 . In particular, a milling pattern which may be introduced into a tool part of the deep-drawing tool is depicted here in a schematic fashion. This milling pattern has first grooves 18 a extending in a first direction, in this case the x-direction, and second grooves 18 b extending perpendicular to these, in this case in the z-direction, which grooves may have a similar embodiment in terms of the width thereof, which corresponds to the milling distance d (cf. FIG. 3 ), and the depth thereof, which is predeterminable by a specific milling radius R (cf. FIG. 3 ). To this end, FIG. 3 shows an elucidation of these milling parameters on the basis of a schematic illustration of a cross section through a groove-shaped milling pattern 20 in a deep-drawing tool part.
[0031] A milling pattern with a cross structure 16 as depicted in FIG. 2 may generate a surface structure 12 b as depicted in FIG. 4 on a glass surface 10 b by deep drawing and, in particular, by a subsequent etching process. Here, FIG. 4 shows a schematic illustration of a wave-shaped surface structure 12 b of a glass panel with elevations 22 a and depressions 22 b arranged in a grid-shaped manner. Here, in particular, the elevations and depressions are arranged in such a way that four elevations 22 a in each case surround one depression 22 b , and vice versa. The edged depressions 22 b possibly arising during deep drawing as a result of the milling pattern with edges may be rounded-off by a final etching and hence it is possible to generate a particularly edge-free and continuous profile of the wave structure 12 b.
[0032] As a result, it is possible, overall, to provide an operating element, in particular a touchpad or a touchscreen, which has a surface optimized for touch operation in respect of sliding capability, visibility of dirt, sliding noises and sharp and clear identifiability of depictions, such as symbols for various function of the operating element, displayed through the glass panel, and which operating element further is generable in a particularly simple and cost-effective manner.
[0033] A description has been provided with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV , 358 F3d 870, 69 USPQ2d 1865 (Fed. Cir. 2004).
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A surface structure of a glass panel is formed by deep-drawing the surface in the heated state of the glass panel to provide a touch-sensitive operating surface of an operating element for a motor vehicle. The surface structure has a wave-shaped design, and additionally at least one glass panel surface part which is completely touchable is formed with the surface structure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/231,946 filed on Aug. 6, 2009.
FIELD OF INVENTION
[0002] The present invention relates to the field of battery conversion and battery adapters and more particularly to the field of energy saving battery conversion devices.
BACKGROUND
[0003] A D battery is a type of electrochemical cell, the largest in the D, C, AA, and AAA family. Each D cell is cylindrical with electrical contacts at each end; the positive end having a nub or bump. D cells are typically used in high current drain applications, such as in large flashlights, radio receivers and transmitters, portable entertainment systems, products with motors, safety systems, or other applications requiring extended run time. Rechargeable and non rechargeable versions are available. Non rechargeable cells are known as primary cells.
[0004] The D cell was standardized by ANSI as “13A” (alkaline) and is known internationally as LR20 (alkaline). The ANSI-13A is based on carbon-zinc chemistry and is marketed as a Heavy Duty cell. The standard D cell has physical dimensions of 60.5 mm (2.38 in), +/−1.0 mm (0.039 in), in length overall with a diameter of 33.2 mm (1.31 in), +/−1.0 mm (0.039 in).
[0005] There are many problems known in the art associated with the use of D batteries. First, D batteries are heavy and increase the weight of the device, which is inconvenient for devices that are handheld or frequently carried, especially when multiplied batteries are required. For example, the average 1.5V alkaline D battery weighs 148 grams, while the average AA battery weighs 23 grams.
[0006] In addition to being significantly heavier than AA batteries, D batteries are also larger, which makes carrying spare batteries more inconvenient. A D battery measures 34.2 mm in diameter and 61.5 mm in length, while an AA battery measures 14.5 mm in diameter and 50.5 mm in length.
[0007] D batteries are also more expensive than AA and AAA batteries and typically cost 2 to 3 times more than AA and AAA batteries.
[0008] AA batteries have become increasingly efficient with the development of new technologies, such as lithium batteries. For example, lithium batteries can produce twice the voltage of alkaline batteries and have a much longer life. In addition, there has been an increase in the availability of rechargeable battery options. AA and AAA batteries are the most common size rechargeable batteries, and some chargers are capable of charging only AA and AAA batteries. Because the initial cost of purchasing rechargeable batteries and a battery charger are greater than purchasing non-rechargeable batteries, the purchaser will want to purchase batteries and a charger for the size he or she most frequently uses, that is, AA and/or AAA.
[0009] Additionally, D batteries are also more prone to corrosion than smaller batteries. Battery acid is caustic and can injure skin, eyes and mucous membranes; this poses a particular hazard when D batteries are used in toys. The corrosion also damages devices by corroding contacts and wires within the devices, rendering them unusable.
[0010] Moreover, D batteries are often used in devices used infrequently (e.g., flashlights and toys). Even if never taken out of the original package, disposable (or “primary”) batteries can lose 8 to 20 percent of their original charge every year at a temperature of about 20° to 30° C. This is known as the “self discharge” rate and is due to non-current-producing “side” chemical reactions, which occur within the cell even if no load is applied to it. The rate of the side reactions is reduced if the batteries are stored at a low temperature, although some batteries can be damaged by freezing.
[0011] In addition, high or low temperatures may reduce battery performance. This will affect the initial voltage of the battery. For an AA alkaline battery this initial voltage is normally distributed around 1.5 volts.
[0012] AA batteries measure 51 mm in length (50.1 mm without the button terminal) and 13.5 to 14.5 mm in diameter (1.97×0.56 in). Traditional alkaline AA batteries have a mass of roughly 23 g (0.81 oz), Lithium AA batteries have a mass around 15 g (0.5 oz), and rechargeable NiMH batteries have a mass of about 31 g (1.1 oz).
[0013] The nominal output voltage of single-use AA batteries is 1.5 volts, while NiCd and NiMH rechargeable batteries have a nominal voltage of 1.2 V. Specialty batteries based on more unusual chemistries can run at a voltage as high as 1.6 V under load. The voltage of a AA battery is the same as a AAA battery, C cell or D cell. AA batteries, however, provide power for a longer period than AAA batteries, because their larger size allows them to store a greater mass of anode material which is consumed as it does electrical work. C and D cells, being larger 26.2 mm diameter, 50 mm length and 33.2 mm diameter, 60.5 mm length, respectively), last longer still; as a rough guide, the capacity of a battery scales linearly with its mass.
[0014] Primary (non-rechargeable) zinc-carbon AA batteries of 400 to 900 mAh capacity are commonly made using Leclanché cell technology. Zinc-chloride batteries of 1000 to 1500 mAh are often sold as “long life” or “heavy duty.” Alkaline batteries from 1700 mAh to almost 3000 mAh cost a little more, but last proportionally longer.
[0015] Single-use (i.e., non-rechargeable) lithium batteries are also available for high demand devices such as digital cameras, where their high cost is offset by longer running time between battery changes. As of 2008, the only 1.5 V lithium AA batteries, the “Ultimate Lithium,” are manufactured by Energizer, although AA-sized batteries with different nominal voltages are available from others. These should be used only in devices rated for the higher voltage.
[0016] It is desirable to have a battery conversion device that allows AA and/or AAA batteries to be used in devices that require large size batteries.
GLOSSARY
[0017] As used herein, the term “conductive” means a material with movable electric charge capable of serving as a channel for electricity. Conductive materials may include, but are not limited to silver, copper, aluminum, gold, beryllium, and other metals.
[0018] As used herein, the ter “foam” refers to any lightweight cellular material, including but not limited to urethane foams, polyurethane, polyethylene, high density polyethylene, syntactic foams and other solid foams.
[0019] As used herein, the term “large size battery” refers to a cylindrical battery with a diameter greater than 26.2 mm, including but not limited to C and D batteries.
[0020] As used herein, the term “lightweight” means a battery conversion device with a total weight less than 148 g per large size battery the device is replacing.
[0021] As used herein, the term “parallel configuration” refers to batteries connected with like terminals together. When batteries are connected in a parallel configuration, the overall voltage remains the same, but capacity is increased.
[0022] As used herein, the term “permanently attached” means not removable. For example, a permanently attached end cap cannot be removed from a battery conversion device.
[0023] As used herein, the term “selectively attachable” means capable of being removed. For example, a selectively attached end cap can be attached to and removed from a battery conversion device.
[0024] As used herein, the term “series configuration” refers to batteries connected with the positive terminal of one battery joined to the negative terminal of a second battery. When batteries are connected in a series configuration, the overall voltage is increased, while capacity remains the same.
[0025] As used herein, the term “small size battery” means a cylindrical battery with a diameter less than 14.5 mm, including but not limited to AA and AAA batteries.
SUMMARY OF THE INVENTION
[0026] The present invention is a battery conversion device which allows a smaller size standard battery to be used in devices that require a larger size battery. For example, an AA battery can be used to power a device that normally requires a D battery. In various embodiments, the device may be manufactured from recycled or “green” materials. The length of the device may also be adjusted to accommodate any number of batteries used in series by cutting with a scissors or other household instrument. The device is also sufficiently lightweight so that objects may be made buoyant by use of the device. Moreover, the device allows batteries to be easily removed or inserted without removing the device itself.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 a illustrates an exemplary embodiment of a battery conversion device which holds two AA batteries in a series configuration and is adapted to receive the negative pole of the battery against a fixed end cap.
[0028] FIG. 1 b illustrates an exemplary embodiment of a battery conversion device which holds a plurality of AA batteries in a parallel and series configuration.
[0029] FIG. 2 illustrates an exploded view of an exemplary embodiment of a battery conversion device which holds a plurality of AA batteries in a parallel and series configuration.
[0030] FIG. 3 illustrates an exemplary embodiment of a battery conversion device which holds a plurality of batteries in use in a flashlight.
[0031] FIG. 4 illustrates an exemplary embodiment of a battery conversion device in use in an audio device.
[0032] FIG. 5 a illustrates a side perspective view of the dimensions and configuration of an exemplary embodiment of a machined, punched end cap for a battery conversation device.
[0033] FIG. 5 b illustrates a top perspective view of the dimensions and configuration of an exemplary embodiment of a machined, punched end cap for a battery conversion device.
[0034] FIG. 6 a illustrates a side perspective view of the dimensions and configuration of an exemplary embodiment of an assembled end cap for a battery conversion device.
[0035] FIG. 6 b illustrates a top perspective view of the dimensions and configuration of an exemplary embodiment of an assembled end cap for a battery conversion device.
DETAILED DESCRIPTION OF INVENTION
[0036] For the purpose of promoting an understanding of the present invention, references are made in the text to exemplary embodiments of a battery conversion device, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate, but functionally equivalent materials, components, sizes, and designs may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.
[0037] It should be understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural element.
[0038] Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related.
[0039] FIG. 1 a illustrates an exemplary embodiment of battery conversion device 100 which holds two AA batteries 50 a , 50 b in a series configuration. Substantially solid foam tube 10 has an outer diameter which corresponds to the diameter of a battery. In the center of substantially solid foam tube 10 is aperture 20 . In the embodiment shown, aperture 20 is slightly larger than the diameter of an AA battery to allow for easy removal of the batteries without having to remove battery conversion device 100 from the device in which it is placed.
[0040] In the embodiment shown, substantially solid foam tube 10 is comprised of polyethylene, a lightweight, recyclable material which is resistant to corrosion. In the embodiment shown, substantially solid foam tube 10 has no seams. In other embodiments, substantially solid foam tube 10 may have one or more seams and/or be made of one or more modular units.
[0041] At one end of substantially solid foam tube 10 is end cap 30 a which will be permanently attached to substantially solid foam tube 10 . Also visible in FIG. 1 a , is optional end cap 30 b for use when positive end of battery is against end cap 30 a . In the embodiment shown, end cap 30 b is identical to end cap 30 a and is selectively attachable to substantially solid foam tube 10 . End cap 30 a is provided loose and may be placed so that it rests on the other end of substantially solid foam tube 10 .
[0042] In the embodiment shown, end cap 30 a will be permanently attached to solid foam tube 10 using adhesive. In various embodiments, end cap 30 a may be permanently attached to solid foam tube 10 using another attachment means known in the art.
[0043] In the embodiment shown, end caps 30 a , 30 b are made of zinc coated steel. In other embodiments, end caps 30 a , 30 b are made of another type of metal or plated metal including, but not limited to steel coated with a material other than zinc (e.g., chrome), silver, copper, aluminum, gold, beryllium, or any other material which resists corrosion and has a similar conductivity.
[0044] Attached to end caps 30 a , 30 b are protuberances 35 a , 35 b which are affixed to one side of end caps 30 a , 30 b . In the embodiment shown, end cap 30 a will be attached to substantially solid foam tube 10 so that protuberance 35 a faces toward the center of substantially solid foam tube 10 and AA batteries 50 a , 50 b . In the embodiment shown, protuberance 35 a makes up the difference in length between AA batteries 50 a , 50 b and D batteries.
[0045] In the embodiment shown, protuberances 35 a , 35 b have a height of 19.05 mm (75 inches). On the opposite side of end caps 30 a , 30 b is a 3.175 mm (0.125 inch) protuberance (See FIGS. 5 a and 6 a ). In the embodiment shown, end caps 30 a , 30 b are manufactured by machining and punching. In various other embodiments, end caps 30 a , 30 b may be manufactured by stamping, assembling and welding of multiple components, or other functionally equivalent process.
[0046] In the embodiment shown, protuberances 35 a , 35 b are made of a metal which is conductive. In other embodiments, more than one end cap and/or protuberance may be used.
[0047] FIG. 1 b illustrates an exemplary embodiment of battery conversion device 100 which holds a plurality of AA batteries in a parallel and series configuration. Substantially solid foam tube 10 has an outer diameter which corresponds to the diameter of a D battery. Substantially solid foam tube 10 has two apertures 20 a , 20 b . In the embodiment shown, apertures 20 a , 20 b are connected. In the embodiment shown, apertures 20 a , 20 b are slightly larger than the diameter of an AA battery to allow for easy removal of the batteries without having to remove battery conversion device 100 in which it is placed.
[0048] In the embodiment shown, substantially solid foam tube 10 is comprised of polyethylene, a lightweight, recyclable material which is resistant to corrosion. In the embodiment shown, substantially solid foam tube 10 has no seams. In other embodiments, substantially solid foam tube 10 may have one or more seams and/or be made of one or more modular units.
[0049] At the ends of substantially solid foam tube 10 are end caps 30 b , 30 c which will be attached to the ends of substantially solid foam tube 10 . In the embodiment shown, end caps 30 b , 30 c are made of coated steel. In other embodiments, end caps 30 b , 30 c are made of another type of metal which resists corrosion and has a similar conductivity (e.g., aluminum). In the embodiment shown, end cap 30 c will be adhesively attached to one end of substantially solid foam tube 10 while end cap 30 b is provided loose and will rest on the opposite end of substantially solid foam tube 10 .
[0050] In the embodiment shown, end cap 30 b is selectively removable so that the foam tube can be cut to any size or aligned with other substantially solid foam tubes. In various embodiments, end cap 30 c , which will be permanently attached, may also be removed from substantially solid foam tube 10 by prying or cutting off. Substantially solid foam tube 10 may be cut with a scissors or other household object to accommodate more or fewer batteries aligned in a series configuration. For example, end cap 30 c may be removed for use in certain four battery flashlights.
[0051] In the embodiment shown, end cap 30 c will be attached to substantially solid foam tube 10 so that protuberances 35 c , 35 d face toward the center of substantially solid, foam tube 10 . In the embodiment shown, protuberances 35 b , 35 c make up the difference in length between AA batteries and D batteries. In the embodiment shown, end cap 30 b will be placed over the end of substantially solid foam tube 10 so that protuberances 35 b extends into substantially solid foam tube 10 making contact between the batteries. In other embodiments, end cap 30 b may be positioned so that protuberance 35 b extends away from substantially solid foam tube 10 and the batteries. How end cap 30 b is positioned depends upon the desired configuration of the batteries (e.g., three-battery or four-battery flashlights, four single batteries with alternating poles).
[0052] FIG. 2 illustrates an exploded view of an exemplary embodiment of battery conversion device 100 which holds four batteries 50 a , 50 b , 50 c , 50 d in a parallel and series configuration. Batteries 50 a , 50 c are in a series configuration and batteries 50 b , 50 d are in a series configuration. Substantially solid foam tube 10 has an outer diameter which corresponds to the diameter of a D battery. Substantially solid foam tube 10 has two apertures 20 a , 20 b which each hold two batteries in a series configuration. In the embodiment shown, apertures 20 a , 20 b are slightly larger than the diameter of an AA battery to allow for easy removal of the batteries without having to remove battery conversion device 100 .
[0053] In the embodiment shown, substantially solid foam tube 10 is comprised of polyethylene, a lightweight, recyclable material which is resistant to corrosion. In the embodiment shown, substantially solid foam tube 10 has no seams. In other embodiments, substantially solid foam tube 10 may have one or more seams and/or be made of one or more modular units. In addition, substantially solid foam tube 10 may be sized to correspond to the diameter of a battery other than a D battery, such as a C battery.
[0054] At the ends of substantially solid foam tube 10 are end caps 30 b , 30 c . In the embodiment shown, end cap 30 c is adhesively attached to one end of substantially solid foam tube 10 while end cap 30 b is provided loose and rests on the opposite end of substantially solid foam tube 10 .
[0055] In the embodiment shown, end cap 30 c is attached to substantially solid foam tube 10 so that protuberances 35 c , 35 d face toward the center of substantially solid foam tube 10 and AA batteries 50 a , 50 b , 50 c , 50 d . In the embodiment shown, end cap 30 b is placed over the end of substantially solid foam tube 10 so that protuberance 35 b faces toward the center of substantially solid foam tube 10 and AA batteries 50 a , 50 b - 50 c , 50 d . In the embodiment shown, end cap 30 b is necessary to complete battery contact.
[0056] FIG. 3 illustrates an exemplary embodiment of battery conversion device 100 which holds two AA batteries 50 a , 50 b in a series configuration and is in use in flashlight 65 . Substantially solid foam tube 10 has an outer diameter which corresponds to the diameter of a D battery. In the center of substantially solid foam tube 10 is aperture 20 . In the embodiment shown, aperture 20 is slightly larger than the diameter of an AA battery to allow for easy removal of the batteries without having to remove battery conversion device 100 . In the embodiment shown, flashlight 65 has a removable lamp end.
[0057] In the embodiment shown, substantially solid foam tube 10 is comprised of polyethylene, a lightweight, recyclable material which is resistant to corrosion. In the embodiment shown, substantially solid foam tube 10 has no seams. In other embodiments, substantially solid foam tube 10 may have one or more seams and/or be made of one or more modular units. In addition, substantially solid foam tube 10 may be sized to correspond to the diameter of a battery other than a D battery, such as a C battery.
[0058] At the end of substantially solid foam tube 10 is end cap 30 a which is permanently attached to the end of substantially solid foam tube 10 . In the embodiment shown, end cap 30 b is not used; however, when battery conversion device 100 is used in various devices, end cap 30 b may be placed on the top of substantially solid foam tube 10 . End cap 30 b would be held into place by the pressure of the device when closed. End cap 30 b provides a contact for the spring, but may not be necessary if the spring contacts the negative end of the battery directly.
[0059] In the embodiment shown, protuberance 35 a faces toward the center of substantially solid foam tube 10 . In other embodiments, more than one end cap and/or protuberance may be used.
[0060] In the embodiment shown, battery conversion device 100 is inside flashlight 65 . To install battery conversion device 100 in flashlight 65 , lamp assembly 55 and D batteries are removed. Battery conversion device 100 is inserted into flashlight 65 with end having end cap 30 a inserted first. AA batteries 50 a , 50 b are inserted into aperture 20 with “+” end facing outward. Lamp assembly 55 is then replaced.
[0061] FIG. 4 illustrates an exemplary embodiment of battery conversion device 100 in use in audio device 60 .
[0062] FIG. 5 a illustrates a side perspective view of the dimensions and configuration of an exemplary embodiment of end cap 30 for battery conversation device 100 . In the embodiment shown, protuberance 35 has a height of 19.05 mm (0.75 inches). In various embodiments, the width of protuberance 35 will vary depending on its use. On the opposite side of end cap 30 is a 3,175 mm (0.125 inch) protuberance.
[0063] In the embodiment shown in FIGS. 5 a and 5 b , end cap 30 is machined and punched. In various other embodiments, end cap 30 is manufactured by stamping, assembling and welding together, or by another functionally equivalent process. In the embodiment shown, protuberance 35 is made of a metal which is conductive. In other embodiments, more than one end cap and/or protuberance may be used.
[0064] FIG. 5 b illustrates a top perspective view of the dimensions and configuration of an exemplary embodiment of end cap 30 for battery conversion device 100 . In the embodiment shown, end cap 30 has a diameter of 31.75 mm (1¼ inches) and protuberance 35 has a width of 6.35 mm (¼ inch).
[0065] FIG. 6 a illustrates a side perspective view of the dimensions and configuration of a second exemplary embodiment of end cap 30 and protuberance 35 . In the embodiment shown in FIGS. 6 a and 6 b , end cap 30 is assembled by sliding a tubular component having a diameter of 4.7625 mm ( 3/16 inch) into a 4.7625 mm ( 3/16 inch) hole in the center of a metal component. The tubular component is then tack welded to end cap 30 forming protuberance 35 . Tack welding results in a ⅛ inch protuberance on the side of end cap opposite protuberance 35 .
[0066] FIG. 6 b illustrates a top perspective view of the dimensions and configuration of a second exemplary embodiment of end cap 30 . In the embodiment shown, end cap 30 has a diameter of 37.25 mm (1¼ inches) and protuberance 35 has a diameter of 4.7625 mm ( 3/16 inch).
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The present invention is an apparatus and method which allows a smaller size battery to be adapted for use in a device which uses larger size batteries, thus saving energy costs. The apparatus can be mass produced from recycled in-expensive materials and is far less costly to manufacture than existing battery conversion devices.
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FIELD OF THE INVENTION
[0001] The invention relates to a CVT belt comprising a multi-ribbed belt with transversely attached clips.
BACKGROUND OF THE INVENTION
[0002] Belts for continuously variable transmissions (CVT) generally comprise a plurality of members mounted transverse to an endless member. The belts must be configured in order for them to be “pushed” as well as “pulled” through a CVT pulley. That is, they must be capable of withstanding both compressive and tensile forces along a longitudinal axis of an endless member.
[0003] The endless member may comprise metal or elastomeric. In the prior art, the endless member generally comprises a form particularly suited to a CVT belt and as such has no industrial applicability other than in a CVT belt. This has the effect of making each CVT endless member costlier than other more readily available belt, such as multi-ribbed power transmission belt.
[0004] Another prior art belt includes a CVT belt comprising a core multi-ribbed belt to which transversely mounted clips are attached. The multi-ribbed belt is of a type that is otherwise useful in power transmission systems when not incorporated in a CVT belt.
[0005] Representative of the art is U.S. Pat. No. 6,306,055 to Serkh (2001) which discloses a core multi-ribbed belt having a plurality of clips arranged about said multi-ribbed belt.
[0006] The prior art multi-ribbed type belt also includes elastomeric bands which hold together the assembled belt. The belt is then engaged with a U-shaped slot between the elastomeric bands in each clip. Engaging the belt in such a manner renders the design susceptible to centripetal forces caused by operation of a system which includes the belt. Further, during operation each ‘arm’ of the U-shaped clip is subject to a bending moment as it moves between CVT pulleys. Such a bending condition represents a potential failure point.
[0007] What is needed is a belt comprising a multi-ribbed belt engaged with a slot disposed in transversely mounted clips. What is needed is a belt comprising two multi-ribbed belts each belt engaged with an opposing slot disposed in transversely mounted clips. The present invention meets these needs.
SUMMARY OF THE INVENTION
[0008] The primary aspect of the invention is to provide a belt comprising a multi-ribbed belt engaged with a slot disposed in transversely mounted clips.
[0009] Another aspect of the invention is to provide a belt comprising two multi-ribbed belts each belt engaged with an opposing slot disposed in transversely mounted clips.
[0010] Other aspects of the invention will be pointed out or made obvious by the following description of the invention and the accompanying drawings.
[0011] The invention comprises a CVT belt having two multi-ribbed belts. Each belt is engaged in an opposing slot in a transversely mounted clip. Each belt is retained in each slot by a flat belt which is sandwiched into each slot with the multi-ribbed belt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a view of a prior art CVT belt clip.
[0013] [0013]FIG. 2 is a view of a prior art CVT belt clip.
[0014] [0014]FIG. 3 front view of a clip of the inventive belt.
[0015] [0015]FIG. 4 is a side view of a portion of the inventive belt.
[0016] [0016]FIG. 5 is a side view of the inventive belt.
[0017] [0017]FIG. 6 is a side view of a step in the assembly of the inventive belt.
[0018] [0018]FIG. 7 is a side view of a step in the assembly of the inventive belt.
[0019] [0019]FIG. 7A is a side view to the view depicted in FIG. 7.
[0020] [0020]FIG. 8 is a side view of a step in the assembly of the inventive belt.
[0021] [0021]FIG. 8A is a side view to the view depicted in FIG. 8.
[0022] [0022]FIG. 9 is a perspective view of a clip in the inventive belt.
[0023] [0023]FIG. 9 a is a side view of a portion of the inventive belt depicted in FIG. 9.
[0024] [0024]FIG. 10 is a side view of a portion of the inventive belt.
[0025] [0025]FIG. 11 is a side view of a step in the assembly of the inventive belt.
DETAILED DESCRIPTION OF THE INVENTION
[0026] [0026]FIG. 1 is a view of a prior art CVT belt clip. Clip C 1 is engaged with endless members E 1 and E 2 . Endless members E 1 and E 2 comprise metallic material. Each member E 1 and E 2 comprise a series of parallel planes.
[0027] [0027]FIG. 2 is a view of a prior art CVT belt clip. Clip C 2 is engaged with endless members E 3 and E 4 . Endless members E 3 and E 4 comprise elastomeric material having tensile bands T 1 and T 2 embedded therein. Clips 2 may comprise either metallic or non-metallic material. Members E 3 and E 4 do not comprise a multi-ribbed profile.
[0028] [0028]FIG. 3 front view of a clip of the inventive belt. The inventive belt comprises a plurality of clips 2 . Each clip 2 is substantially planar and generally describes an “I” shape. The “I” shape of clip 2 assures that compressive forces created as the belt and clips pass through CVT pulleys will remain compressive and will not otherwise subject the clip to a bending moment. In the inventive belt a plurality of clips 2 are arranged in an adjacent parallel manner, see FIG. 5.
[0029] Tensile members 12 , 14 each comprise a multi-ribbed belt. The ribs extend along a longitudinal axis of the belt. Tensile members 12 , 14 also comprise tensile bands 40 , 41 embedded therein. Tensile bands 40 , 41 may comprise aramid, nylon 4.6, nylon 6.6, polyester, any combination thereof and their equivalents.
[0030] Spacer bands 8 , 10 each engage clip 2 in slots 44 , 46 . A lower portion of each slot 44 , 46 describe a multi-ribbed profile 48 , 50 for cooperative engagement with a multi-ribbed belt 12 , 14 respectively.
[0031] [0031]FIG. 4 is a side view of a portion of the inventive belt. Clips 2 each comprise arms 22 , 24 . Spacers 30 fill a space between clips 2 to assure proper engagement of the clip with members 10 (not shown) and 12 .
[0032] [0032]FIG. 5 is a side view of the inventive belt. Belt 500 comprises a plurality of clips 2 engaged with tensile members 12 , 14 to form the endless inventive CVT belt.
[0033] [0033]FIG. 6 is a side view of a step in the assembly of the inventive belt. A length of an inventive belt will be determined by the number of clips as well as by an overall length of the tensile members 12 , 14 . In order to install the tensile bands 12 , 14 in a belt having a predetermined number of clips, each tensile band must be stretched slightly. For example, in the case of a belt shaving a length of 720-740 mm, tensile bands 12 , 14 will be stretched 2-3 mm radially. This means a stretch in belt length of 12-19 mm, which represents a stretch in the range of 1.6% to 2.6%. Belts having an elastic modulus in the range of approximately 1500 to 3000 N/mm are well suited for being stretched as described herein.
[0034] To assemble a belt, a sufficient number of clips are arranged in a final constructed from and then each tensile member 12 , 14 is stretched and inserted into each slot 44 , 46 .
[0035] Another method of assembly also comprises beginning with a predetermined number of clips 2 from belt 50 initially arranged in an endless form. However, in this method the initial assembly begins with a number of spacers 30 , see FIG. 4, removed from the belt. For example, if a spacer 30 thickness is 1 mm, then 18 to 21 spacers are initially omitted. This results in the belt initially being 18-21 mm shorter. This allows sufficient clearance for tensile bands 12 , 14 to be inserted into slots 44 , 46 . Once tensile members 12 , 14 are in place, they are first disposed in an upper portion of each slot 44 , 46 , see FIGS. 7 and 7A. A gap in each of the remaining clips is then made to accommodate addition of the remaining 18 to 21 clips. This has the effect of increasing a belt radius, thereby disposing tensile members 12 , 14 to a lower portion of each slot 44 , 46 , thereby preventing a transverse movement between clip 2 and the tensile members 12 , 14 , see FIGS. 8 and 8A.
[0036] Once the remaining spacers are in place, a last compensating spacer 30 is inserted between two remaining clips 2 in order to remove any remaining clearance between each clip, see FIG. 9, FIG. 9 a and FIG. 10. A spacer 30 locks each clip in place in the assembled belt. Spacers 30 cause a tight fit between each clip thereby enabling the desired pushing effect as the inventive belt operates.
[0037] Once tensile members 12 , 14 are in place in slot 44 , 46 , then each of members 8 , 10 are inserted into a respective slot space 60 , 62 . Members 8 , 10 comprise elastomeric material such as natural rubbers, synthetic rubbers or any equivalent or combination thereof. A combined thickness T of member 8 , 10 and member 12 , 14 is greater than a width W of slot 44 , 46 creating a compression of members 8 , 10 and members 12 , 14 . This assures a proper engagement of member 12 , 14 with a slot surface 48 , 50 preventing a transverse movement of a tensile member relative to a clip.
[0038] [0038]FIG. 7 is a side view of a step in the assembly of the inventive belt.
[0039] [0039]FIG. 7A is a side view to the view depicted in FIG. 7.
[0040] [0040]FIG. 8 is a side view of a step in the assembly of the inventive belt. Members 12 , 14 are shown engaged with the multi-ribbed profile 48 , 50 in the lower portion of clots 44 , 46 of clip 2 .
[0041] [0041]FIG. 8A is a side view to the view depicted in FIG. 8.
[0042] [0042]FIG. 9 is a perspective view of a clip in the inventive belt. Spacer 30 comprises a low friction material in order to facilitate a movement between adjacent clips 2 . Arms 22 , 24 each comprise inclined surfaces 54 , 56 , for engagement with a pulley or other driving surface (not shown) . Arms 26 , 28 each comprise inclined surfaces 58 , 59 , for engagement with a pulley or other driving surface (not shown). Spacer 30 is inserted between each clip 2 after members 12 , 14 have been installed.
[0043] [0043]FIG. 9 a is a side view of a portion of the inventive belt depicted in FIG. 9.
[0044] [0044]FIG. 10 is a side view of a portion of the inventive belt. End 36 is bent during assembly in order to clamp spacer 30 onto a clip 2 .
[0045] [0045]FIG. 11 is a side view of a step in the assembly of the inventive belt. Once members 12 , 14 are in place, members 8 , 10 are stretched slightly and transversely moved into slots 60 , 62 . Members 8 , 10 comprise elastomeric material such as natural or synthetic rubbers, any combination thereof and their equivalents.
[0046] Although a form of the invention has been described herein, it will be obvious to those skilled in the art that variations may be made in the construction and relation of parts without departing from the spirit and scope of the invention described herein.
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The invention comprises a CVT belt having two multi-ribbed belts. Each belt is engaged in an opposing slot in a transversely mounted clip. Each belt is retained in each slot by a flat belt which is sandwiched into each slot with the multi-ribbed belt.
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CROSS-REFERENCE TO A RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 61/146,883, filed Jan. 23, 2009, the disclosure of which is hereby incorporated by reference in its entirety, including all figures, tables and drawings.
BACKGROUND OF THE INVENTION
[0002] Worldwide more than 70 metric tons of ground calcium carbonate (GCC) is produced per year, where nearly 80% is used as filler in paper, plastics paints, sealants and adhesives. Much of the growth in capacity has been devoted to producing grades of GCC for paper coating. Paper accounts for around 38% of world demand and plastics account for an additional 20% of demand. Papermakers commonly use ground limestone products that are “fine-ground” or “ultrafine-ground” where 60% to 90% of the equivalent particle size is smaller than 2 μm based on their sedimentation rates.
[0003] GCC plants are typically sited near sources of limestone, marble or chalk and the product is stored and shipped to the user as a slurry in water. To minimize cost of transportation and drying, high solids slurries are formed, and the industries goal is to have the highest loading of GCC with the lowest possible viscosity. Although GCC is generally non-hazardous, unstirred tanks and pipes containing stagnant GCC slurry can lead to sites of dense sedimentation that are very difficult to resuspend. In some cases the thickening of the slurry can be so severe that it can be difficult, if not impossible, to empty tank trucks or tank rail cars by gravity discharge when the slurry stands for more than about eight hours. This problem can be very pronounced with finely ground high solids GCC slurries bleached with reductive bleaching agents.
[0004] To lessen the problem of sedimentation, GCC slurries include a dispersant, usually at a level of about 1% or less as the cost of the dispersant can be prohibitive for many uses of GCC. Common dispersants are low molecular weight acrylic polymers and copolymers with different molecular weights, molecular weight distributions and degree of neutralization. However, even with state of the art acrylic homopolymer anionic dispersants of molecular weight less than 4,000, unstirred slurry can more than double its viscosity when aged for a single week.
[0005] In spite of significant effort in development of dispersants, cost effective anti-aging methods and formulations are needed to expand the use of GCC to many application and to improve the cost and reliability of fine GCC slurries.
BRIEF SUMMARY OF THE INVENTION
[0006] An embodiment of the invention is directed to a method to inhibit viscosity increases of high solids slurries upon aging. The method involves combining a particulate solid with a solution containing water, at least one dispersant and at least one water structure breaker. The water structuring around the particulate solid is inhibited due to the addition of the water structure breaker. In one embodiment the particulate solid is calcium carbonate, for example ground calcium carbonate. A slurry can be prepared to have 70 to 85 percent or more particulate solid by weight. Common dispersants, such as sodium salts of an acrylate polymers or copolymers can be use at levels less than 1 percent, for example 0.1 to 2 percent. The water structure breaker can be a di- tri- or tetra-alcohol, low molecular weight polyethylene glycols, or salts such as K 2 CO 3 , Cs 2 CO 3 , Rb 2 CO 3 , KCl, RbCl, CsCl, KBr, RbBr, CsBr, KI, RbI, and CsI. For example, ethylene glycol can be used at levels of 0.1 to about 5 percent of the slurry.
[0007] Another embodiment of the invention is directed to the stabilized slurry comprising the components combined in the above method. Hence, a stabilized slurry contains water, at least one particulate solid, at least one dispersant, and at least one water structure breaker. Such a slurry is very stable for extended periods of time relative to an equivalent slurry that omits the water structure breaker.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a composite trace of overlaid FTIR spectra of the O-D band of deuterated water for a 75 weight percent GCC slurry with a poly(acrylic acid) sodium salt (PAAS) dispersant aged for less than 1, 25, and 51 hours with a spectrum of a PAAS free GCC slurry in D 2 O.
[0009] FIG. 2 is a composite trace of overlaid FTIR spectra of the O-D band of water for a 75 weight percent GCC slurry containing ethylene glycol immediately after preparing the slurry and after aging for 64 hours.
[0010] FIG. 3 shows plots of 75 weight percent slurries of GCC with a dispersant with and without added ethylene glycol after 48 hours as a function of shear rate.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The stabilization of high solids slurries is carried out by the stabilization of the liquid aqueous phase structure. Traditionally, the focus has been on the stabilization of the interface between the solid particle and the aqueous phase. It has been discovered that by inclusion of an agent to inhibit changes in the aqueous solution's structure, the slurry is stable and does not undergo the adverse changes with aging that complicate the use of the slurries. In an embodiment of the invention, an aqueous suspension of ground calcium carbonate (GCC) is stabilized by the inclusion of a small amount of a dispersant and a small amount of a water structure breaker, which stabilizes the structure of the aqueous phase, as can be monitored by infrared spectroscopy. For example, in one embodiment of the invention, the dispersant can be the sodium salt of polyacrylic acid and the water structure breaker can be ethylene glycol. The inclusion of the water structure breaker has been found to stabilize GCC slurries against the common symptoms of aging, particularly an increase in viscosity of the slurry. In other embodiments, the particulate solid can be any solid that can be dispersed with an increase in entropy due to the release of structured water molecules from the solid surface. The particulate solid can be precipitated calcium carbonate, kaolin, titanium dioxide, silica, other effectively water insoluble salts, or any combination thereof. In one embodiment, the particulate solid can be precipitated calcium carbonate (PCC) or a mixture of PCC with GCC.
[0012] The GCC or other solid particle can have a significant fraction of the particles that are less than 2 μm in diameter, for example, the GCC can have 90% or more of the particles being less than 2 μm in diameter. The particles can be loaded in excess of 70 weight percent of the slurry and can be in excess of 80, 85, or even 90 weight percent of the slurry although lower levels of particulates can be used.
[0013] The dispersant that can be included in the slurry can be poly-salts of polyacrylate or polymethacrylate comprising polymers or copolymers. Polyacrylates can have molecular weights of about 1,000 to 20,000 or even to 100,000. The salts can be those with alkali metal cations or ammonium cations. Other polyelectrolyte dispersants that can be used include, for example, salts of polymaleic acid or polyaspartic acid comprising polymers and copolymers. The dispersant can be a mixture of dispersants. The dispersant can be used at loadings of less than two percent by weight. The dispersant can be used at loadings of less than one percent by weight.
[0014] By the inclusion of ethylene glycol, or other chemicals that can inhibit the change of the water structure, the slurry is stabilized. Other water structure breakers can be used in place of, or in addition to, ethylene glycol as the agent to inhibit changes in the aqueous solution structure include propylene glycol and other water soluble di- tri- or tetra-alcohols. Low molecular weight polyethylene glycols can be used as water structure breakers. Salts such as K 2 CO 3 , Cs 2 CO 3 , Rb 2 CO 3 , KCl, RbCl, CsCl, KBr, RbBr, CsBr, KI, RbI, and CsI can be used as water structure breakers. Combinations of various water structure breakers can be used as the water structure breaker. The agent for inhibiting the structuring of the water, such as ethylene glycol, can be included at five percent or less and although higher levels of ethylene glycol or other water structure breakers to inhibit changes in the aqueous solution structure can be used, the lower levels are generally sufficient for stabilization. For example, the agent can be used at 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5, 2, 2.5, 3, 3.5, 4, 4.5 or 5% by weight.
MATERIALS AND METHODS
[0015] Attenuated Total Reflectance Fourier Transform Infrared Spectroscopy (ATR-FTIR) was carried out to demonstrate that the aging of a GCC suspension is accompanied by a change in the structure of water solutions and that these changes can be inhibited by a dispersant and a water structure breaker. The dispersant was a commercial sodium salt of polyacrylic acid, KK-7-44 by Kemira Chemicals, Inc, Kennesaw, Ga., used at 1 weight percent. To perform this analysis, deuterated water (D 2 O) was used to prepare an aqueous solution and the bands from 2200 to 2700 cm −1 were observed for the slurries prepared with the deuterated water over time.
[0016] FIG. 1 displays overlaid FTIR spectra, where one spectrum is that of a relatively freshly prepared, <1 hour old, 75% slurry of GCC was scanned. The slurry was prepared using the dispersant, but without the water structure breaker. Other overlaid spectra were taken after 25 and 51 hours. These spectra were compared with those of a slurry of GCC in D 2 O prepared without a dispersant, where the band from the water of the solid-like hydrated CaCO 3 aggregate at about 2380 cm −1 was clearly seen. In a freshly prepared slurry, a strong fluid-like associated D 2 O band at 2500 cm −1 can he readily seen. As the slurry aged, the band at 2500 cm −1 diminishes in intensity and the solid-like association band at 2380 cm −1 builds. This spectral change is accompanied by a significant viscosity increase.
[0017] FIG. 2 shows a pair of FTIR spectra for a 75 weight percent GCC slurry that contains 0.5 M, about 3 weight percent, ethylene glycol and 1 weight percent KK-7-44 for the freshly prepared and for the 64 hour aged slurry. The two spectra were nearly identical with no indication of the increase of the signal for the solid-like association. The pair of spectra was nearly superimposable with that of the freshly prepared slurry of FIG. 1 and the viscosity did not increase over the 64 hour period.
[0018] FIG. 3 shows the viscosity of 75 weight percent slurries of GCC with the dispersant at 1 weight percent with and without ethylene glycol after 48 hours as a function of shear rate. The viscosity of the slurry with ethylene glycol was approximately half that of the viscosity for the slurry without ethylene glycol over all shear rates.
[0019] Hence, adverse effects associated with aging of high solids slurries can be inhibited by the inclusion of an agent that inhibits structural changes of the aqueous solution. By inhibiting the aqueous solutions structural changes, slurries can be stable for a long period of time.
[0020] All patents, patent applications, provisional applications, and publications referred to or cited herein, supra or infra, are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification.
[0021] It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application.
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Water structure breakers are included with dispersants in high solids aqueous slurries to stabilize the aqueous solution structure over a long period of time. The incorporation of a dispersant and a water structure breaker effectively inhibits the viscosity increase typically associated with high solid slurries, such as ground calcium carbonate (GCC) slurries, The inclusion of a small amount of water structure breaker inhibits change in the solution structure over that of a typical slurry lacking the water structure breaker, allowing longer storage and distribution periods for such slurries.
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BACKGROUND OF THE INVENTION
The present invention relates to an in-vivo tomographic imaging system utilizing a nuclear magnetic resonance phenomenon, and more particularly to a phase distortion correcting method and apparatus suitable for attainment of phase distortion correction with high precision by use of only a tomographic or cross-sectional image.
In an inversion recovery (IR) method which is one of the magnetic resonance (MR) imaging methods, an image is acquired in which information concerning a parameter of an object called a longitudinal relaxation time is emphasized. A detection signal acquired by use of the IR method involves phase information. Therefore, this method has a problem in that the influence of phase distortion appears on a complex image reconstruction.
In a Dixon method of separating water and fat images from each other by use of chemical shift information, a difference in resonance frequency between water and fat is used to deliberately provide a phase difference between water and fat, thereby separating water and fat from each other. Since this method also uses phase information, it is affected by phase distortion.
Angiography for extracting the shape of blood vessels and blood flow measurement of measuring the flow rate of blood utilize the fact that the phase of a moving portion changes on a reconstructed image. Therefore, there is a problem that the presence of any phase distortion makes it difficult to correctly determine the shape of blood vessels or the flow rate of blood.
The conventional approaches of correcting phase distortion in a reconstructed complex image acquired in the above-mentioned IR method, Dixon method, blood flow measurement and angiography involve two methods, e.g. a method (1) in which phase distortion is calculated and corrected by preliminarily imaging a uniform object called a phantom in the same procedure as a procedure for acquiring a tomographic image, as disclosed by JP-A-61-194338, and a method (2) in which phase distortion is estimated and corrected through repetitive calculation (see "A Spatially Non-linear Phase Correction for MR Angiography", Sixth Annual Meeting and Exhibition, p. 29, 1987).
The method (1) has a problem in that the phase distortion generally changes depending on the time, the imaging means and the position of a tomographic image acquired, and therefore the imaging of the phantom has to be carried out frequently, thereby requiring a complicated operation and a long operation time. In the method (2), the phase distortion is corrected by use of only a tomographic image. However, since the phase distortion is estimated by use of the repetitive calculation, a large amount of calculation and hence a long time are required for estimation of the phase distortion. Therefore, the method (2) has a problem that the precision of correction is deteriorated since the optimum estimation value cannot always be determined in the case where the calculation is discontinued after a finite number of repetitions.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the above-mentioned problems, thereby providing a method and apparatus in which phase distortion can be corrected in a short time and with high precision by use of only data of a tomographic image acquired.
In the present invention, the problem in the above-mentioned conventional correction method (2) is solved as follows. First, the reconstructed image consisting of complex valved pixels is partitioned into a plurality of one or more partial regions (hereinafter referred to as block) each having any given shape although generally rectangular, is and a calculated size and then non-linear phase distortion is estimated and corrected for every block. The division of the complex image into blocks reduces large non-linear phase distortion of the whole complex image, thereby improving the precision of correction.
A processing of phase distortion correction for each block is derived from Fourier-transforming image data in that block to determine the coordinates of a peak position as well as a phase rotation angle at the peak position coordinates. The determined values are used to approximately correct phase distortion in the block. Thereby, the phase distortion which assumes apparently discontinuous values in the block can be regarded as being phase distortion which is continuous within a range from +π to -π. The remaining phase distortion is estimated and corrected through the least square method or the like. Thereafter, the discontinuity of phase distortion between blocks is corrected. Since the complex image is constructed in itself by only a real part if no phase distortion is present, the values of image data in blocks are converted into the values of real numbers after the discontinuity of phase distortion between blocks has been corrected.
The problem in the above-mentioned conventional correction method (1) is solved in the present invention as follows. A plurality of phase distortion patterns are preliminarily measured through phantom imaging and are stored. Since these phase distortion patterns are invariable, it is not necessary to carry out the measurement every imaging. Phase distortion included in data later acquired by imaging is corrected by representing it as a summation of the stored plurality of phase distortion patterns with weighting factors. Now assume that the data acquired by imaging are C ij (i, j=1, 2, ..., N and N being the size of image, the phase distortion is θ ij =arg(C ij ), the phase distortion patterns are ψ ij .sup.(k) (k=1, 2, ..., M and M being the number of phase distortion patterns equal to or greater than 1) and the weighting factors are α.sup.(k) (k=1, 2, ..., M). Here, "arg" is a function by which the phase (or argument) of a complex number is determined. The weighting factor α.sup.(k) is defined so as to minimize ##EQU1## The phase distortion is corrected by the following equation: ##EQU2## where C ij is an image after the phase distortion has been corrected. In order to eliminate the influence of noise summation over the whole image following the equation (1) may be replaced by a summation for only the positions (i, j) of pixels at which the absolute value of C ij is greater than a given threshold value. If phase distortion θ ij =arg(C ij ) for C ij of the equation (2) is determined and the correction according to the equations (1) and (2) is repeated, the precision of correction is further improved.
A range of values which the phase distortion θ ij can take, maybe -180°≦θ ij <180°. However, this range is limited to, for example, -90°≦θ ij <90° and the summation following the equation (1) is calculated for only pixel positions (i,j) at which θ ij has values within the limited range.
Alternatively, an assembly S={(i,j)|-90°≦θ ij <90°} of such pixel positions (i,j) is classified into partial regions connected on the image and the summation following the equation (1) is made for only pixel positions (i,j) belonging to a partial region which includes the most pixels. Subsequently, the correction of phase distortion is performed in a similar manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of phase distortion correction for explaining an embodiment of the present invention
FIG. 2 shows in block diagram an MR imaging system to which the present invention is applied;
FIGS. 3 and 4 are views showing pulse sequences which are imaging procedures;
FIGS. 5a to 5c are views for supplementarily explaining step 111 in FIG. 1;
FIG. 6 is views showing pulse sequences; and
FIG. 7 is a flow chart of phase distortion correction for explaining another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First of all, the principle of a method according to the present invention for solving the problem in the above-mentioned conventional correction method (2) will be explained.
A complex image reconstructed can be represented as follows:
C.sub.ik =R.sub.ik ·exp(jθ.sub.ik)+n.sub.ik (3)
where C ik is the reconstructed complex image (at the value of a complex number), R ik a true image to be obtained (at the value of a real number), θ ik a phase distortion (at the value of a real number), n ik noises (at the value of a complex number), j the unit of an imaginary number equal to √k-1, and i and k indices representative of the position of a pixel. A reconstructed complex image C mn in each of blocks into which the reconstructed complex image C ik is divided can be represented as follows: ##EQU3## In the case where θ mn does not satisfy the inequality in the relation (4), θ mn takes apparently discontinuous values since it takes periodical values every 2π. The division of C ik into the blocks or C mn is done for preventing the discontinuity of the phase distortion to occur in C mn and for making the non-linearity of large non-linear phase distortion in C ik small. If the non-linearity is made small, any apparent discontinuity of phase distortion which may exist in a block can be removed by a process which corresponds to steps 105 to 107 in FIG. 1.
First, C mn is Fourier-transformed as follows:
B.sub.xy =F(C.sub.mn).
Next, coordinates (x', y') at which the absolute value of B xy takes its maximum value are determined. Further, a phase rotation angle A at (x', y') represented by
A=cos.sup.-1 (real(B.sub.x',y')/|B.sub.x'y' |)
is calculated. Provided that the origin for C mn is (N/2, N/2) (N: the size of a block), the correction of phase distortion in the block can be realized by the following equation: ##EQU4##
This phase distortion correction results in that the peak position of B xy is made equal to or lower than one sample point of discrete Fourier transformation. But, precise correction is not still attained. Therefore, the remaining phase distortion is estimated and corrected by means of the least square method (to obtain a corrected image E mn ).
However, apparent discontinuity of phase distortion still exists between blocks. This discontinuity is corrected by comparing it with a calculated offset value of the phase distortion between blocks (see step 111 in FIG. 1). As shown by the equation (3), the reconstructed image assumes only a real part when no phase distortion exists. Therefore, the values of image data in a block are converted into real numbers by the following equation:
G.sub.mn =|F.sub.mn |·sign (real (E.sub.mn))
where G mn is a block image (at the value of a real number) after correction, F mn a block image (in the value of a complex number) after step 111 of FIG. 1 has been performed, sign(x) the sign (+1 or -1) of a real number x, and "real" a function by which the real part of a complex number is determined. In this manner, the phase distortion can be corrected with high precision.
As for an image containing positive and negative values as obtained by the IR method or the like, the estimation and correction of phase distortion can be made in such a manner that the image is squared to separate the phase distortion from the positive and negative information.
Explanation will now be made of a first embodiment of the present invention in which phase distortion contained in a complex image obtained by the IR method is corrected according to a method of the present invention.
FIG. 2 is a block diagram of an MR imaging system which embodies the present invention. The system comprises a sequence controller 201 for controlling components of the system in accordance with a predetermined procedure in order to detect a nuclear magnetic resonance signal from an object to be examined, a transmitter 202 for RF (or high frequency) magnetic field pulses generated for causing resonance, a field gradient driver 204 for driving field gradients, a field gradient controller 203 for controlling the field gradient driver 204, a receiver 205 for receiving and detecting the magnetic resonance signal generated from the object to be examined, a processor 206 for performing various operations inclusive of image reconstruction processing, phase distortion correction processing, and so on, a CRT display 207 for image display, and an external memory 208 for storing detecting signal data, reconstruction image data, and so on.
A pulse sequence in the above construction using the IR method is shown in FIG. 3. First, a 180° RF magnetic field pulse 301 is applied to invert the direction of nuclear spins in an area of the object to be examined. After the lapse of a time T I , a 90° RF magnetic field pulse 302 and a field gradient pulse 303 for generation of a field gradient G Z in a z-direction are simultaneously applied to cause the resonance of spins in a slice to be imaged. Next, a field gradient pulse (or phase encoding pulse) 304 for generation of a field gradient G y in a y-direction and a field gradient pulse 305 for generation of a field gradient G x in an x-direction are applied and thereafter a 180° RF magnetic field pulse 306 is applied to generate spin echoes. The generated spin echo signal 307 is measured while a field gradient G x pulse 308 is applied. This sequence is repeated while changing the intensity or amplitude of the phase encoding pulse 304.
It is known that an image reconstructed from data measured in accordance with the sequence shown in FIG. 3 takes a positive or negative value, depending on the value of a parameter of the object called a longitudinal relaxation time and the value of T I if no phase distortion is present. However, when any phase distortion is present in the reconstructed image, sign information of the reconstructed image is inverted due to the phase distortion, thereby yielding an erroneous reconstructed image. Therefore, it is necessary to correct the phase distortion.
The flow of a processing for correcting with high precision the phase distortion contained in the image reconstructed from the data measured by means of the IR method is shown in FIG. 1 The procedure is as follows.
Step 101: The reconstructed image C ik containing the phase distortion is brought to square, thereby obtaining an image C' ik =(C ik ) 2 . This is made in order that sign information contained in the intrinsic image is separated from the phase distortion through the square calculation, thereby allowing the estimation of phase distortion with high precision using the assumption that the phase distortion has a sufficiently gentle change in the image.
Step 102: The absolute value of each pixel of C' ik is produced to determine its maximum value (CMAX).
Step 103: C' ik is divided into blocks C' mn . The block size can be determined such that a change of the phase distortion falls within a range from +π to -π, if possible. For example, in the case where the size of the original image is 256×256 pixels and the original image is divided into 4×4 blocks, the size of one C' mn block is 64×64.
Step 104: It is judged how many of the number of pixels in C' mn which satisfy |C' ik |>CMAX·TH (TH: a predetermined threshold value) and the predetermined number M of pixels is larger or smaller than the other. For example, TH=0.1 and M=10. In the case of M≦ (the number of pixels satisfying |C' ik |>CMAX·TH), the process skips to step 110. In the case of M>(the number of pixels satisfying |C' ik |>CMAX·TH), steps 105 to 109 are carried out.
Step 105: The block C' mn is Fourier-transformed to obtain B' xy .
Step 106: The absolute value of each complex valued Fourier component B' xy is produced to determine coordinates (x', y') at which the absolute value takes its maximum value. Also, there is determined a phase rotation angle A at (x', y') represented by
A=cos.sup.-1 (real(B'.sub.x'y')/|B'.sub.x'y' |),
where "real" is a function by which the real part of a complex number is determined.
Step 107: A central pixel (N/2, N/2) in B mn is chosen as the origin, N being the block size. It is known that since the value of any image after Fourier-transformation thereof at the origin in a frequency space corresponds to a d.c. component of the image, an image obtained by the Fourier-transformation has its peak value at the origin if no phase distortion is present. Therefore, the presence of any deviation between the origin (N/2, N/2) and the maximum value point (x', y') means that there is phase distortion which changes linearly on the image. Also, since the angle A is a phase rotation angle for the d.c. component, it can be regarded as being the offset of phase distortion in a block. Accordingly, the phase distortion is corrected by the following equation: ##EQU5## This correction means that the peak position of B' xy is made equal to or lower than one sample point of discrete Fourier-transformation.
Step 108: A phase angle A' mn is calculated from D' mn by the following equation:
A'.sub.mn =cos.sup.-1 (real(D'.sub.mn)/|D'.sub.mn |).
In the case where A' mn does not satisfy an inequality of -π≦A' mn <π, A' mn apparently takes discontinuous values. However, for the processing for phase distortion correction in step 107, A' mn in blocks can be regarded as being phase distortion which is continuous in a range between +π and -π.
Step 109: The least square method is applied to C' mn to estimate the phase distortion. For example, parameters α, β and γ minimizing the equation of ##EQU6## are estimated.
Though the phase distortion is estimated by the three parameters α, β and γ in the above example, the estimation of parameters may alternately be made by means of hyperbolic approximation. Namely, parameters are estimated which minimizes the equation: ##EQU7##
Generally, the equation based on m and n used for the estimation of phase distortion may be a multi-term equation of any order. Also, it is of course that the estimation of phase distortion can be made by means of repetitive calculation instead of the least square method though the amount of calculation is increased.
The foregoing process from step 105 results in that the phase distortion contained in the image C' ik obtained by the square calculation in step 101 is estimated (in a doubled form).
Now, let us represent the phase distortion estimated by the foregoing process as follows (taking as an example the case where the phase distortion is estimated by mean of three parameters): ##EQU8## The phase distortion is corrected by the following equation:
E.sub.mn =C.sub.mn ·exp(2πj(P.sub.lx m+P.sub.ly n+PO)/2).
As a result, only phase distortion which smoothly or gently changes on an image containing no sign information is corrected.
Step 110: The presence/absence of an uncorrected block is judged. In the case where an uncorrected block is present, the process step returns to step 103. In the case where no uncorrected block is present, the process step proceeds to step 111.
Step 111: The discontinuity in phase between blocks is corrected. This will now be explained by virtue of the example, shown in conjunction with step 109, in which P lx , P ly and PO are used. P lx is the phase tilt or inclination in an x-direction in a block, P ly the phase tilt in a y-direction in the block, and PO the offset value. The correction of phase discontinuity between blocks 1 and 2 adjacent to each other in the x-direction as shown by shaded portions in FIG. 5a (in the case where the block 2 is processed on the basis of the block 1) may be effected by determining k (k: integer) which minimizes the equation of ##EQU9## where P lx is the transversal tilt in the block PO the offset in the block , and PO' the offset in the block 2.
The correction of phase discontinuity between blocks is made in such a manner that it starts from a central block and moves on the surrounding blocks, as shown in FIG. 5b. However, in the case where there is a block as shown in shaded portion in FIG. 5c (a block having been judged in step 104 as one in which the number of pixels satisfying the threshold condition is less), there arises a problem that correction cannot be made for blocks above the shaded block 1. In one solution of this problem, after the above-mentioned correction has been finished, correction is again carried out through blocks indicated by arrow in FIG. 5c. This correction may start from any block.
Step 112: Image data values in each block are converted into real number values. A reconstructed complex image includes in itself only a real part if no phase distortion is present. Accordingly, image data in a block is converted into the value of real number by the equation of
G.sub.mn =|F.sub.mn |·sign(real(R'.sub.mn)),
where F mn is an image after step 111, "sign" a function by which a sign is examined, and "real" a function by which the real part of a complex number is determined.
The above-mentioned processing provides G mn in which the phase distortion contained in the image reconstructed from the IR method is corrected with high precision. In the foregoing embodiment, the square (or second-power) calculation has been used in step 101. However, the same effect is attainable even if the n-th power calculation (n: any even number larger than 2) is employed. Also, the same effect can be obtained even if after data has been shifted such that the peak position coordinate (x', y') determined on B' xy obtained through the Fourier-transformation in step 105 is placed onto the origin (N/2, N/2), the phase rotation angle A is corrected and B' xy is thereafter subjected to inverse Fourier-transformation followed by steps in FIG. 1 from step 108 on.
Next, an explanation will be given of a second embodiment of the present invention in which phase distortion contained in a complex image obtained by a method of separating water and fat from each other by means of chemical shift information is corrected according to the method of the present invention.
FIG. 4 shows sequences in accordance with which water and fat are separated from each other in the MR imaging system shown in FIG. 2 and explained in conjunction with the first embodiment. The sequence shown in (a) of FIG. 4 corresponds to the case where the 180° RF magnetic field pulse 301 is omitted from the sequence shown in FIG. 3. A spin echo signal 406 is measured by applying a 90° RF magnetic field pulse 401, a field gradient pulse 402 for generation of a field gradient G z in a z-direction, a field gradient pulse (or phase encoding pulse) 403 for generation of a field gradient G y in a y-direction, a field gradient pulse 404 for generation of a field gradient G x in an x-direction, a 180° RF magnetic field pulse 405, and a field gradient G x pulse 407 at the order shown in (a) of FIG. 4. The sequence shown in (b) of FIG. 4 is different from the sequence shown in (a) of FIG. 4 in that the 180° RF magnetic field pulse 405 in (a) of FIG. 4 is applied at a timing shifted by ΔT, as indicated by 408 in (b) of FIG. 4. It is known that the value of a reconstructed image acquired by the sequence shown in (a) of FIG. 4 is proportional to the density of (water) plus (fat) and the value of a reconstructed image acquired by the sequence shown in (b) of FIG. 4 is proportional to the density of (water) minus (fat) by properly selecting ΔT. From the two images the density image of each of water and fat can be obtained.
The image acquired through the sequence of (b) of FIG. 4 takes positive and negative values, like the image acquired through the sequence of FIG. 3. Accordingly, phase distortion has to be corrected.
A processing for correcting phase distortions contained in the (water) plus (fat) image and the (water) minus (fat) acquired by the sequences shown in (a) and (b) of FIG. 4 will now be explained.
As for the (water) plus (fat) image, since the value of the image is positive, the correction of phase distortion is effected by producing the absolute value of the image.
The sequence of (a) of FIG. 4 is designed such that a change in phase induced by any inhomogeneity of a static magnetic field is cancelled. In the sequence of (b) of FIG. 4, on the other hand, since the RF magnetic field pulse 408 is applied at the timing shifted from the RF magnetic field pulse 405 in (a) of FIG. 4 by ΔT, the phase change induced by the inhomogeneity of the static magnetic field is not cancelled and hence this phase change is added to phase distortion. Therefore, as for the (water) minus (fat) image, the phase change induced by the inhomogeneity of the static magnetic field is preliminarily determined and the determined phase change is corrected before a processing for correction of phase distortion as in the first embodiment is carried out. This is realized by imaging a uniform object called a phantom in the same procedure as a procedure for acquiring a tomographic image. The phantom image obtained contains a phase change induced by the inhomogeneity of the static magnetic field but does not contain a phase change induced by the chemical shift since the phantom is the uniform object. The inhomogeneity of the static magnetic field can be regarded as being sufficiently stable with respect to the lapse of time since it is settled by the shape of the system and so on. Therefore, one preliminary imaging of the phantom suffices. Accordingly, the phase change induced by the inhomogeneity of the static magnetic field ca be corrected by the equation of ##EQU10## where F mn is the phantom image, A mn a phase from the phantom image, C mn an image obtained for separating water and fat from each other, and D mn an image obtained by the correction of the phase change induced by the inhomogeneity of the static magnetic field. The correction may be effected by the least square method. In that case, α is first determined which minimizes the equation of ##EQU11## where A' mn is the phase of the image C mn . The correction is effected on the basis of the determined α by the following equation:
D.sub.mn =C.sub.mn ·exp(2πj(αA.sub.mn)).
After the phase change induced by the inhomogeniety has been removed through the above procedure, steps 101 to 112 in FIG. 1 are performed.
By the above processing, the water image and the fat image can be obtained from the two images in which phase distortions are corrected with high precision.
Next, an explanation will be given of a third embodiment of the present invention in which phase distortion contained in a complex image acquired through a method of imaging only blood vessels, by use of the fact that the phase of a moving portion such as blood flowing in the blood vessels changes on a reconstructed image (angiography) or through a method of measuring the flow rate of blood on the basis of a proportional relation of the phase change with respect to the flow rate of blood (blood flow measurement) is corrected according to the method of the present invention.
FIG. 6 shows sequences for the angiography or blood flow measurement in the MR imaging system shown in FIG. 2 and explained in conjunction with the first embodiment. The sequence shown in (a) of FIG. 6 is similar to the sequence of (a) of FIG. 4. The sequence shown in (b) of FIG. 6 is different from the sequence of (a) of FIG. 6 only with respect to field gradients 608 and 609 in an x-direction. The portion indicated by 608 shows that a first field gradient and a second or inverted field gradient (having the same amplitude as the first gradient but a sign reverse to the first gradient) are applied in the x-direction. In the case of a stationary object, the influences of the first and second gradients are cancelled from each other because the object involves no motion. The moving portion or blood is sensible of the different magnetic fields so that the influences of the first and second gradients are not cancelled, thereby changing the phase of spins. Since this phase change is proportional to the flow rate of the blood, the flow rate can be determined if the phase change is determined.
If each of two images acquired by the sequences of (a) and (b) of FIG. 6 contains no phase distortion, it can be considered that a phase change is not present except in a moving portion associated with the blood flow. In that case, the phase change can be determined from the two images. A portion the phase of which is changing corresponds to the position of blood vessels and the blood flow rate can be determined on the basis of that phase change.
In practice, however, the image contains phase distortion and the phase distortions contained in the two images are different from each other if imaging instants of time and/or imaging sequences are different.
The processing for phase distortion correction in the above-mentioned case will now be explained.
Images acquired by the sequences shown in (a) and (b) of FIG. 6 can be represented as follows:
f.sub.ik =F.sub.ik ·expo(jθ.sub.ik)
g.sub.ik =G.sub.ik ·exp(jψ.sub.ik)
where f ik is a (complex) image reconstructed from the sequence of (a) of FIG. 6, F ik n true (complex) image obtained from the sequence of (a) of FIG. 6, θ ik phase distortion in the case of (a) of FIG. 6, g ik is a (complex) image reconstructed from the sequence of (b) of FIG. 6, G ik a true (complex) image obtained from the sequence of (b) of FIG. 6, and ψ ik phase distortion in the case of (b) of FIG. 6.
In order to separate the flow induced phase change and the phase distortion from each other, f ik ·g ik * (*: complex conjugate) is calculated as follows:
f.sub.ik ·g.sub.ik *=F.sub.ik G.sub.ik *·exp(j(θ.sub.ik -ψ.sub.ik)).
At this point of stage, steps 102 to 112 of FIG. 1 are performed to estimate θ ik -ψ ik as a phase which smoothly changes on the image. The estimated value of θ ik -ψ ik is used to change the phase of g ik as shown by the following equation: ##EQU12##
As the result of the above processing, a smooth phase distortion change other than the flow induced phase change can be eliminated. Thus, the flow induced phase change can be determined by determining f ik -g' ik , thereby realizing the blood flow measurement or angiography.
Next, the principle of a method according to the present invention for solving the problem in the earlier mentioned conventional correction method (1) will be explained.
Phase distortion appearing on an image is caused from a plurality of factors. Main factors include the inhomogeneity of a static magnetic field and the eddy current effect induced by gradient switching. If each of the patterns of phase distortions caused from those factors is measured and stored, any phase distortion contained in image data acquired through any given imaging procedure can be represented by a summation of the plurality of phase distortion patterns with weighting factors, thereby allowing highly precise phase distortion correction without frequently imaging a phantom.
When the phase distortion is large, there may be the case where it is beyond a range from -180° to 180°. However, even in that case, the value of an "arg" (argument) function gives -180°≦θ ij <180°. Therefore, θ ij k involves the uncertainty of ±360°·n (n: an integer). In the case where α.sup.(k) is determined on the basis of the equation (1) (see SUMMARY OF THE INVENTION), errors occur if such uncertainty exists. But, since the most of the values of θ ij fall within the range from -180° to 180°, the approximate value of α.sup.(k) can be determined. Accordingly, the precision of phase distortion correction can be further improved if after the phase distortion has been corrected in accordance with the equation (2) (see SUMMARY OF THE INVENTION) by use of the approximately determined α.sup.(k), the above-mentioned procedure for phase distortion correction is repeated again.
As one approach of eliminating the uncertainty is known a method in which the fact that θ ij itself smoothly or gently changes is utilized to determine the value of n in ±360°·n such that the values of phase distortions of adjacent pixels are smoothly connected with each other. As for a tomographic image of a human body, however, there may be a possibility that the image is affected by noises since regions (such as coelomata) involving no or weak signal exist in the human body. Even in that case, if the values of the phase distortions are limited to a range of, for example, from -90° to 90° and pixel positions (i, at which the phase distortions have their values in the limited range are divided into regions which are connected the uncertainty can be eliminated in each region. Accordingly, if one of the regions is selected and α.sup.(k) is determined on the basis of the equation (1) by use of only pixels which belong to the selected region, at least the approximate value of α.sup.(k) can be obtianed.
A concrete example will now be described by virtue of FIGS. 2 and 7.
FIG. 7 shows a processing of phase distortion correction for image data acquired by the system shown in FIG. 2. First or in advance, a phantom is imaged under various imaging conditions and the patterns of phase distortions produced are stored into a memory 13. The correction processing is performed in accordance with the following steps.
Step 11: Uncorrected images C ij (i, j=1, 2, ..., N) at the values of complex numbers containing phase distortions and M phase distortion patterns ψ ij .sup.(k) (i, j=1, 2, ..., N and k=1, 2, ..., M) at the values of real numbers are inputted from memories 12 and 13, respectively.
Step 14: The maximum value among the absolute values |C ij | of the uncorrected images C ij is determined.
Step 15: The phase angle θ ij is determined by θ ij =arg(C ij ). Here, -180°≦θ ij <180°.
Step 16: There are selected or searched pixel positions (i, j) at which the phase angle θ ij determined in step 15 satisfies -90°≦θ ij <90°. Namely, binary images B ij i, j=1, 2, ..., N and B ij =0 or 1) having the same sizes of the uncorrected images C ij are prepared and B ij is defined as follows. ##EQU13## Here, T h is a parameter to determine a threshold value and may be, for example, 0.1. The condition of |C ij |>A max ·T h is provided for eliminating locations at which the influence of noises is large. A process is applied to the binary images B ij and the pixel positions (i, j) are classified and divided into several connected regions of "k1". This classification and division process is described by many articles (see, for example pages 75 to 76 of the book entitled "Introduction to Computer Image Processing" and edited by the Nippon Kogyo Center under the supervision of Hideyuki Tamura). Any classification and division algorithm can be used without giving any influence in embodying the present invention. One region where the number of pixels included is the maximum is selected among the classified connected regions and B ij for the other regions are set to be "0".
Step 17: There is determined α.sup.(k) which mimimizes ##EQU14## The summation is made over all of (i, j) which give B ij =1. The value of α.sup.(k) is determined by solving M simultaneous first-degree equations ##EQU15## by means of a general technique of the least square method.
Step 18: judgement is made as the process of minimizing converges of whether or not the phase distortion correction ha been made with satisfactory precision. Namely, provided that a required precision of correction is P (in the unit of degree), the fulfillment of the relation of ##EQU16## for all of pixel positions (i, j) is decided as convergence and the other is regarded as non-convergence. When the decision of convergence is made, the process step proceeds to step 20. If the decision of non-convergence is made, the process step proceeds to step 19. Step 19: In the case of non-convergence, the correction of phase distortion is made by the following equation: ##EQU17## After the approximate correction following the above equation has been made, steps from step 15 on are repeated.
Step 20: In the case of convergence, phase distortion-corrected images C ij are outputted to a memory 21.
By the above-mentioned flow of processing, the processing for phase distortion correction is effected.
In the above processing, the phase distortion patterns ψ ij .sup.(k) are stored in the memory 13 as they are. However, this step can be combined with a method in which the phase distortion patterns are subjected to proper compression processing to reduce the amount of data. The compression is reversed and the original data are restored upon read-out. Also, though the phase angle θ ij is limited to the range of -90°≦θ ij <90° in step 16, the present invention is effective even if a partial range from -180° to 180° including 0 is employed. Further, though α.sup.(k) is determined through the least square method, the other optimization techniques are applicable to obtain similar effects.
According to the present invention, there is provided a benefit in that non-linear phase distortion contained in a complex image acquired by an MR imaging system can be corrected from only the acquired image, with the small amount of calculation and with high precision without a need of performing the phase distortion correction by use of a phantom for every imaging process, whereby imaging with satisfactory precision is possible in an imaging method (such as IR method, Dixon method or the like) in which an object to be examined is imaged by use of phase information. There are also provided benefits in that phase distortion on a tomographic image generated due to a plurality of factors can be corrected with high precision by using phase distortion patterns which are preliminarily measured and stored and that phase distortion change depending on imaging procedures can be corrected by changing weighting factors for the phase distortion patterns. Therefore is possible to omit the complicated operation of requiring the image of a phantom to be formed for every imaging process.
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In one aspect of correcting phase distortion in an MR imaging system at high speed and with high precision, partial regions having any shapes are established on a complex image reconstruction, linear phase distortion is estimated for every partial region and the phase distortion of the whole image is corrected by use of the estimated phase distortion. In another aspect, a plurality of phase distortion patterns are measured in advance through phantom imaging and stored. The phase distortion pattern is invariable and hence it is not necessary to perform the measurement for each impage processed. Phase distortion included in data acquired through imaging is corrected by representing it as a summation of the plurality of phase distortion patterns with weighting factors.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention provides novel anthracycline glycoside derivatives belonging to rhodomycin-group, and relates to a process for the production thereof, and more particularly, the present invention relates to the novel derivatives of anthracycline glycoside of the general formula I: ##STR1## wherein R 1 is a hydrogen atom or hydroxyl group, and
R 2 is a hydrogen atom or the following sugar chain:
--O--rhodosamine-2-deoxyfucose-cinerulose residue ##STR2## and R 3 is a hydroxyl group or carbomethoxy(--COOCH 3 ) group or the foregoing sugar chain, --O--rhodosamine-2-deoxyfucose-cinerulose residue, or the following sugar chain: --O--rhodosamine-2-deoxyfucose-rhodinose residue ##STR3## and R 4 is a hydrogen atom or hydroxyl group, and to a process for the production thereof.
(2) Description of the Prior Art
A number of anthracycline glycosides have been found in the culture medium of Streptomyces, and described in prior literature. Among them, daunomycin and adriamycin have already been applied clinically for human cancers.
Rhodomycinones, iso-rhodomycinone and rhodomycin-related antibiotics are described in Chem. Ber. 88, 1792-1818 (1955); Chem. Ber. 101, 1341-1348 (1968); J. Med. Chem., 20, 957-960 (1977); Pharmacie 27, 782-789 (1972); Zeit. Allg. Mikrobiol., 14, 551-558 (1974); Tetrahed. Lett. No. 38, 3699-3702 (1973); Folia Microbiol., 24, 293-295 (1979); and J. Antibiotics, 32, 420 (1979).
Aclacinomycin A is disclosed in U.S. Pat. No. 3,988,315 and by Oki et al. in J. Antibiotics 28, 830 (1975) and 32, 791-812 (1979).
Cinerubins A and B are disclosed in U.K. Pat. No. 846,130, U.S. Pat. No. 3,864,480, Keller-Schierlein et al., "Antimicrobial Agents and Chemotherapy," page 68 (1970), Chemical Abstracts 54, 1466i (1960) and J. Antibiotics 28, 830 (1975).
Further illustrative and summary disclosures of anthracycline antibiotics can be located in Index of Antibiotics from Actinomycetes, Hamao Umezawa, Editor-in-chief, University Park Press, State College, Pennsylvania, U.S.A. (1967) as follows:
______________________________________Antibiotics Page numbers______________________________________Aclacinomycins A and B 101-102Adriamycin 122Carminomycin I 225Galirubins S - D 405-408Rhodomycins X - Y 879-880β-Rhodomycins 881-885γ- Rhodomycins 886-892Steffimycin 945______________________________________
The textbook, Antibiotics, Volume 1, Mechanisms of Action, edited by David Gottlieb and Paul D. Shaw, Springer-Verlag New York, Inc., N.Y. (1967) at pages 190-210 contains a review by A. DiMarco entitled "Daunomycin and Related Antibiotics."
Information Bulletin, No. 10, International Center of Information of Antibiotics, in collaboration with WHO, December, 1972, Belgium, reviews anthracyclines and their derivatives.
In their continuation of a study on biogenesis and biosynthesis of anthracycline antibiotics, especially aclacinomycins produced by Streptomyces galilaeus and rhodomycins produced by Actinomyces roseoviolaceus or Streptomyces purpurascens, the present inventors have developed an unique method for obtaining new anthracycline antibiotics from biologically inactive anthracyclinone by microbial glycosidation, and applied it to the search for useful anthracycline antibiotics having more potent antitumor activity and lower toicity than adriamycin and daunomycin, which are widely used as cancer chemotherapeutic agents. As a result, they found that aclacinomycin-producing microorganisms (Japan Patent Kokoku No. SHO 51-34915, Japan Patent Kokai No. SHO 53-44555, Japan Patent Kokai No. SHO 54-63067), for example, Streptomyces galilaeus MA 144-M1 (ATCC 31133, FERM-P 2455), and mutants therefrom, produced new rhodomycin-group antibiotics from various anthracyclinones such as ε-rhodomycinone, γ-rhodomycinone, β-rhodomycinone, ε-isorhodomycinone and ε-pyrromycinone by the microbial glycosidation, confirmed that these antibiotics, named as rhodomycins RDC or RDRs and pyrromycin RDC, are new compounds which have potent antitumor activity and low toxicity in animals, and established the processes and method for their preparation and purification.
OBJECTS OF THE INVENTION
Accordingly, it is an object of this invention to provide new anthracycline glycoside derivatives having potent anticancer activities and lower toxicities.
Another object of the invention is to provide a new process for producing anthracycline glycoside derivatives by microbiological conversion of anthracyclinone to the corresponding anthracycline glycoside.
Still another object of this invention is to provide a pharmaceutical composition for antitumor agents.
SUMMARY OF THE INVENTION
The novel derivatives of rhodomycin-group of antibiotics according to the present invention include the following six compounds:
ε-rhodomycin RDC, ε-isorhodomycin RDC, β-rhodomycin RDC, γ-rhodomycin RDC, γ-rhodomycin RDRs and β-pyrromycin RDC
wherein
R is rhodosamine, D is 2-deoxyfucose, C is cinerulose and Rs is rhodinose residue, respectively, and R 1 , R 2 , R 3 and R 4 of the formula I have the following combinations of definition in said compounds
______________________________________ R.sup.1 R.sup.2 R.sup.3 R.sup.4______________________________________ε-rhodomycin RDC --Ho-r-d-c --COOCH.sub.3 --OHε-isorhodomycin RDC --OHo-r-d-c --COOCH.sub.3 --OHβ-rhodomycin RDC --Ho-r-d-c --OH --OHγ-rhodomycin RDC --H --Ho-r-d-c --OHγ-rhodomycin RDRs --H --Ho-r-d-r --OHβ-pyrromycin RDC --OHo-r-d-c --OH --H______________________________________
wherein
-o-r-d-c is --O--rhodosamine-2-deoxyfucosecinerulose residue and
-o-r-d-r is --O--rhodosamine-2-deoxyfucoserhodinose
and the non-toxic acid addition salts thereof.
Other embodiments of the present invention provide a new process for biological production of ε-rhodomycin RDC, ε-isorhodomycin RDC, β-rhodomycin RDC, and γ-rhodomycin RDC by cultivating a microorganism of streptomyces capable of converting anthracyclinone to corresponding anthracycline glycoside and adding said anthracyclinone to the culture of said microorganism during cultivation to produce and isolate said anthracycline glycoside from the cultured medium.
Still other embodiments of the present invention provide a pharmaceutical containing sufficient amounts of the anthracycline glycoside derivatives of the present invention or non-toxic acid addition salts thereof to inhibit the growth and nucleic acid biosynthesis of malignant tumors, such as L 1210, in mammals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2, 3, 4, 5 and 6 show the PMR spectra in CDCl 3 of ε-rhodomycin RDC, ε-isorhodomycin RDC, β-rhodomycin RDC, γ-rhodomycin RDC, γ-rhodomycin RDRs and β-pyrromycin RDC, respectively.
DETAILED DESCRIPTION OF THE INVENTION
The starting materials of the present invention are biologically inactive anthracyclinone having the formula II: ##STR4## wherein R 1 , R 2' , R 3' and R 4 are the following groups:
______________________________________ R.sup.1 R.sup.2' R.sup.3' R.sup.4______________________________________ε-rhodomycinone --H --OH --COOCH.sub.3 --OHε-isorhodomycinone --OH --OH --COOCH.sub.3 --OHβ-rhodomycinone --H --OH --OH --OHγ-rhodomycinone --H --H --OH --OHβ-pyrromycinone --OH --OH --OH --H______________________________________
At present the anthracyclinone used for substrate in the present invention are the above five, which can be prepared by extraction and purification from fermented medium, but if structurally related anthracyclinone are prepared in the future they can be preferably utilized based on the substrate specificity of microbial reaction. Furthermore, not only rhodomycinones but the various structurally related anthracyclinones such as aklavinone, ε-pyrromycinone, 10-decarbomethoxyaklavinone, 4-methoxyaklavinone also can be used as presursors to produce novel anthracycline glycosides.
Anthracyclinones as described above can be isolated directly from their cultured mediums or obtained by acid hydrolysis of the corresponding anthracycline glycosides, for example, from aclacinomycin A, aclacinomycin B (U.S. Pat. No. 3,988,315), MA 144 G1, G2, L, N1, S1, S2, U1, U2 (Japan Patent Kokai No. SHO 53-44555), MA 144 Y (Japan Patent Kokai No. SHO 54-63067), roseorubicin A and B (J. Antibiotics 32, 420-424, 1979) and rhodomycins by Actinomyces roseoviolaceus or Streptomyces purpurascens (before mentioned).
Microorganisms used for the present invention are aclacinomycin-producing strains such as Streptomyces galilaeus MA 144-M1 (ATCC 31133) (FERM-P 2455) and various mutants therefrom obtained by the physical treatment with irradiation such as ultraviolet, α-, β-, γ- and X-ray, or by the mutation using chemical mutagens such as NTG and diepoxybutane. For example, mutant strain KE 303 (FERM-P 4808) derived from Streptomyces galilaeus MA 144-M1 (ATCC 31133) (FERM-P 2455) is most preferably used for the present invention.
As an example of obtaining mutant strains, the spores were obtained from the parent strain grown on YS agar slant, treated by N-methyl-N'-nitro-N-nitrosoguanidine (NTG) at the concentration of 1000 μg/ml after ultrasonic disintegration, harvested, and inoculated onto YS agar medium. Colonies grown on YS agar medium were inoculated in the seed medium, and cultured in the production medium. The resulting mycelium was extracted with organic solvents, and the extract was checked for the productivity of yellow pigment due to aclacinomycins by spectrophotometry. The yellow pigment (anthracycline)-non-producing colonies were selected and then tested for the capability of producing aclacinomycin A from aklavinone by shaking culture in the producing medium containing aklavinone. Thus, the mutant strains possessing ability to produce aclacinomycin A were selected and isolated.
Streptomyces galilaeus KE 303 (FERM-P 4808) thus obtained has the following morphological and physiological properties similar to those of the parent strain MA 144-M1, excepting a little difference in the color of substrate mycelium. This mutant, thus, can be defined as a mutant strain incapable of producing pigments. Therefore, other than the newly isolated mutant mentioned above, other mutants derived from aclacinomycin-producing strains, incapable of producing anthracycline pigments and capable of producing anthracycline glycosides from anthracyclinone as substrate, also can be used in the present invention.
The strain KE 303 (FERM-P 4808) has the following properties:
1. Morphological characteristics:
Under a microscope, open spirals well developed from branched substrate mycelia are observed. There are no whorls. The mature spore chain has more than ten spores.
The spores are ellipsoidal, 0.4-0.8×0.7-1.6 μm insides, and their surface is smooth. The strain could not produce any sporangium and sclerotium. The strain was assigned to spirales section in genus Streptomyces.
2. Properties on various media:
The description in parenthesis follows the color standard of the "Color Harmony Manual" published by Container Corporation of America, U.S.A.
(1) On sucrose-nitrate agar, incubated at 27° C.:
White to pale yellow (2 db) growth; no aerial mycelium; no soluble pigment.
(2) On glucose-aspargine agar, incubated at 27° C.:
Pale yellow (1ba) to pale yellow green (11/2ec) growth; light gray (d) aerial mycelium; no soluble pigment.
(3) On glycerol-asparagine agar (ISP medium No. 5), incubated at 27° C.:
Pale yellow green (1cb) to light grayish olive (11/2ge) growth; yellowish gray to light gray (2dc) aerial mycelium; no soluble pigment.
(4) On starch-inorganic salts agar (ISP medium No. 4), incubated at 27° C.:
Pale yellow (1ba) to pale yellow green (1cb) growth; medium gray (2fe, Covert Gray) to gray (d) aerial mycelium; no soluble pigment.
(5) On tyrosine agar (ISP medium No. 7), incubated at 27° C.:
Light grayish yellowish brown (3ge) to grayish brown (4li) growth; lately observed pale gray aerial mycelium; black soluble pigment.
(6) On nutrient agar, incubated at 27° C.:
Grayish yellow (3ec) growth, yellowish gray (2dc) to light gray (d) aerial mycelium; brown soluble pigment.
(7) On yeast extract-malt agar (ISP medium No. 2), incubated at 27° C.:
Pale olive (2gc) to pale yellowish green (11/2 ec) growth; light brownish gray (3fe, Silver gray to dark gray 3ih, Beige gray) aerial mycelium; no soluble pigment or slightly brownish soluble pigment.
(8) On oatmeal agar (ISP medium No. 3), incubated at 27° C.:
Pale yellow (2db) to grayish yellow (3ec) growth; yellowish gray (2dc) to light gray (d) aerial mycelium, brown soluble pigment.
3. Physiological Properties:
(1) Growth temperature was examined on maltose-yeast extract agar (maltose 1.0%, yeast extract (Oriental Yeast KK) 0.4%, agar 3.5%, (pH 6.0)) at 20, 24, 27, 30, 37 and 50° C. Optimal temperature for the growth is 27° C. to 37° C. but no growth at 50° C.
(2) Gelatin liquefaction (15% gelatin, incubated at 20° C.; and glucose-peptone-gelatin agar, incubated at 27° C.):
In case of simple gelatin medium, gelatin liquefaction was obseved as weak at 14 days incubation, but, in glucose-peptone-gelatin agar medium, as weak or moderate after 7 days incubation.
(3) Starch hydrolysis on starch-inorganic salts agar at 27° C.:
Weak hydrolysis was observed after 5 days incubation.
(4) Peptonization and coagulation of skimmed milk at 37° C.:
Moderate to stron peptonization began after 5 days incubation and finished after around 17 days. No coagulation.
(5) Melanin formation on tryptone-yeast extract medium (ISP medium No. 1); peptone-yeast extract-ferrous agar (ISP medium No. 7) incubated at 27° C. The formation of melanin-like pigment was positive.
(6) Utilization of carbon sources on Pridham-Gottlieb basal medium (ISP medium No. 9), incubated at 27° C.:
Abundant growth with L-arabinose, D-xylose, glucose, D-fructose, sucrose, inositol, L-rhamnose and raffinose; no growth with D-mannitol.
(7) Liquefaction of calcium malate on calcium malate agar at 27° C.
Calcium malate was strongly liquefied.
(8) Nitrate reduction on peptone medium containing 1% sodium nitrate (ISP medium No. 8), incubated at 27° C.:
Positive.
The above mutant in the present invention was deposited in the Fermentation Reseach Institutue, Japan as Streptomyces galilaeus KE 303, and added to their culture collections of microorganisms as FERM-P 4808.
Fermentative production of the compounds in the present invention is carried out by cultivating an anthracycline-non-producing strain capable of converting exogenous anthracyclinones to anthracycline glycosides according to the conventional fermentation process used for microorganisms belonging to the genus Streptomyces and adding corresponding anthracyclinone to the cultured media during the cultivation.
The media preferably contain commercially available products such as glucose, glycerol, starch, dextrin, sucrose, maltose, fats and oils as carbon sources; soybean powder, cotton seed cake, meat extract, peptone, dried yeast, yeast extract, corn steep liquor etc. as organic nitrogen sources; ammonium sulfate, sodium nitrate, ammonium chloride etc. as inorganic nitrogen sources; and, if necessary, sodium chloride, potassium chloride, phosphates, magnesium salts, heavy metal salts, and vitamins as trace elements can be used.
Submerged aerobic cultivation is preferably employed for the production, and can be carried out within the range of 20° C. to 38° C., and the preferred range of cultivation temperature is from 25° C. to 32° C.
The following procedure is provided as an example for fermentation and isolation of the compounds in the present invention.
The streptomyces culture grown on agar slant, for example, containing 0.3% yeast extract, 1.0% soluble starch, 1.5% agar and having pH 7.0 and stored at 6° to 7° C. is shakecultured for 1 to 2 days at 25° to 32° C. in an aqueous medium consisting of glucose, organic nitrogen sources and inorganic salts to prepare the seed culture. Then, the above seed culture is inoculated 1 to 3% in volume to an aqueous medium, for example, consisting of sucrose, glucose, soybean meal, and inorganic slats, and aerobically cultivated at 25° to 32° C. for 24 to 72 hours. During cultivation, anthracyclinone such as γ-rhodomycinone, ε-isorhodomycinone, β-rhodomycinone, ε-rhodomycinone and β-pyrromycinone at the concentration of 10 to 200 μg/ml is added as a substrate to the medium on the logarithmic growth phase, and the cultivation is further continued for 12 to 72 hours to complete the microbial conversion. Cultured medium thus obtained is centrifuged to separate mycelium from filtrate, and pigments are extracted from mycelium and purified as follows. To extract the compounds of the present invention, acetone, chloroform, methanol, toluene and acidic buffer solution can be used. Purification can be favorably carried out by adsorption column chromatography using silicic acid, and ion-exchange column chromatography using, for example, CM-cellulose (carboxymethyl cellulose, Brown Co.) and gel filtration using Sephadex LH-20 (crosslinked dextran gels Pharmacia Fine Chemical AB). Chemical structure of the compounds thus obtained in the present invention was determined as follows by ultraviolet and visible absorption (abbreviated as UV), infrared absorption (IR), 100 MHz proton and 13 C-NMR and mass spectral analyses, and also by spectral analyses of the anthracyclinone and sugar moieties obtained by acid hydrolysis.
For example, when ε-rhodomycinone was used as substrate for microbial conversion, ε-rhodomycin RDC having the formula III was obtained. ε-Isorhodomycin RDC (Formula IV), β-rhodomycin RDC (Formula V) and β-pyrromycin RDC (Formula VIII) were obtained from ε-isorhodomycinone, β-rhodomycinone and β-pyrromycinone, respectively. γ-Rhodomycinone gave both γ-rhodomycin RDC (Formula VI) and γ-rhodomycin RDRs (Formula VII). ##STR5##
The compounds in the present invention can be obtained as free base or non-toxic acid addition salts with a variety of organic and inorganic salt-forming reagents. Thus, acid addition salts can be formed with such acids as sulfuric, phosphoric, hydrochloric, bromic, nitric, acetic, propionic, maleic, oleic, citric, succinic, tartaric, fumaric, glutamic, pantothenic, laurylsulfonic, methansulfonic, naphthalenesulfonic and related acids. For use as anticancer agent, free base form of the compounds is equivalent to their non-toxic acid addition salts. Free base of the compounds can be lyophilized with non-toxic acid in the proper solution or acid addition salts can be recovered by precipitation from solvents capable of dissolving slightly their non-toxic acid addition salts. These acid addition salts can be changed in original free base form by neutralizing with basic compounds, and vice versa.
The following are physiocochemical properties of the compounds in the present invention:
__________________________________________________________________________ Compound III IV V VI VII VIII__________________________________________________________________________Melting point (°C.) 160-162 162-164 163-165 143-145 139-142 128-135UV and visible 235(513) 240(508) 235(502) 236(431) 236(380) 234(496)absorption 255(307) 295( 90) 252(315) 254(384) 254(344) 256(265)spectrum 292(102) 490s(123) 292( 98) 295( 98) 295( 86) 290(106) λ.sup.max .sub.nm (E.sup.1% 1cm ) 492(184) 521(184) 495(183) 495(196) 495(174) 492(132) 527s(118) 547(175) 528(136) 528(150) 528(133) 512(102)90% methanol 585s( 14) 560(187) 580( 30) 560s(33) 560s(30) 526( 84) 605( 48)0.1N HCl-90% 235(526) 240(555) 234(530) 236(468) 236(418) 234(504) methanol 255(319) 295( 98) 254(330) 254(400) 254(362) 256(265) 292(106) 490s(145) 290(105) 295(106) 295( 96) 290(106) 492(191) 521(210) 495(198) 495(201) 495(180) 492(143) 527s(119) 547(185) 528(135) 528(148) 528(132) 514(115) 559(194) 570s(14) 560s(30) 560s(25) 526( 93) 605( 48)0.1N NaOH-90% 242(555) 243(585) 241(595) 242(591) 242(525) 235(433) methanol 287( 99) 280s(95) 285(107) 290(108) 290s(98) 296( 88) 566(222) 589(229) 565(220) 558(232) 558(198) 560(141) 605(194) 632(261) 600s(175) 592(200) 592(177) 597(127)PMR spectrum FIG. 1 FIG. 2 FIG. 3 FIG. 4 FIG. 5 FIG. 6IR spectrum (KBr) 3475,2940 3450,2940 3450,2950 3425,2940 3450,2950 3420,2930 1730,1600 1730,1590 1730,1600 1730,1600 1605,1445 1730,1595cm.sup.-1 1440,1400 1450,1435 1440,1400 1445,1400 1400,1300 1440,1285 1290,1240 1400,1300 1300,1240 1295,1255 1260,1210 1215,1160 1195,1165 1260,1190 1200,1170 1205,1170 1170,1120 1120,1100 1120,1010 1170,1120 1120,1010 1120,1100 1005 1010 1010 1000 1015Appearance red red red red red dark powder powder powder powder powder red*R.sub.f value (1) 0.73 0.71 0.55 0.54 0.25 0.41Solvent (2) 0.37 0.31 0.25 0.25 0.07 0.08(3) 0.43 0.42 0.32 0.34 0.20 0.06__________________________________________________________________________ *Silica gel thinlayer (Kieselgel 60F, Merck Co.) Solvent: (1)Chloroform:Methanol (10:1, vol) (2)Chloroform:Methanol:Formic acid (100:10;1, (3)Benzene:Ethylacetate:Methanol:formic (5:5:1:0.3, vol)
The following describes usefulness of the compounds in the present invention.
(1) The compounds in the present invention inhibited markedly the growth and nucleic acid biosynthesis of murine leukemic L 1210 cells in culture. In an example, L 1210 cells were inoculated in RPMI (Rosewell Park Memorial Institute) 1640 medium containing 20% calf serum at the cell density of 5×10 4 cells/ml, and the compound in the present invention was simultaneously added to the medium at the concentration of 0.1 and 0.5 μg/ml and incubated at 37° C. in a CO 2 incubator. 50% growth inhibition concentration of the compound over controls was determined. L 1210 cells as described above were also inoculated at 5×10 5 cells in RPMI 1640 medium containing 10% calf serum and incubated at 37° C. for 1 to 2 hours in a CO 2 incubator. The cells were cultured for 15 min. at 37° C. after the compounds according to the present invention at various concentrations were added, and then 14 C-uridine (0.05 μCi/ml) or 14 C-thymidine (0.05 μCi/ml) was added and incubated for further 60 min. at 37° C. After stopping the pulse-labeling by addition of 10% trichloroacetic acid (TCA) solution to the reaction mixture, acid-insoluble materials were precipitated, washed three times with 5 to 10% TCA, and dissolved in a small amount of formic acid. Then, radioactivity was determined, and inhibitory effects on the DNA and RNA biosynthesis were indicated by the 50% inhibition concentration (IC 50 ) of the incorporation of radioactivity over controls. The results are shown in the following table.
______________________________________ IC.sub.50 (μg/ml) Inhibition DNA RNA ratioCompound Growth synthesis DNA/RNA______________________________________ε-Rhodomycin RDC 0.01 0.7 0.08 8.8ε-Isorhodomycin RDC 0.007 1.25 0.11 11.1β-Rhodomycin RDC 0.01 0.57 0.15 3.8γ-Rhodomycin RDC 0.11 0.85 0.28 3.0γ-Rhodomycin RDRs 0.09 0.7 0.3 2.3β-Pyrromycin RDC 1.0 2.0 1.5 1.3______________________________________
(2) The compounds in the present invention showed the marked inhibitory effects on experimental animal tumors. Antitumor action was most significantly demonstrated in L 1210 leukemia in mice. For example, when CDF 1 mice weighing 18 to 22 grams were inoculated with 1×10 6 cells of L 1210 cells intraperitoneally and the compound was administered intraperitoneally once daily for 10 days consecutively 24 hours after inoculation, the survival time of mice was over 200% by T/C(%) at optimum dose as shown in the following table. On the other hand, their LD 50 values against mice upon a single intravenous injection were more than 28 mg/kg, and thus their acute toxicity was much lower than that of adriamycin, which gave 14.2 mg/kg.
Antitumor effect and acute toxicity in mice
______________________________________ Opt. dose T/C LD.sub.50 (i.v.)Compound (mg/kg/day) (%) (mg/kg)______________________________________ε-Rhodomycin RDC 2 240 32.5ε-Isorhodomycin RDC 2 235 28.2β-Rhodomycin RDC 2 306 28.0γ-Rhodomycin RDC 2 209 39.8γ-Rhodomycin RDRs 2 203 40.6ε-Pyrromycin RDC 20 202 85.5Adriamycin 1 286 14.2______________________________________
As mentioned above, the compounds in the present invention are useful anticancer agents with their characteristic inhibitory action, since ε-rhodomycin RDC, ε-isorhodomycin RDC and β-rhodomycin RDC suppressed the growth of murine leukemic cells at extremely low concentration, and ε-rhodomycin RDC and ε-isorhodomycin RDC inhibited specifically RNA synthesis of L 1210 cells. The following provides for the illustrative preparation procedure of anthracyclinones used in the Example below.
Example
A preparation of anthracyclinones used as substrate
Anthracyclinones as substrate in the present invention can be prepared as follows:
Actinomyces roseoviolaceus IFO 13081 capable of producing roseorubicins A and B was shake-cultured in the seed medium consisting of 0.3% yeast extract and 1% soluble starch, pH 7.0 (100 ml/500-ml Erlenmeyer flask) for 3 days.
Two hundred and fifty 500-ml flasks containing 50 ml of the sterilized production medium consisting of 4% sucrose, 2.5% soybean meal, 0.1% yeast extract, 0.25% sodium chloride, 0.32% calcium carbonate, 0.0005% CuSO 4 .7H 2 O, 0.0005% MnCl 2 .4H 2 O and 0.0005% ZnSO 4 .7H 2 O, (pH 7.4) (%: wt/vol%) were inoculated respectively with 1 ml each of the seed culture, and shake-cultured for 5 days at 28° C. on a rotary shaker (210 rpm). The resulting cultured medium was centrifuged to separate mycelium and supernatant fluid. Mycelium was extracted with 2 liters of acetone, concentrated and reextracted with 1 liter of chloroform, and the supernatant fluid was extracted with 2 liters of chloroform, combined with the extract from mycelium, and concentrated to dryness to obtain crude substance. Crude substance was dissolved in 70 ml of methanol and the insoluble materials were centrifuged off. The supernatant fluid was applied onto a cross-linked dextran gel (Pharmacia Fine Chemical AB, Sephadex LH-20) (φ4.0×40 cm), eluted with methanol, and fractionated to obtain the initial glycoside fraction and following anthracyclinone fraction. The glycoside fraction was concentrated to dryness; 200 ml of 3.0 N hydrochloride acid were added; and hydrolysis was effected for 1 hour at 85° C. Hydrolysate was extracted with 500 ml of chloroform, and concentrated to obtain crude anthracyclinones containing γ-rhodomycinone, β-rhodomycinone and β-pyrromycinone. The crude anthracyclinones were spotted on preparative thin-layers (60 PF 254 , E. Merck & Co.) and developed with the solvent system of chloroform:methanol (20:1 vol.), and the bands showing R f s 0.53, 0.44 and 0.34 corresponding to γ-rhodomycinone, β-rhodomycinone and β-pyrromycinone were respectively scratched off. Each anthracylinone was extracted from silica gel with the mixture of chloroform-methanol (5:1 vol.), concentrated to dryness, dissolved in a small amount of methanol, and chromatographed with methanol using a cross-linked dextran gel (before mentioned) (φ1.5 cm×50 cm). There were obtained 130 ml of γ-rhodomycinone, 68 mg of β-rhodomycinone and 43 mg of β-pyrromycinone. On the other hand, the above mentioned anthracyclinone fraction (on page 26, line 23) was concentrated to dryness, spotted onto preparative thin-layer, and developed with the solvent system of benzene-acetone-formic acid (100:20:1 vol.). The bands corresponding to ε-rhodomycinone and ε-isorhodomycinone showing R f values at 0.75 and 0.70, respectively, were scratched off and extracted separately with a mixture of chloroform-methanol (5:1 vol.). Each extract was concentrated to dryness, chromatographed on a cross-linked dextran gel (before mentioned) column as mentioned above, and 28 mg of ε-rhodomycinone, and 32 mg of ε-isorhodomycinone were obtained. Physicochemical properties of the resultant anthracyclinones coincided fully with those of authentic samples in the absorption spectra of UV, IR, mass and NMR, elementary analysis, melting point and R f values on silicic acid thin layer, and with those values published in the literature (Chem. Ber. 100, 3578-3587 (1967) for ε-rhodomycinone, ε-isorhodomycinone and β-rhodomycinone; Tetrahedron (London) 19, 395-400 (1963) for ε-rhodomycinone). On the other hand, β-pyrromycinone is a new anthracyclinoe having the following physicochemical properties:
Physicochemical Properties of β-Pyrromycinone:
Melting point: 193°-198° C.
Mol. Wt.: 386 (Mass spectrum, M + )
Elementary analysis: C 20 H 18 O 8
______________________________________ C H O______________________________________Calcd. (%) 62.18 4.70 33.13Found (%) 62.02 4.82 33.41______________________________________
UV and visible absorption spectra:
______________________________________ ##STR6## 233(1173), 256(579), 290(212), 491(359), 511s(282), 525s(230) ##STR7## 233(1315), 256(672), 290(243), 491(389), 510s(311), 525s(247) ##STR8## 235(1053), 290s(205), 511(358), 593s(276)______________________________________
IR (KBr) spectrum, cm -1 : 3400, 2900, 1595, 1440, 1280, 1220
Mass spectrum: 386 (M 30 ), 368 (M + --H 2 O)
PMR spectrum (100 Hz, CDCl 3 ): δ ppm: 1.04, t, CH 2 --CH 3 ; 1.75, q, J=7 Hz, CH 2 -CH 3 ; 2.13, d, J=5 Hz, CH 2 -8; 4.74, s, CH-7 & CH-10; 7.95, s, CH-11 7.35, s, CH-2 & CH-3; hydrogen bonded phenolic hydroxyls (12.1, 12.7 & 12.9)
The following example is provided for illustrative purpose only and is not intended to limit the scope of the invention.
EXAMPLE 1
A nutrient medium having the following composition was prepared:
______________________________________Soluble starch 1.5 wt/vol %Glucose 1.0 wt/vol %Soybean meal 1.0 wt/vol %Yeast extract 0.1 wt/vol %NaCl 0.3 wt/vol %K.sub.2 HPO.sub.4 0.1 wt/vol %MgSO.sub.4 . 7H.sub.2 O 0.1 wt/vol %CuSO.sub.4 . 5H.sub.2 O 0.007 wt/vol %FeSO.sub.4 . 7H.sub.2 O 0.001 wt/vol %MnCl.sub.2 . 4H.sub.2 O 0.0008 wt/vol %ZnSO.sub.4 . 7H.sub.2 O 0.0002 wt/vol %pH 7.4______________________________________
One hundrend ml of this medium was sterilized in a 500-ml Erlenmeyer flask which was inoculated respectively from an agar slant culture of Streptomyces galilaeus KE 303 by platinum loop, and incubated for 48 hours at 28° C. on a rotary shaker. Fifteen hundred 500-ml flasks containing 50 ml of the previously sterilized medium consisted of the same composition as above except for the soybean meal being increased to 3% were respectively inoculated by 1 ml of the seed culture, and cultivated for 20 hours at 28° C. on a rotary shaker (210 rpm). After dividing into five groups of flasks, to 300 flasks of the first group were added 2 ml of ε-rhodomycinone solution (500 μg/ml) in methanol (final concentration of substrate: 20 μg/ml in flask). In the same manner, β-rhodomycinone, ε-isorhodomycinone, γ-rhodomycinone and β-pyrromycinone were added respectively to the other groups of flasks, and cultivation was continued for 24 hours. Respective cultured medium was centrifuged to harvest the mycelium, and respective products were extracted twice from mycelium with 2 liters of acetone. After concentrating the acetone extract to one third volume under reduced pressure, pigments were reextracted with chloroform and concentrated to dryness. The crude conversion product was dissolved in 500 ml of methanol, and insoluble materials were removed by centrifugation. The supernatant methanol solution was introduced onto a cross-linked dextran gel (before mentioned) column (3.5 cm×40 cm) and eluted with methanol. Initial pigment fraction was collected, concentrated to dryness, dissolved in a small amount of chloroform, spotted on preparative thin-layers (kiesalgel 60 PF 254 , E. Merck & Co.) and developed in a mixture of chloroform-methanol (20:1 vol.).
The band corresponding to the conversion product was scratched off, eluted with chloroform-methanol (5:1 vol.), and concentrated to dryness to obtain red crude preparation. This red preparation was dissolved in 10 ml of toluene, shaken vigorously with 10 ml of 0.1 M acetate buffer (pH 3.0) containing 2 mM ethylene diaminetetraacetic acid and the conversion product was transferred to acidic aqueous layer. The aqueous layer was adjusted to pH 7.0 with 1 N NaOH aqueous solution, reextracted with chloroform, dried over sodium sulfate anhydride and concentrated under reduced pressure. n-Hexane was added to the concentrate, and resulting red precipitate was filtered and dried in vacuo to obtain pure compound. The conversion products from other anthracyclinone were extracted from the cultured medium and purified by the same procedure as for ε-rhodomycin RDC, and 57 ml of ε-rhodomycin RDC, 27 mg of ε-isorhodomycin RDC, 48 ml of β-rhodomycin RDC, 18 mg of γ-rhodomycin RDC, 14 mg of γ-rhodomycin RDRs and 24 mg of β-pyrromycin RDC were obtained respectively.
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New anthracycline glycoside derivatives of rhodomycin-group, ε-rhodomycin RDC, ε-isorhodomycin RDC, β-rhodomycin RDC, γ-rhodomycin RDC, γ-rhodomycin RDRs and β-pyrromycin RDC having potent anticancer activities and lower toxicities and a process for the production thereof by microbiological conversion method are disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a titanium dioxide coating method and the electrolyte used therein, and more particularly to an electrodeposition method for coating titanium dioxide and the electrolyte used therein.
[0003] 2. Description of the Prior Art
[0004] Titanium dioxide, also known as titania, is widely recognized as an important electrode material in semiconductor photo-electrochemistry. Among the three main crystalline phases: anatase, rutile, and brookite TiO 2 , the anatase form (A-TiO 2 ) is the most popular photo-electrode because the lowest unoccupied molecular orbital of dyes, such as N719, is very close to the conduction band of A-TiO 2 .
[0005] In addition, A-TiO 2 generally shows relatively high reactivity and chemical stability under ultraviolet light excitation for water and air purifications, photocatalysts, gas sensors, electrochromic devices, and so on, further emphasizing its practical importance.
[0006] Several techniques were proposed for fabricating TiO 2 , such as sol-gel, chemical vapor deposition, hydrothermal, electrospinning, anodizing, and electrodeposition.
[0007] Among these methods, cathodic deposition of TiO 2 becomes attractive because electrochemical deposition provides the advantages of controlling the thickness and morphology by varying the electroplating parameters, relatively uniform deposits on complex shapes, and use of low cost instrumentations.
[0008] To sum up, it is now a current goal to develop a cathodic deposition method for coating titanium dioxide.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to provide an electrolytic method for coating titanium dioxide to gain the advantages of controlling the thickness, porosity, and morphology by varying the electroplating parameters, relatively uniform deposits on complex shapes, and use of low cost instrumentations.
[0010] The present invention is directed to a cathodic deposition method for coating a titanium dioxide film.
[0011] The present invention is also directed to an electrolyte for coating titanium dioxide including Ti 3+ and at least one of NO 3 − and NO 2 − .
[0012] According to one embodiment, the present invention provides a titanium dioxide coating method, which includes following steps. An electrolyte containing Ti 3+ and at least one of NO 3 − and NO 2 − is provided for an electrodeposition device. A substrate is immersed into the electrolyte and electrically connected to the electrodeposition device. A cathodic current from the electrodeposition device is applied to the substrate for reducing NO 2 − or NO 3 − and to form titanium dioxide film on the surface of the substrate.
[0013] Other advantages of the present invention will become apparent from the following descriptions taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing aspects and many of the accompanying advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0015] FIG. 1 illustrates a flowchart of a titanium dioxide coating method according to one embodiment of the present invention;
[0016] FIG. 2 illustrates LSV (linear sweep voltammetry) curves according to one embodiment of the present invention;
[0017] FIG. 3A illustrates first and second scans of LSV curves according to one embodiment of the present invention;
[0018] FIG. 3B illustrates the corresponding EQCM (electrochemical quartz crystal microbalance) responses of the first and second scans of LSV in FIG. 3A according to one embodiment of the present invention;
[0019] FIG. 3C illustrates an enlarged view of FIG. 3B ;
[0020] FIGS. 4A and 4B illustrate SEM (Scanning Electron Microscope) images according to one embodiment of the present invention;
[0021] FIGS. 4C and 4D illustrate TEM (Transmission Electron Microscope) images according to one embodiment of the present invention; and
[0022] FIGS. 4E and 4F illustrate depth profiles of XPS (X-ray photoelectron spectra) according to one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] FIG. 1 illustrates a flowchart of a titanium dioxide coating method including following steps. Beginning at step S 1 , an electrolyte containing Ti 3+ and at least one of NO 3 − and NO 2 − initiates the redox reaction between Ti 3+ and NO 3 − /NO 2 − to form Ti(IV) and NO 2 − /N 2 . This electrolyte is provided for an electrodeposition device. Next, at step S 2 , a substrate is then immersed into the electrolyte and at step S 3 , the substrate is electrically connected to the electrodeposition device. At step S 4 , a cathodic current is applied on the substrate via the electrodeposition device for reducing NO 2 − or NO 3 − to generate extensive OH − for depositing TiO 2 films on the surface of substrates. The cathodic current can be applied by galvanostatic (constant dc current), potentiostatic (constant voltage), potentiodynamic, or galvanodynamic methods, or in the pulse voltage or pulse current modes.
[0024] The continuous reduction of NO 2 − to N 2 and NH 3 generates extensive OH − , and effectively enhances the deposition of TiO 2 films on the surface of substrates.
[0025] In one embodiment, a post annealing step is further performed after forming the titanium dioxide film on the surface of the substrate, wherein the post annealing step is carried out at about 100-800° C.
[0026] The following descriptions of specific embodiments of the present invention have been presented for purposes of illustrations and description, and they are not intended to be exclusive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention can be defined by the Claims appended hereto and their equivalents.
[0027] TiO 2 particulates are cathodically deposited onto graphite substrates from an electrolyte bath containing 0.47 M HCl, 25 mM TiCl 3 and 75 mM NaNO 3 in an electrodeposition device according to an embodiment of the present invention. A pretreatment procedure of graphite substrates may be performed and the detailed description thereof is herein omitted.
[0028] According to one embodiment of the present invention, the redox reaction between Ti 3+ and NO 3 − during preparation of the deposition solution is herein disclosed. Nitrates, acting as the oxidizers, were reduced to NO 2 (reddish-brown bubbles) when the transparent NaNO 3 solution was added into the purple TiCl 3 solution. Since NO 2 molecules are soluble in aqueous media, they will automatically convert into NO 3 − and NO 2 − . This statement is supported by the observation that reddish-brown bubbles gradually disappear within 30-40 seconds and the purple TiCl 3 solution in presence of Ti 3+ is a colorless transparent solution indicating the formation of TiO 2+ (see equations 1 and 2)
[0000] Ti 3+ +NO 3 —→TiO 2+ +NO 2 (1)
[0000] 2NO 2 +H 2 O→HNO 3 +HNO 2 (2)
[0029] Curves 1 - 5 in FIG. 2 correspond to the i-E responses measured from various electrolytes. As can be seen from the curves 1 and 2 , reduction commences at potentials negative to −0.6 V and no gas evolution is found at potentials positive to −0.6 V. However, a rapid generation of many bubbles is clearly observed when potentials are negative to −0.6 V, indicating H 2 evolution. On curves 3 and 4 , reduction starts in the more positive potential region, revealing the facile reduction of NaNO 2 . In addition, minor gas evolution commences from 0.4 V to −0.4 V with a low current density, while gas evolution ceases in the potential range from −0.4 V to −1.2 V and occurs dramatically again at potentials behind −1.2 V. The above results indicate that NO 2 − is responsible for the reduction in the more positive potential region with minor gas evolution, presumably due to the reduction of NO 2 − into N 2 molecules. Since gas evolution temporarily disappears in the potential range from −0.4 V to −1.2 V. This result suggests a further reduction of N 2 to NH 4 + in such a negative potential range (see equations 3 and 4).
[0000] 2NO 2 − +4H 2 O+6e→N 2 +8OH − (3)
[0000] N 2 +8H 2 O+6e→2NH 4 + +8OH − (4)
[0030] On curve 5 , gas evolves gently at about −0.1 V, disappears at ca. −0.4 V and, dramatically evolves again at potentials negative to −1.2 V, which completely follows the gas evolution-disappearance phenomena measured from the solution containing NO 2 − . Accordingly, NO 2 − reduction in the designed deposition bath for generating concentrated OH − at the vicinity of electrode surface is concluded to be an effective step in promoting the deposition of TiO(OH) 2 (see equation 5). The TiO(OH) 2 is then dehyrated to form TiO 2 .
[0000] TiO 2+ +2OH − +xH 2 O→TiO(OH) 2 .xH 2 O (5)
[0031] The mechanism proposed in this invention not only reasonably interprets the gas evolution/disappearance phenomena but also explains the slight increase in bath pH after the deposition, which is different from the slight decrease in pH found in previous case of NO 3 − reduction. Based on equations 3 and 4, OH − is mainly provided by the NO 2 − reduction and the consequent N 2 reduction, resulting in the generation of NH 4+ . As a result, a slight increase in pH found in this formulated solution after TiO 2 deposition is reasonable because the OH − /electron ratio for the reduction of NO 2 − and N 2 is 4/3, larger than the proton/electron ratio (equal to 1) for oxygen evolution at the anode. Moreover, the deposition rate in this formulated solution is very fast, attributable to the massive generation of OH − .
[0032] FIG. 3A illustrates the first and second scans of LSV (linear sweep voltammetry) curves and FIG. 3B illustrates the corresponding EQCM (electrochemical quartz crystal microbalance) responses of the first and second scans of LSV measured from the designed solution in order to precisely obtain the onset potential of deposition. A comparison of the i-E and mass-E responses indicates that there is always an incubation period for N 2 evolution in the positive potential range, e.g., from 0.2 to −0.7 V and from 0.1 to −0.65 V for the first and second sweeps, respectively. Although in the incubation range, NO 2 − starts to be reduced to N 2 , no significant increase in mass is observed. The slight weight gain in this potential region is probably due to the NO 2 − adsorption at the cathode. Based on the EQCM result, once the potential is negative enough to generate/accumulate concentrated OH − , TiO 2+ will combine with OH − to form TiO 2 and an obvious weight gain is visible behind this onset potential of deposition (−0.85 and −0.65 V for the first and second scans, respectively). Also note the positive shift in the onset potential of deposition during the second scan. This phenomenon is probably due to the electrocatalytic property of TiO(OH) 2 and TiO 2 already deposited onto the graphite surface during the first scan for NO 2 − /N 2 reduction.
[0033] The electrodes were cleaned in an ultrasonic DI water bath and dried under a cool air flow after cathodic deposition. After cleaning and drying, some electrodes were annealed at 400° C. in air for 1 hr. The morphologies were examined by a FE-SEM (Field-Emission Scanning Electron Microscope, FE-SEM). The EQCM study was performed by an electrochemical analyzer, CHI 4051A in a one-compartment cell. The microstructure and SAED (selected area electron diffraction, SAED) patterns of as-deposited and annealed TiO 2 deposits were observed through a TEM (FEI E.O Tecnai F20 G2). The depth profiles of Ti and O were measured by an X-ray photoelectron spectrometer (XPS, ULVAC-PHI Quantera SXM), employed Al monochromator (hv=1486.69 eV) irradiation as the photosource.
[0034] It is favorable to prepare porous A-TiO 2 films by combining cathodic deposition from this designed Ti 3+ +NO 3 − solution and post-deposition annealing. As illustrated in FIGS. 4 A and 4 B, TiO 2 films before and after annealing are porous and the particle size is roughly estimated to be 60-100 nm. The porous nature of TiO 2 films prepared in this invention is probably due to the extensive tiny bubble evolution during the deposition. The particulates are considered as aggregates of TiO 2 primary particles.
[0035] The average size for as-deposited TiO 2 primary particles is about 6 nm, which is enlarged by post-deposition annealing (ca. 10 nm for TiO 2 annealed at 400° C.) from FIGS. 4C and 4D . The lattice clearly visible in FIG. 4D and the diffraction rings in its inset indicate the anatase structure which is transformed from the amorphous, as-deposited TiO 2 by post-deposition annealing. FIGS. 4E and 4F illustrate the depth profiles of Ti, O, and C for as-deposited and annealed samples. Clearly, the atomic ratio of Ti/O is approximately constant (ca. ½) within the whole oxide matrix.
[0036] This result confirms the formation of TiO 2 in the as-prepared and annealed films. Accordingly, combining cathodic deposition from this designed Ti 3+ +NO 3 − solution and post-deposition annealing is favorable for preparation of porous A-TiO 2 films.
[0037] The aforementioned embodiment exemplified the reaction from the electrolyte solution containing Ti 3+ +NO 3 − ; however, the redox reaction between Ti 3+ and NO 2 − in an electrolyte solution can be used for depositing titanium dioxide films (See Equation 6 and Equation 3-5).
[0000] 6Ti 3+ +2NO 2 -+2H 2 O→6TiO 2+ +N 2 +4H + (6)
[0038] To sum up, a titanium dioxide coating method according to the present invention includes a cathodic deposition using an electrolytic solution containing Ti 3+ and at least one of NO 3 − and NO 2 − , and a post-deposition annealing process, which is favorable for preparing porous A-TiO 2 films. The redox reaction between Ti 3+ and NO 3 − /NO 2 − to form Ti(IV) and NO 2 − /N 2 prior to cathodic deposition effectively promotes the TiO 2 deposition. The continuous reduction of NO 2 − to N 2 and NH 3 generates extensive OH − and effectively enhances the deposition of TiO 2 for forming a TiO 2 film at the substrate surface.
[0039] The porous, anatase structure of annealed TiO 2 , examined by FE-SEM, TEM, and SAED analyses is expected to be good for the dye-sensitized solar cell (DSSC) application. In addition, A-TiO 2 may be applicable for water and air purifications, photocatalysts, gas sensors, electrochromic devices, and so on.
[0040] While the invention is susceptible to various modifications and alternative forms, a specific example thereof has been shown in the drawings and is herein described in detail. It should be understood, however, that the invention is not to be limited to the particular form disclosed, but to the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the appended claims.
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A titanium dioxide coating method is disclosed. An electrolyte containing Ti 3+ and at least one of NO 3 − and NO 2 − is provided for an electrodeposition device. A substrate is immersed into the electrolyte and electrically connected to the electrodeposition device. A cathodic current is applied to the substrate via the electrodeposition device for reduction of NO 2 − or NO 3 − . A titanium dioxide film is thus formed on the surface of the substrate. The thickness, porosity, and morphology of the titanium dioxide film can be controlled by varying the electroplating parameters, and relatively uniform deposits on complex shapes can be obtained by use of low cost instruments.
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BACKGROUND OF THE INVENTION
This invention relates to a semiconductor memory test system which is capable of testing semiconductor memories by providing address signals and write-in data to the memories under test from a pattern generator, reading out the stored data from the memories under test, and comparing this read-out data with expected data.
FIG. 1 is a block diagram of one example of a conventional semiconductor memory test system 20. According to this system, an address signal is supplied to a memory 13 that is to be tested from an address terminal 12, and data generated by a conventional pattern generator 11 is written-in to this address of the memory 13 via a data terminal 14. After that, the data in the memory 13 is read out to a logic comparator 15, and the readout data is then compared with expected data in the logic comparator 15 to determine whether the memory 13 works correctly or not.
The conventional pattern generator 11 is composed of an address generator 21, a data generator 22, a data memory 23, a clock generator 24, and a sequence control unit 25. The sequence control unit 25 controls the address generator 21, the data generator 22, and the clock generator 24. The address generator 21 generates address signals that are supplied to the memory 13. The data generator 22 generates data to be written into the memory 13 and expected data to be supplied to the logic comparator 15.
Similarly to the data generator 22, the data memory 23 generates write data to be supplied to the memory 13 and the expected data to be outputted to the logic comparator 15. The data generator 22 is utilized for sequential and/or repeatable data generation but the data memory 23 is utilized for irregular or random data generation. A multiplexer 26 selects to output data from the data generator 22 or from the data memory 23 and provides it to the data terminal 14.
In a conventional semiconductor memory test system, such as the one illustrated in FIG. 1, there are several disadvantages, as described below.
(a) One type of memory is capable of inhibiting the writing-in procedure for arbitrary selected bits. In this memory, supplied data is written into the bits which are not inhibited, whereas the previously stored data remains in the bits for which writing-in is inhibited. For testing this type of memory, the expected data must be determined from the combination of data in the memory before write-in, supplied data, and mask data, which determines the inhibited bits. However, since there are many variations of combinations possible, generating the expected data is not possible in a convention memory test system.
(b) For testing a memory which incorporates a logical arithmetic function, expected data must be determined from the supplied data of the pattern generator, the written-in data of the memory under test, and the nature of the arithmetic function in this memory. Therefore, generating the expected data for this type of memory is difficult for a conventional test system.
(c) Another type of memory has both a random access port and a serial access port, as illustrated in FIG. 9. A RAM unit 27 is accessed through the random access port and its operation is identical to dynamic random access memories generally employed. A SAM unit 28 of the memory is accessed by a pointer contained in the memory chip and synchronized by a clock. The pointer is incremented by one as each clock pulse is inputted. Data transfer between the RAM unit 27 and the RAM unit 28 is also possible. The RAM unit 27 functions as a dynamic RAM through the random access port, however, the RAM unit 27 and the SAM unit 28 can also function independently and asynchronously.
For testing the type of memory which has both a random access port and a serial access port as described above, address and data signals have to be provided simultaneously and independently to the RAM unit 27 and the SAM unit 28. Since there is only one set of address and data generators in the conventional pattern generator 11 of a conventional test system, such generation is not possible. Even if the data memory 23 is utilized to generate data, an address from the address generator 21 is needed to access the memory. And if this address is used for the SAM unit 28, it has to be generated in sequential order; thus, address generation for the RAM unit 27, which needs random address generation, is not available.
(d) In a FIFO memory, a write-in address and a read-out address of the FIFO memory having a write-in pointer and a read-out pointer are determined by each pointer, and these pointers are incremented by a write-in clock and a read-out clock respectively. for testing the memory of this kind, the addresses have to be determined by the write-in pointer and the read-out pointer during the write-in and the read-out operations respectively. However, in the conventional memory test system there is only one kind of address generating unit for accessing the data memory 23 for generating the expected data pattern. Therefore, in a conventional test system, it is not possible to generate the address for the read-out pointer while simultaneously generating the address for the write-in pointer.
SUMMARY OF THE INVENTION
An object of this invention is to provide a semiconductor memory test for high accuracy testing of semiconductor memories.
It is another object of this invention to provide a high accuracy testing for different varieties of semiconductor memories.
According to this invention, address signals generated by a modified pattern generator are provided to a memory under test, which is composed so that data is supplied and written-in to this memory in the same way as in the conventional system. In addition, the pattern generator accesses a buffer memory using the above address signals and writes the identical data into the buffer memory. That is, the same data is stored at the same location both in the buffer memory and the memory under test. When reading-out an address from the memory under test, the same address is also read out from the buffer memory and is used as expected data for comparison with read-out data from the memory under test in a logic comparator.
For testing a memory in which arbitrary bits can be inhibited from having data written-in, it is sufficient to utilize a buffer memory which has control terminals so that it can selectively read and write the write-in data for each bit. Further, in instances where the memory under test contains a mask register and thus write-in for each bit depends upon the contents of the mask register, a mask register is also provided to the buffer memory and stores therein the same mask data as stored in the mask register of the memory under test. In addition, the mask data and an input write-in control signal are supplied to AND gates and outputs of the AND gates are connected to write-in control terminals of the buffer memory. Therefore, write-in prevention for each bit of the buffer memory would be executed in the same manner as for the memory under test, using the above procedures.
In order to test a memory internalizing an arithmetic function device, first, an arithmetic function unit is provided between the buffer memory and the pattern generator and connected in series with the data input terminal of the buffer memory; secondly, write-in data for the memory under test is also provided to a first input terminal of the arithmetic function unit, while read-out data from the buffer memory is simultaneously provided to a second input terminal of the arithmetic function unit; and thirdly, the arithmetic operation is carried out and the result is stored in the buffer memory.
In order to test a memory with random and serial access ports, a multiplexer and a counter are provided at the address input of the buffer memory. The counter sets an address so that a pointer identical to a pointer in the memory under test can be set and is incremented by a clock. A multiplexer selects either the contents of the counter or the address supplied to the memory under test from the address generator and provides its selection to the buffer memory as an address. When randomly accessing the memory under test, the buffer memory is also provided with the same random address through the multiplexer. On the other hand, when accessing the memory under test serially through the serial access port, the counter provides the buffer memory with a serial address, beginning with the address indicated by the pointer, and which is then incremented by the clock.
In instances where the memory under test operates both write-in and read-out functions at the same time, an additional multiplexer and a buffer memory pair is provided so that one pair is used for write-in while the other pair is used for read-out, and both operations can be conducted simultaneously.
In order to test a FIFO memory which has a write-in pointer and a read-out pointer, a multiplexer and two counters are provided between the pattern generator and the buffer memory so that the multiplexer can select from three sources, that is, the contents of the two counters and the address from the address generator, for allowing access to he buffer memory. Each counter stores an address which is identical to the address in one of the pointers for the memory under test. More specifically, the write-in pointer address is set in one counter and the read-out pointer address is set in the other counter. Those counters are driven by a write-in clock and/or read-out clock of the memory under test so that exactly the same write-in and read-out operation as the memory under test is executed in the buffer memory.
These together with other objects and advantages of the invention will become more apparent from the following descriptions, reference being had to the accompanying drawings wherein like reference numerals designate the same or similar parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a conventional semiconductor memory test system;
FIG. 2 is a block diagram showing a basic embodiment of a semiconductor memory test system according to the present invention;
FIG. 3 is a block diagram of the test system according to the present invention for testing a memory which prevents write-in for selected bits;
FIG. 4 is another block diagram showing a modification of the test system according to FIG. 3;
FIG. 5 is a block diagram illustrating a memory test system for testing a memory which internalizes computational functions;
FIG. 6 is a block diagram which illustrates a memory test system for testing a memory with a random access port and a serial access port;
FIG. 7 is a block diagram illustrating another embodiment of the memory test system for testing a memory that has both random and serial access ports;
FIG. 8 is a block diagram of the test system for a FIFO memory which has a write-in pointer and a read-out pointer; and
FIG. 9 is a block diagram illustrating a semiconductor memory which has a random access port and a serial access port.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 illustrates a basic structure of this invention. Some parts corresponding to FIG. 1 are indicated by the same reference numerals, and function as indicated above.
In this invention, a buffer memory 31 with the same or greater memory capacity than a memory 13 to be tested is provided, as well as a control signal generator 32 along with the previously described elements in a modified pattern generator 11M.
The control signal generator 32 is controlled by a sequence control unit 25. Its function is to generate control signals for the buffer memory 31. The buffer memory 31 can change its structure depending on the structure of the memory 13 under test. That is, for example, the buffer memory 31 is of a one word bit structure when the test memory 13 is one word one bit, and a one word four bit structure when the test memory 13 is one word four bit.
Exactly the same data and address signals are provided to both the buffer memory 31 and the test memory 13; therefore, exactly the same data should be stored in the same address of both the buffer memory 31 and the test memory 13. During a read process, the test memory 13 and the buffer memory 31 are accessed by address signals generated by the pattern generator 11M. Thereafter, read-out data of the test memory 13 is compared with expected data read-out from the buffer memory 31 at a logic comparator 15 for determining whether the memory 13 under test functions properly.
EXAMPLE A
FIG. 3 shows a block diagram for testing a memory 13A that can inhibit the writing-in of arbitrary bits. In this example, AND gate 34 1 -34 n are provided, one corresponding to each write enable terminal of the buffer memory 31. The data and address signals are supplied commonly both to the buffer memory 31 and the memory 13A during the writing-in process. A mask register 35 stores mask data which is identical to the data stored in the memory 13A for inhibiting arbitrary bits from being written-in. That is, bits restricted from being written over are indicated in the mask register 35 and a "0", and unrestricted bits are indicated as a "1". A write-in to buffer memory 31 is unable to occur into a bit for which a "0" is set in the mask register 35 because a write enable signal is not provided through its corresponding AND gate. However, for a bit for which a "1" is set in the mask register, write-in will occur, since during any write-in process the control signal generator 32 will be generating a "1". Thus, both inputs for the corresponding AND gate will be a "1", and the AND gate will output a "1" to the write enable terminal for that bit.
As a result, exactly the same data is stored in both the memory 13A and the buffer memory 31. The data stored in the buffer memory 31 is used as expected data. In the actual testing of the memory 13A, the logic comparator 15 compares the data read out of test memory 13A with the expected data read-out of buffer memory 31. If a difference is discovered between the sets of data, the memory 13A under test is rejected as defective.
EXAMPLE B
In another type of semiconductor memory 13B, the writing-in for arbitrary selected bits is not inhibited by the data stored in a mask memory but by data supplied in real time to the memory 13B. FIG. 4 is a block diagram illustrating a system for testing a memory of this type. Shown in FIG. 4 are the modifications necessary from the system of FIG. 3. The pattern generator 11M provides data via the multiplexer 26 and through the data terminal 14 which determines whether or not to inhibit write-in for each bit to the AND gates corresponding to each bit. During a write-in process, the control signal generator 32 will generate a "1" as a write enable signal. So during a write-in process, any bit for which the pattern generator 11M sends a "1" (write signal) to the corresponding AND gate, data will be written-in. For any bit that the pattern generator 11M sends a "0" (inhibit signal) to its corresponding AND gate, data will not be written-in.
In this situation, data inputted to the buffer memory 31 would be the same as that inputted into the memory 13B under test. Thus the logic comparator 15 may test this type of memory 13B in the same way as for the test memory 13A in Example A above.
EXAMPLE C
FIG. 5 illustrates a block diagram of a testing system for a memory 13C which internalizes a calculating function. Data from the pattern generator 11M and read-out data from the buffer memory 31 are inputted to an arithmetic function unit 36, the output of which is connected to the data input terminal of the buffer memory 31. The result of an arithmetic operation is then written-in to the buffer memory 31.
The same address generated by the address generator 21 of the pattern generator 11M is supplied to both the memory 13C and the buffer memory 31. Also data from the data terminal 14 that is generated by the pattern generator 11M is provided to both the memory 13C and the arithmetic funtion unit 36. The address signal from the address generator 21 via the address terminal 12 contains information for setting a mode of operation for an arithmetic unit embedded in the memory 13C being tested. As shown in FIG. 5, the address signal is also supplied to the arithmetic function unit 36 to set it to the same arithmetic mode as that of the internalized arithmetic unit of the memory 13C. The output signal from the control signal generator 32 determines whether it is time for the arithmetic function unit 36 to operate. The data resulting from the operation of arithmetic function unit 36 is stored in the buffer memory 31. As a result, the contents of the buffer memory 31 and the memory 13C should be identical.
Therefore, by accessing the memory 13C and the buffer memory 31 with the same address and comparing the read-out data in the logic comparator 15, the testing of the memory 13C which contains an arithmetic function is accomplished.
EXAMPLE D
FIG. 6 is a block diagram which illustrates the testing of a memory 13D, which has a random access port and a serial access port as shown in FIG. 9. A memory system of this type consists of a random access memory (RAM) unit 27 and a serial access memory (SAM) unit 28, and is able to transfer stored data between the two memories.
In FIG. 6, a multiplexer 37 is connected in series with the address input terminal of the buffer memory 31. A counter 38 is connected to one of the input terminals of the multiplexer 37. The counter 38 has the ability to load an address that is generated by the address generator 21 of the pattern generator 11M and increment, decrement, and preserve the address. The multiplexer 37 selects either the address from the address generator 21 of the pattern generator 11M or the counter 38 to provide to the buffer memory 31.
The counter 38 is controlled by a counter control signal, and the multiplexer 37 is controlled by a multiplexer control signal. Both signals are generated by the control signal generator 32 of the pattern generator 11M.
The SAM unit 28 of the memory 13D being tested is accessed serially by a pointer included in the memory 13D. The initial address of this pointer is determined by address signals from the address generator 21, and the pointer can then be incremented by a clock signal. Thus, the identical initial address is set in the counter 38 and the pointer.
When the address and data signals are supplied from the pattern generator 11M to the RAM unit 27 of the memory 13D, the address signal passes through the multiplexer 37 to access the buffer memory 31, and the same data signal is simultaneously supplied to the buffer memory 31. After this procedure, data in the RAM unit 27 is transferred to the SAM unit 28 in the memory 13D. A pointer of the SAM unit 28 of the memory 13D is set internally by the address from the address generator 21 of the pattern generator 11M, therefore the serial address is also set simultaneously in the counter 38 by the same address. The counter 38 accesses the buffer memory 31 to generate expected data for comparing with the read-out data from the SAM unit 28 of the memory 13D. Therefore, testing a memory of this kind can be accomplished.
EXAMPLE E
It is possible for a memory 13E with a random access port and a serial access port to control each port separately. For instance, the SAm unit 28 can be read out independently from the serial access port wile the RAM unit 27 is being written-in at the same time. For testing this type of memory 13E according to this invention, an additional buffer memory and multiplexer set is provided. A second buffer memory 41 and a second multiplexer 42 are added as shown in FIG. 7, supplementing the first buffer memory 31 and the first multiplexer 37. Also added is third multiplexer 43 for selecting, based on control signals from the control signal generator 32, between data outputs of the buffer memories 31, 41 for supplying to the logic analyzer 15.
To test the memory 13E when it is reading out from the serial access port and simultaneously writing-in data from random access port, the counter 38 acceses the second buffer memory 41 through the second multiplexer 42 to read out expected data for the serial port data. The read out data is supplied via the third multiplexer 43 to the logic comparator 15 for comparison with the read out data from the serial access port. At the same time, the address signal from the address generator 21 accesses the memory 13E through the random access port as well as the first buffer memory 31 through the first multiplexer 37. Thus, the same data should be written into the same address location for both the memory 13E and the buffer memory 31. These two sets of data will also be read out and compared for determining whether the memory 13E functions properly.
EXAMPLE F
A block diagram of the test system for a FIFO memory with a write-in pointer and a read-out pointer is illustrated in FIG. 8. A second counter 44 is added in this embodiment to the embodiment shown in FIG. 6, and the second counter 44 and the first counter 38 are controlled to function independently by control signals from the control signal generator 32. The multiplexer 37 selects either the address from the address generator 21 of the pattern generator 11M, the first counter 38, or the second counter 44 to provide to the buffer memory 31.
The address from the pattern generator 11M is stored in the first counter 38 when a write-in pointer of the memory 13F is changed to the initial stage, and the address from the pattern generator 11M is stored in the second counter 44 when a read-out pointer is also changed to the initial stage. When a write-in clock pulse is provided to the memory 13F, the multiplexer 37 selects the address in the first counter 38 to write into the buffer memory 31 during write-in procedures. On the other hand, when a read-out clock pulse is provided to the test memory 13F, the multiplexer 37 this time selects the address in the second counter 44 with which to access the buffer memory 31. The outputs of the buffer memory 31 are compared with the outputs of the memory 13F at the logic comparator 15. As the stored data should be identical, the memory 13F is rejected if a difference is found.
In the above procedures, the address would be generated by the pattern generator 11M only when the first counter 38 and the second counter 44 are changed to the initial stage. That is, it is not necessary for the pattern generator 11M to generate an address when a write-in clock pulse and a read-out clock pulse are provided to the memory 13F.
According to this invention of the semiconductor memory testing device, a buffer memory is accessed by the testing device with the same address as the one used to access the memory under test. In addition, by properly composing the write-in data or corresponding data of the memory under test, it is possible to write into the buffer memory under the same conditions and thus with the same data as for the memory under test. The testing of memories having various functions is possible in accordance with the present invention as described above. Therefore, since numerous modifications and changes will readily occur to those skilled the art, it is not desired to limit the invention to the exact construction and applications shown and described and accordingly, all suitable modifications and equivalents may be resorted, falling within the scope of the appended claims and their equivalents.
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In a semiconductor test system, higher accuracy testing of semiconductor memories is achieved by providing test data from a modified pattern generator to identical addresses in both the memory under test and a buffer memory. This is achieved for various types of semiconductor memories by treating data generated by the modified pattern generator for the memory under tests in ways that would correspond to how the data is treated in various memories to be tested before storing the data in the buffer memory. This is accomplished using a variety of multiplexers and counters under control of a control signal generator. Data stored at locations with the same address in both memories is read out for comparison in a logic comparator. If the data is not identical, the semiconductor memory under test is rejected as defective.
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BACKGROUND OF THE INVENTION
The present invention relates to a partition assembly and, in particular, to panels that can be connected together through an intermediate post.
It is known to divide an office floor by using quickly assembled partitions. These partitions are free standing and therefore do not become part of the real estate. Often these panels do not reach the ceiling of the office. These known partitions include a post having four or more positions into which a panel can be attached. It is know to attach a decorative cap atop the intermediate post. A disadvantage with known partition assemblies is the difficulty of assembling them, as well as the lack of sufficient structural rigidity.
The following U.S. Pat. Nos. show partition assemblies and fastening hardware: 1,065,758; 1,354,983; 1,368,646; 2,393,514; 2,568,390; 3,370,389; 3,738,073; 3,768,222; 3,854,269; and 3,967,427.
Accordingly, there is a need for an improved partition assembly, which is rigid and easily assembled.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a partition assembly having a hollow post with an upper open end. The assembly has a panel with an edge recess and a post clip mounted in the recess for releasably attaching to the hollow post. The assembly has a spanner with a central prong sized to fit into the upper open end of the hollow post. This spanner has a pair of panel clips oppositely positioned about the central prong. Each of the panel clips can releasably attach to the top of the panel.
By employing equipment of the foregoing type, an improved partition assembly is achieved. In a preferred embodiment, a post has a cruciform shape with two wings that project outwardly and are perforated to allow mounting of shelf brackets, for example. The post also has two other wings with grooved ridges. The grooved ridges can hold a barbed frame clip designed to mate with a barbed post clip in an edge recess of the panel. The edges of the panel are defined by a frame, preferably formed of extrusions. The frame has an U-shaped midsection with shelves that engage flanges on the above mentioned post clip.
The post is quickly assembled to the panel by thrusting together the post clip and frame clip. After these are locked together, a spanner plate having an U-shaped prong is inserted into the open top end of the post. On this spanner plate, U-shaped clips snap into the recess on the top edge of the panel so that the top of the post is locked between the post and the two panels.
The recessed midsection of the frame extrusions also have an internal ledge that can abut a hollow square beam. The beam can be bolted to the ledge using a backup slat on the other side of the ledge. Adjustable supporting feet can be threadably attached to the beam. In the preferred embodiment, the extrusions of the frame have projections that can encircle a facade such as decoratively covered wood or particle board.
The frame extrusions can have a 45° miter cut and be joined at right angles to form a rectangular frame. The frame extrusions can preferably have slots or tracks into which right angle brace plates or brackets are mounted. The frame can be made rigid when the right angle plates or brackets are slid into the appropriate slot, and, optionally, screwed into place.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred but nontheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is an exploded perspective view of the partition assembly of the present invention;
FIG. 2 is an end view of a post attached to the frame extrusion of FIG. 1;
FIG. 3 is an inside plan view of the miter joint between the frame extrusions of the panel of FIG. 1;
FIG. 4 is an end view of the bottom most edge of the frame extrusion in the panel of FIG. 1;
FIG. 5 is a side view of the spanner of FIG. 1;
FIG. 6 is an end view of one of the panel clips of FIG. 5;
FIG. 7 is a partial side view of an end cap from FIG. 1; and
FIG. 8 is an end view of a corner post designed to connect at right angles two of the posts of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a partition assembly is shown comprising a hollow post 10 having a cruciform cross section. On opposite wings of post 10, are two pairs of frame clips 12.
Panel 14 is shown with a rectangular frame 16 having an edge recess. A pair of post clips 17 are shown mounted in the vertical recess of frame 16 at a position to engage the frame clips 12. End caps 26 and 28 are each shown with a pair of cap clips 30 sized to fit within the recess of rectangular frame 16. A lower beam 32 is shown mounted in the lowermost recess of frame 16.
A spanner 18 is shown having a center prong 20 in the form of an inverted U-shaped clip mounted between a pair of panel clips 22 and 24 having an inverted U-shape. Prong 20 and clips 22 and 24 are shaped to fit into the top of post 10 and the edge recess of frame 16, respectively.
Referring to FIG. 2, previously mentioned post 10 is shown having a cruciform cross section with a pair of connecting wings 34 and perforated wings 36 for mounting shelf brackets. Mounted on the outside of connecting wings 34 are two pairs of opposing ridges 38. Each pair of ridges 38 are sized to hold the flanges of frame clips 12 by their flanges. As shown in this view, frame clips 12 have a parallel pair of outwardly barbed legs 40.
A decorative cap 42 fits over the perforated wing 36 when it is unencumbered with shelves. Cap 42 can be a plastic channel. The sides of wings 34 have saw tooth ridges to keep caps 42 in place.
Previously mentioned rectangular frame 16 is shown as an extruded aluminium channel 46 having a U-shaped midsection and outward projections 48. Channel 46 is symmetrical about a central plane. A pair of rails 60 inwardly projecting from the rear side of channel 46 form a pair of tracks 60. Inside the midsection of channel 46 are a pair of parallel opposite shelves 50, spaced from the floor of the channel to grasp the flanges of post clip 17. Post clip 17 is shown having a pair of inwardly barbed legs 52. Post clip 17 is shown screwed to the floor of channel 46 with self tapping screw 53.
At the inside corners made by projections 48 there are a pair of rails forming a slot 54. These rails forming slot 54 also act as an abutment for supporting facade 56, which is made of wood, particle board, styrofoam or other materials appropriate for decorative purposes. In this embodiment, facade 56 is covered with a fabric 58.
Referring to FIG. 3, previously mentioned frame 16 is shown employing a pair of channels 46 that are joined at a 45° miter joint. The channels 46 are laid so that the slot 54 and track 60 merge together and form two right angle paths. A right angle bracket 62 is shown screwed into track 60 to hold channels 46 together. A right angle brace plate 64 is shown slipped into slot 54 to provide additional rigidity for the miter joint.
Referring to FIG. 4, previously mentioned bottom beam 32 is occupying the midsection of channel 46. Beam 32 is a hollow square beam resting on parallel ledges 66 that mounted on opposing inside faces of the mid section of channel 46 above shelves 50. A slat 68 is slipped between ledges 66 and shelves 50. The beam 32 is shown bolted to slat 68 by means of nut and bolt 70, although other fastenings means are possible. A pair of feet depend from beam 32, one such foot, foot 72, is a disk mounted on threaded stem 74. Stem 74 is threaded into the underside of beam 32 to allow height adjustment and leveling of beam 32.
Referring to FIG. 5, previously mentioned spanner 18 is shown having a rectangular top plate 76. In some embodiments where a right angle joint is made between panels, plate 76 can have a similar right angle bend. Previously mentioned prong 20 is shown herein as an inverted U-shaped clip sized to fit within the upper opening of the previously mentioned post (post 10 of FIG. 2). Panel clips 22 and 24 are shown welded to the lower faces of top plate 76. As shown in FIG. 6, clip 22 has an inverted U-shape with rolled edges having nubs 78. Nubs 78 are designed to snap over the ledges of the frame (ledges 66 of FIG. 2).
Referring to FIG. 7, an edge view is given of previously mentioned end cap 26. In this embodiment, cap 26 can be a wooden or plastic decorative molding. Previously mentioned cap clip 30 is screwed to end cap 26. The cross section of clip 30 is similar to that shown in FIG. 6 except that the clip legs are slightly longer.
In FIG. 2 ridges 38 of post 10 hold frame clips 12 at positions 180° apart. In some embodiments, however, walls must be joined at a 90° angle. The hollow connecting standard 80 of FIG. 8 can perform such a connection. Standard 80 is an extrusion having four identical faces spaced 90° apart. Each of these faces have a recess containing a pair of parallel grooves 82. Grooves 82 are shaped to engage ridges 38 (FIG. 2) on post 10. While a four sided structure is shown in FIG. 8, in some embodiments, fewer or more faces can be employed to allow positioning partitions at various angles.
To erect the partition assembly of FIG. 1, the panel 14 is placed in position and panel clips 12 of post 10 are thrust into post clips 17. Thereafter, an adjacent panel 14A having similar post clips (not illustrated) are thrust onto panel clips 12 on the opposite face of post 10. Thereafter, spanner 18 is thrust down with its prongs 20 entering the upper open end of post 10. Simultaneously, panel clips 22 and 24 snap into the recesses of frame 16. Finally, decorative end caps 26 and 28 are snapped into the recessed edges of frame 16 by means of cap clips 30.
It is to be appreciated that various modifications may be implemented with respect to the above described preferred embodiments. For example, the channel comprising the frame can have varying thickness and depths depending upon the size and desired structural rigidity. Furthermore, the dimensions of the panel and post clips can be altered and other locking mechanism may be employed other than barbed legs. To accommodate differently sized and shaped post and frame clips, the shelves within the midsection of the frame extrusions can be altered accordingly. Also, the post can be sized to accommodate various sized panels. In addition, the post can be rearranged to allow angled connections between the panels. The post can be shaped to provide a right angle corner or corners of various angles. Also, the beam supporting the feet can be of various shapes and, in some embodiments, no feet will be used at all. Additionally, the spanner can have various lengths depending upon the desired structural rigidity between adjacent panels. Furthermore, the center prong of the spanner can be a solid post or a hollow beam having four sides or other shapes that will fit into the open top of the post. Also, clips shown with rolled, nubbed edges can be altered to roll in different directions, have barbs or may be altered in various ways to accomplish clipping.
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 partition assembly has a hollow post with an upper open end. The assembly includes a panel having an edge recess and a post clip mounted in the recess for releasably attaching to the hollow post. The assembly also has a top spanner having a central prong sized to fit into the upper open end of the hollow post. This spanner has a pair of panel clips oppositely positioned about the central prong. Each of the panel clips are operable to releasably attach to the top of the panel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/082,414, filed on Nov. 20, 2014, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to power electronics, and more specifically to electrical systems.
BACKGROUND
[0003] Electronic devices are a core component of everyday life. Power supply systems bring necessary power from an outside source into an electronic device. They can range from AC adaptors for laptops, to a USB wall adaptor for charging a cellphone or tablet, to many other forms. Electronic devices can include external electronics and internal electronics. For example the USB wall adaptor may include external electronics, for example, an external AC/DC converter to convert the inputted power to a form compatible with the device, and/or internal electronics, for example, a DC/DC converter to adjust the converted power to a voltage level usable by the device.
[0004] There is a large body of art relating to methods of power supply system design. In general, the art focuses on refining the existing paradigms, increasing efficiency, reducing manufacturing costs, etc.
[0005] The majority of electronic devices have a single internal power supply connected to a single power input. For example, a cellphone may only be able to bring in power through its USB port, or a laptop my only be able to bring in power through a specific charging port. External power supplies must be used to convert a power source into a form that can be accepted by the internal power supply. In general, this is an adequate solution as the use cases for these devices are not highly variable.
[0006] Some electronic devices must be able to accept power inputs from a variety of power sources with variability in availability, type, and power output capability. For example, a mobile battery system for emergencies might be configured to be charged by whatever power source is available, for example, a wall outlet, a generator, a solar panel, a wind turbine, etc.
[0007] Solutions that rely on a single power input are limited by the capabilities of that converter. For example, an electronic device that uses a solar charge controller as its single input will have power input capability that is limited by the throughput of that converter. It is often the case that solar charging is the driving factor of the power supply system, in these cases the power input from another energy source, for example a wall outlet, is limited.
[0008] Solutions that rely on multiple power inputs provide means to decouple the different charging methods. In this case, the electronic device in the previous example may have one power input for a wall outlet and another power input for a solar panel. The two inputs may include different electronics and connectors to account for the differences between the power sources.
[0009] This approach offers increased flexibility, but has several problems.
[0010] First, additional power input capability is often expensive from cost, weight, size, and complexity perspectives. A device featuring a separate, correctly sized power input system for every possible power source would be prohibitively expensive, large, heavy, and complicated.
[0011] Second, physical connectors are often complex and expensive. Having a specific connector for each of a plurality of possible power sources results, in many cases, to connectors remaining unused. This unnecessarily increases the cost to manufacture the device.
[0012] Third, a variety of different connectors can be difficult for a user to understand. Often it requires detailed labeling and specific instructions to ensure that the user knows where to connect each power source. This may result in user error that is potentially dangerous to the user and/or destructive to the device.
[0013] What is needed is a power supply system with a combination of internal and external power supplies that is easier to use, more flexible, and more cost effective than existing solutions.
SUMMARY OF THE INVENTION
[0014] The present invention describes an advantageous system and method for supplying power to an electronic device from a plurality of different power sources in a way that is simple for a user to configure, can easily accommodate a variety of power sources, and is cost effective to implement. The present invention also describes an advantageous device powered by a plurality of different power sources.
[0015] One advantage of the present invention is that it simplifies user interaction with the power system. This not only makes the power system easier and faster to use, it reduces the likelihood of user error by eliminating possible mistakes.
[0016] Another advantage of the present invention is that it increases the power input flexibility of electronic devices, allowing for dynamic reallocation of charger electronics between different power sources through a simple user interaction.
[0017] The use of multiple, smaller, similar internal power converters vs. larger monolithic converters allows for dynamic reallocation of converter resources to different power sources, increasing redundancy, and greatly simplifying the use of the device.
[0018] External power supplies that connect to a plurality of similar power converters allow for smaller connectors, the dynamic reallocation of converter resources to different power sources, charging of multiple devices from a single power adaptor, and simplification of the use of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Aspects, features, benefits, and advantages of the present invention will be apparent with regard to the following description and accompanying drawings, of which:
[0020] FIG. 1 is a block diagram of an exemplary embodiment of the invention.
[0021] FIG. 2 is a block diagram of an alternative embodiment of the invention.
[0022] FIG. 3 is a block diagram of an alternative embodiment of the invention.
[0023] FIG. 4 is a block diagram of an alternative embodiment of the invention.
[0024] FIG. 5 is a block diagram of an alternative embodiment of the invention.
[0025] FIG. 6 is a block diagram of an alternative embodiment of the invention.
[0026] FIG. 7 is a block diagram of an alternative embodiment of the invention.
[0027] FIG. 8 is a block diagram of an alternative embodiment of the invention.
[0028] FIG. 9 is a block diagram of an alternative embodiment of the invention.
[0029] FIG. 10 is a block diagram of an alternative embodiment of the invention.
[0030] FIG. 11 is a block diagram of an alternative embodiment of the invention.
[0031] FIG. 12 is a block diagram of an alternative embodiment of the invention.
[0032] FIG. 13 is a block diagram of an alternative embodiment of the invention.
[0033] FIG. 14 is a block diagram of an alternative embodiment of the invention.
[0034] FIG. 15 is a block diagram of an alternative embodiment of the invention.
[0035] FIG. 16 is a block diagram of an alternative embodiment of the invention.
[0036] FIG. 17 is a block diagram of an alternative embodiment of the invention.
[0037] FIG. 18 is a block diagram of an alternative embodiment of the invention.
[0038] FIG. 19 is a block diagram of an alternative embodiment of the invention.
[0039] FIG. 20 is a block diagram of an alternative embodiment of the invention.
[0040] FIG. 21 is a block diagram of an alternative embodiment of the invention.
[0041] FIG. 22 illustrates an isometric view of an alternative embodiment of the invention.
[0042] FIG. 23 is a block diagram of an alternative embodiment of the invention.
[0043] FIG. 24 illustrates an isometric view of an alternative embodiment of the invention.
[0044] FIG. 25 is a block diagram of an alternative embodiment of the invention.
[0045] FIG. 26 illustrates an isometric view of an alternative embodiment of the invention.
[0046] FIG. 27 is a block diagram of an alternative embodiment of the invention.
[0047] FIG. 28 illustrates an isometric view of an alternative embodiment of the invention.
[0048] FIG. 29 is a block diagram of an alternative embodiment of the invention.
[0049] FIG. 30 illustrates an isometric view of an alternative embodiment of the invention.
[0050] FIG. 31 is a block diagram of an alternative embodiment of the invention.
[0051] FIG. 32 is a block diagram of an alternative embodiment of the invention.
[0052] FIG. 33 is a block diagram of an alternative embodiment of the invention.
[0053] FIG. 34 is a block diagram of an alternative embodiment of the invention.
[0054] FIG. 35 illustrates an isometric view of an alternative embodiment of the invention.
[0055] FIG. 36 is a block diagram of an alternative embodiment of the invention.
[0056] FIG. 37 is a block diagram of an alternative embodiment of the invention.
[0057] FIG. 38 is a block diagram of an alternative embodiment of the invention.
[0058] FIG. 39 is a block diagram of an alternative embodiment of the invention.
[0059] FIG. 40 is a block diagram of an alternative embodiment of the invention.
[0060] FIG. 41 is a block diagram of an alternative embodiment of the invention.
[0061] FIG. 42 is a block diagram of an alternative embodiment of the invention.
[0062] FIG. 43 is a block diagram of an alternative embodiment of the invention.
DETAILED DESCRIPTION
[0063] The system of the invention comprises an electrical system containing one or a plurality of power adapters. Each power adapter is connected to a power interface and a power bus. One or a plurality of power sources may be connected to one or a plurality of power interfaces. FIG. 1 illustrates an exemplary embodiment of the invention in which electrical system 1 contains a plurality of power adapters 2 a and 2 b . Power adapters 2 a and 2 b are connected to power interfaces 3 a and 3 b , and to power bus 4 , and power source 5 is connected to power interfaces 3 a and 3 b.
[0064] The electrical system 1 may be any collection of hardware and/or software in which the flow of electrical energy causes a physical, electrical, or digital change.
[0065] Power adapters 2 a and 2 b may be any collection of hardware and/or software that receive an input of electrical energy of one set of characteristics and outputs electrical energy of a different set of characteristics. For example, at least one of power adapters 2 a and 2 b may be a battery charger that automatically converts inputted DC power into the correct form of power to properly charge a battery. In an alternative embodiment, at least one of power adapters 2 a and 2 b may be able to automatically draw the maximum power point for a given power source.
[0066] Power interfaces 3 a and 3 b may be any components of combination of components that connect electrical systems and/or an electrical system to a power source including, but not limited to, a connector, a transmitter and receiver for wirelessly transferring power, a plug, or any other such component of combination of components.
[0067] Power bus 4 may be any form of electrical or mechanical system that connects two or more components within electrical system 1 including, but not limited to, a bus bar, a wire, or a printed circuit board.
[0068] Power source 5 may be any source of electrical potential including, but not limited to, an AC power source such as an AC grid connection or an AC generator, or a DC power source such as a a solar panel, a turbine, vehicle power system, and energy storage element, a DC grid connection, or a DC generator. An AC generator or DC generator may be a combustion generator, a hydro-electric generator, a wind generator, a solar cell, a fuel cell, or any other form of generator. A power source may include one or more of the examples provided as well as others.
[0069] FIG. 2 illustrates an alternative embodiment of the invention in which a plurality of power adapters 6 a and 6 b are similar power adapters and a plurality of power interfaces 7 a and 7 b are similar power interfaces.
[0070] The plurality of power adapters may be considered similar power adapters if each of the power adapters is capable of receiving electrical energy of a similar range of characteristics such as, for example, voltage ranges and current capacities, and outputting electrical energy of a similar range of characteristics. For example, two DC-DC converters with similar input voltage ranges and current capacities and similar output voltage ranges and current capacities may be considered similar power adapters.
[0071] The plurality of power interfaces may be considered similar power interfaces if they can interface with one or more similar power sources and/or similar external power adapters (as shown in FIG. 15 ). For example, the similar power interfaces 7 a and 7 b in FIG. 2 may be connectors that can mate with similar external connectors or systems for transferring wireless power that can interface with other external systems for transferring wireless power.
[0072] In an alternative embodiment, the power sources that can connect to one of the power interfaces may connect to any of the other power interfaces. In addition, power from one of the power sources that can be processed by one of the power adapters may be able to be processed by any of the other power adapters.
[0073] As illustrated in FIG. 3 , the similar power interfaces 7 a and 7 b can each be connected to separate power sources 5 a and 5 b . Any number and combination of power sources connected to one or more similar power interfaces is possible.
[0074] FIG. 4 illustrates an alternative embodiment in which a different power interface 8 is connected to a plurality of similar power adapters 6 a and 6 b , and to power source 5 b . The similar power adapters 6 a and 6 b are also connected to a plurality of similar power interfaces 7 a and 7 b . Similar power interfaces 7 a and 7 b are also connected to power sources 5 a and 5 c . One or a plurality of different power interfaces may also be connected to one or a plurality of similar power adapters.
[0075] FIG. 5 illustrates an alternative embodiment in which a different power interface 8 is connected to a different power adapter 9 . The different power adapter 9 is connected to a plurality of similar power adapters 6 a and 6 b . One or a plurality of different power interfaces may also be connected to one or a plurality of different power adapters, and the one or a plurality of different power adapters may be connected to one or a plurality of similar power adapters. The different power adapter 9 may also be connected to the power bus 4 .
[0076] FIG. 6 illustrates an alternative embodiment. In this embodiment, an AC-DC Power Supply 10 has a plurality of output cables with connectors of a similar type. The cables are attached to a plurality of Connector Type 1s 11 a and 11 b . Power travels through the connectors 11 a and 11 b , through the DC/DC converters 12 a and 12 b , to the power bus 4 . The DC/DC converters 12 a and 12 b draw power from the AC-DC power supply 10 and output power to the power bus 4 .
[0077] FIG. 7 illustrates an alternative embodiment in which a solar panel 13 is attached to a Connector Type 1 11 a . In addition, a Vehicle Electrical System 14 is attached to another Connector Type 1 11 b . One of the DC/DC converters 12 a would draw power from the solar panel 13 , and the other DC/DC converter 12 b would draw power from the vehicle electrical system 14 .
[0078] FIG. 8 illustrates an alternative embodiment in which an AC/DC power supply 10 is attached to a connector type 2 14 . Power is then fed into a plurality of DC/DC converters 12 . Power may be fed into one or a plurality of DC/DC converters.
[0079] FIG. 9 illustrates an alternative embodiment in which an AC source 15 is connected directly to a connector type 2 14 . The AC power is then fed into an AC/DC converter 16 , and then into a plurality of DC/DC converters 12 a and 12 b . AC power may be fed into an AC/DC converter and then into one or a plurality of DC/DC converters.
[0080] It will be understood that in any of the foregoing or similar embodiments, the type, quantity, and configuration of the power sources, power interfaces, and power adaptors may vary.
[0081] FIG. 10 illustrates an alternative embodiment in which one or a plurality of power adapters 2 a and 2 b may be attached to the power bus 4 through power adapter mounting bays 17 a and 17 b . A power adapter mounting bay may be any mechanical or electrical component that connects a power adapter to the power bus. For example, the power adapter mounting bay may be a physical mounting point in the form of one or a plurality of holes and/or an electrical mounting point in the form of an electrical connector.
[0082] FIG. 11 illustrates an alternative embodiment, in which a plurality power adapter mounting bays 18 a and 18 b connect a plurality of similar power adapters 6 a and 6 b to the power bus 4 . One or a plurality similar power adapter mounting bays may connect one or a plurality of similar power adapters to the power bus.
[0083] As shown in an alternative embodiment of the invention in FIG. 12 , one or more power adapter mounting bays may not connect to a power adapter. In this embodiment, additional similar power adapters may be added. This modularity allows for the use of common electrical components across electronic systems that are sold as different products with different feature sets.
[0084] FIG. 13 illustrates an alternative embodiment in which the power bus 4 is connected to an accumulator 19 . Accumulator 19 may be any device designed to store energy including, without limitation, a battery, a flywheel, a mainspring, a capacitor, or other energy storage components.
[0085] FIG. 14 illustrates an alternative embodiment in which an output power adapter 20 may connect the power bus 4 to an output power interface 21 a . One or a plurality of output power adapters may connect the power bus to one or a plurality of output power interfaces. As shown in FIG. 14 , power bus 4 is directly connected to output power interface 21 b . The power bus may be directly connected to one or a plurality of output power interfaces. As further shown in FIG. 14 , a plurality of electrical loads 22 a and 22 b are connected to the output power interfaces 21 a and 21 b . One or a plurality of electrical loads may be connected to the output power interfaces. As further shown in FIG. 14 , internal electronics 23 is connected to the power bus 4 . One or a plurality of internal electronics may be connected to the power bus. Internal electronics may be any form of electronics that converts, consumes, or otherwise uses power internal to the electrical system.
[0086] The output power adapter 20 may be any combination of hardware and/or software that alters the characteristics and/or controls power moving from the power bus 4 to the output power interface 21 a . The output power adapter may be connected to one or a plurality or output power interfaces. In one embodiment, the output power adapter 20 may be a DC/AC inverter that converts DC power from the power bus 4 to AC power, and the output power interface 21 a may be one or more wall outlets. The electrical load 22 a in this embodiment may be any electrically powered device that may be plugged into a wall outlet. In an alternative embodiment, the electrical load may be any device that is powered by electricity. The output power adapter 20 may also be a DC/DC converter that converts DC power from the power bus 4 to a form of DC power that is compatible with USB electronics. The output power interface may be one or a plurality of USB ports and the electrical load may be USB electronics.
[0087] As illustrated in FIG. 15 , power source 5 is connected to an external power adapter 24 , which then in turn connects to a plurality of power interfaces 3 a and 3 b . Alternatively, a plurality of power sources may connect to one or a plurality of external power adapters, which then in turn may be connected to one or a plurality of power interfaces.
[0088] FIGS. 16-19 illustrate exemplary embodiments of the external power adapter 24 . The external power adapter may contain one or a plurality of power interfaces connected to one or a plurality of external power adapters. The external power adapter may also consist of one or a plurality of power buses connected to one or a plurality of power interfaces. In alternative embodiments, the external power adapter may consist of any number, combination, and configuration of power interfaces, power adapters, and/or power interfaces.
[0089] FIG. 16 illustrates one embodiment of the external power adapter 24 . This embodiment does not contain a power adapter. The power interface 3 a is connected to another power interface 3 b through power bus 4 . Alternatively, the power interface may be connected to a plurality of other power interfaces through power bus. For example, the external power adapter 24 may be a cable that has one end that is a 12V accessory plug, the power interface that is connected to an automotive power system through a 12V accessory port. At the other end of the cable, the power bus may end in a connector that can interface with the electrical system through the other power interface. In another example, the external power adaptor may be a cable connected to a solar panel that ends in a connector that can interface with the electrical system.
[0090] FIG. 17 illustrates an alternative embodiment of the external power adaptor 24 . In this embodiment, power interface 3 a is connected to a plurality of other power interfaces 3 b and 3 c through power bus 4 . For example, the external power adaptor may be a cable that has one end that terminates in a connector to a car battery, the power interface that is connected to an automotive power system, through a direct connection with the battery. The other end of the cable may end in a plurality of connectors. As shown in FIG. 17 , these connectors are power interfaces 3 b and 3 c that connect with power interfaces 3 d and 3 e on the electrical system 1 .
[0091] FIG. 18 illustrates an alternative embodiment of the external power adaptor 24 . In this embodiment, a first power interface 3 a is attached to a second power interface 3 b through power adapter 2 . For example the first power interface may be an AC power cable that is able to plug into a wall outlet, the power adapter may be an AC/DC converter, and the second power interface may be a cable ending in a connector that can mate with the power interface on the electrical system.
[0092] FIG. 19 illustrates an alternative embodiment of the external power adaptor 24 . In this embodiment a first power interface 3 a is attached to a plurality of other power interfaces 3 b and 3 c through power adapter 2 . For example the first power interface may be an AC power cable that is able to plug into a wall outlet, the power adapter may be an AC/DC converter, and the other power interfaces may be more than one cable ending in a connector that can mate with more than one of the power interfaces on the electrical system.
[0093] In another example, the first power interface may connect to an automotive power system, the power adapter may be a DC/DC converter that converts the DC power from the automotive system to a different voltage, and the other power interfaces may be more than one cable ending in a connector that can mate with more than one power interfaces on the electrical system. In one example, the different voltage may be a higher voltage. For example, the 12V automotive power might be converted to a higher voltage, such as 40V. This higher voltage would allow the power adapters in the electrical system to draw more power in at the lower currents.
[0094] FIG. 20 illustrates an alternative embodiment of the external power adaptor 24 . In this embodiment a plurality of first power interfaces 3 a and 3 b are attached to a power bus 4 through a plurality of power adapters 2 a and 2 b . The power bus may be connected to one or a plurality of other power interfaces. As shown in FIG. 20 , power bus 4 is connected to power interfaces 3 c . The power interfaces connected to the power sources may be more than one cable plugged into more than one solar panel, the power adapters may be DC/DC converters that convert the power from the solar panels to a different, common voltage, and the other power interfaces may be one or more cables ending in a connector that can mate with more than power interface on the electrical system.
[0095] FIG. 21 illustrates an alternative embodiment of the invention. In this embodiment a single external power adapter 24 is attached to a plurality of power interfaces 3 a , 3 b , 3 c , and 3 d on a plurality of electrical systems 1 a and 1 b . For example the power source may be an AC power source, such as the grid or a generator. The external power adapter may be an AC/DC converter. The external power adapter 24 may have a plurality of cables with connectors that are able to mate with the power interfaces on the plurality of electrical systems 1 a and 1 b.
[0096] FIGS. 22 and 23 illustrate an alternative embodiment of the invention. In this embodiment, the electrical system 1 is housed in an enclosure 26 . The electrical system may be a portable power storage and delivery system. It may use one or a plurality of a variety of external power adapters 24 to charge an energy storage element 19 from a one or a plurality of a variety of power sources 5 . It may have a plurality of similar power interfaces 7 . One or a plurality of the external power adapters may be able to interface with each of the similar power interfaces 7 a , 7 b , 7 c , and 7 d . For example, a user may plug a solar panel into one or more of the similar power interfaces. A user may also attach a desktop-style power supply to the similar power interface. A user may also attach an automotive attachment cable to the power adapters. Because the power interfaces 7 a , 7 b , 7 c , and 7 d and DC/DC converters 25 a , 25 b , 25 c , and 25 d are similar, the user does not need to think about which power interface to plug the external power adapter into. This is advantageous because it makes the electrical system 1 much easier to use.
[0097] FIGS. 24 and 25 illustrate an alternative embodiment of the invention. In this embodiment, while power adapter mounting bay 18 a is connected to DC/DC converter 25 , power adapter mounting bays 18 b , 18 c , and 18 d are unused, in that they are not connected to a power adapter or a power interface. While these bays may seem to be vestigial or useless, they serve a useful purpose. A modular approach to power adapters and power adapters allows an electrical system to be produced in a plurality of variants. Each variant may be similar in hardware and/or software and may feature a different number of power interfaces and power adapters. A user that does not want to pay for multiple channels of charging does not need to pay for it and can purchase an electrical system with fewer channels of charging. A charging channel refers to the a power interface or a combination of power interfaces and power adapters that bring in power from a power source or an external power adapter.
[0098] FIGS. 26 and 27 illustrate an alternative embodiment of the invention. This embodiment has a different power interface 8 along with a plurality of similar power interfaces 7 a and 7 b . The different power interface connects to a plurality of similar DC/DC converters 25 a and 25 b . For example, the similar power interfaces may each feature two wires, a positive and negative wire. The different power interface 8 , may feature four wires, two positive and two negative wires. The similar power interfaces 7 a and 7 b may be used to connect to a power source 5 that has an amount of available power less than the available capacity of the similar DC/DC converters 25 a and 25 b . For example, if the DC/DC converter has a capacity of 250 W, a 100 W solar panel or a 200 W AC/DC converter may be plugged into the similar power interfaces 7 a and 7 b , and the similar DC/DC converters 25 a and 25 b would be able to take advantage of all the available power. If a 500 W AC/DC converter were attached to a single similar DC/DC converter with capacity of 250 W, then 250 W of available power would go unused.
[0099] In one embodiment, the external power adapter, for example a 500 W AC/DC converter, could attach to a plurality of similar power interfaces. In such an embodiment, each of the similar DC/DC converters would use 250 W of the available power, and more power would be used than if the external power adapter were plugged into fewer similar power interfaces.
[0100] In another embodiment, the external power adapter, for example a 500 W AC/DC converter, could connect to a different power interface. The different power interface would then in turn be connected to a plurality of similar DC/DC converters, for example a DC/DC converter with 250 W capacity. In this embodiment, each of the similar DC/DC converters would use 250 W of the available power, and more power would be used than if the external power adapter were plugged into fewer similar power interfaces. This is an advantageous configuration because a high power external adapter could be attached to the electrical system through a single connector instead of two connectors in alternative configurations without a different power interface.
[0101] A high power external adapter may be considered an external power adapter with more available power capacity than a single similar DC/DC converter. A low power external adapter may be considered an external power adapter with an amount of available power of less than or equal power to the power capacity of a single similar DC/DC converter. The present invention is advantageous in that it provides an economical and simple way to connect a wide variety of high power external adapters and low power adapters to an electrical system.
[0102] FIGS. 28 and 29 illustrate an alternative embodiment of the invention. In this embodiment, a different power interface 8 is connected to an AC/DC converter 16 which is then connected to a plurality of similar DC/DC converters 25 a and 25 b . For example, the different power interface may be an AC power cable or an AC power inlet. This is an advantageous configuration because it allows the electronic system to be powered off an AC source, for example a wall plug or a generator, without an external power adapter. Connecting the AC/DC converter 16 to the plurality of DC/DC converters 25 a and 25 b allows the AC/DC converter to be simpler and cheaper. The electrical system 1 may have an accumulator 19 . In that case, it as advantageous to control the flow of power into the system. A simple AC/DC converter may not control the power. For example, it may not limit current. This functionality may be provided by the similar DC/DC converters 25 a and 25 b . This allows the electrical system to utilize the same hardware across a variety of power input scenarios. This also reduces the extra cost and complexity that may be required if all possible charging scenarios are handled by a unique set of hardware. In an alternative embodiment, the AC/DC converter 16 may be connected directly to the power bus 4 .
[0103] FIGS. 30 and 31 illustrate and alternative embodiment of the invention. In this embodiment, a different power interface 8 is directly connected to power bus 4 . This connection facilitates the flow of energy into and/or out of the device without power conversion. One or a plurality of different power interfaces may be directly connected to power bus.
[0104] FIG. 32 illustrates an alternative embodiment of the invention. In this embodiment, a plurality of power sources 5 a and 5 b are connected to a single power adapter 2 through a power selector 27 . The power selector automatically or manually allows for the transfer of energy from a single power interface to a power adapter while disallowing the transfer of energy from a different power interface to the power adapter. For example, the power selector 27 may be an ORing diode setup that automatically allows for power to flow from the power interface with the higher voltage. The power selector 27 could also be any electrical and/or mechanical system that can accomplish the selection function as would be known by those familiar with the field.
[0105] This embodiment is advantageous in that it would allow for two or more different power sources to be connected to the device, and the device would require a fewer number of power adapters to utilize the multiple charging sources. For example, a solar panel and an AC power source may be connected to the device at the same time. When the AC power source is available, the device would draw power from it instead of from the solar panel. When the AC power source is not available, the device would draw power from the solar panel. It is advantageous that this would require no reconfiguring between the two charging states by a user.
[0106] FIG. 33 illustrates an alternative embodiment of the invention. In this embodiment, two or more power sources 5 are connected to a power selector 27 through two or more similar power interfaces 7 a and 7 b . This is advantageous in that a user may plug any of the power sources into any of the similar power adapters and the device would function properly. This makes operating the device easier for the user.
[0107] FIG. 34 illustrates an alternative embodiment of the invention. In this embodiment, a plurality of power interfaces 7 a , 7 b , and 8 are each connected to a different power sources and to different power adapters. The different power adapter is then connected to a plurality of similar power adapters 6 a and 6 b through power selectors 27 a and 27 b.
[0108] FIGS. 35 and 36 illustrate an alternative embodiment of the invention. In this embodiment, a different power interface 8 is connected to power selectors 27 a and 27 b through AC/DC converter 16 . Similar power interfaces 7 a and 7 b are also connected to power selectors 27 a and 27 b . Power selectors 27 a and 27 b are then connected to power converters 25 a and 25 b . It is advantageous that this would require no reconfiguring between the two charging states by a user and that the device could utilize power from multiple sources with fewer components, which would lead to it being less expensive to produce, lighter, and less complex.
[0109] In this embodiment, if an AC power source is connected to a different power interface, the device could draw power from it instead of a power source connected to a similar power interface. When the AC power source is not available, the device could draw power from a power source connected to a similar power interface. It is advantageous that this would require no reconfiguring between the two charging states by a user and that the device could utilize power from multiple sources with fewer components, which would lead to it being less expensive to produce, lighter, and less complex.
[0110] FIGS. 36 through 42 illustrate alternative embodiments of the invention. These embodiments illustrate how the present invention can support a variety of power sources by type and size with an array of identical connectors connected to a corresponding array of similar DC/DC converters.
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A system and method is disclosed for supplying power to an electronic device from a plurality of different power sources, comprising a plurality of input power interfaces, a plurality of power adapters connected to the input power interfaces, and at least one power bus connected to the power adapters, wherein any of the power sources may be connected to any one or more of the input power interfaces. Devices powered by a plurality of different power sources are also described.
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TECHNICAL FIELD
[0001] The invention relates to an operating aid for use on a touch-sensitive display of an electronic device, such as a smart phone or tablet computer.
BACKGROUND
[0002] Operating-aids for touch-sensitive displays are generally known. Such operating aids are often used, for example, in games that are played on a tablet computer or a smart phone with a touch-sensitive screen, to give the player tactile actuation regions over which he can actuate the respective virtual control elements of the device. The tactile actuation regions thereby allow the player easier operation and provide an improved gaming experience.
[0003] The Invisible Gampad™ of the Obinova LLC company is known for this on the market, for example. This operating aid essentially consists of a thin transparent adhesive film, in which, for example, cross-shaped or circular recesses are embedded. The film is glued over a virtual control element of a game on the display of the electronic device in question. The user can then execute a guided control movement along the edges of the recesses or actuate a virtual control element via the actuation region. A corresponding operating aid is shown, for example, in US 2013 0095301 A1.
[0004] A disadvantage of the known operating aid is that in the moment in which the actuation region or the respective material recess is being tactilely sensed, a control signal is usually also delivered to the display surface. In addition, the transparent adhesive film used is so thin that a control signal can be generated next to the material recess through the adhesive film. Further, the known operating aid that is primarily intended for permanent disposition on the respective device has the disadvantage that it can only be removed from the display surface relatively cumbersomely.
[0005] Furthermore, operating aids are known by means of which a conventional alphanumeric keyboard can be at least subsequently modeled on a touch screen.
[0006] US 2011/0241999 describes a keyboard for this that can be attached, for example, retroactively by means of lateral adhesive regions on a touch screen. The individual keys are thereby formed by a thin plastic profile which is modeled on the outside after a conventional alphanumeric keyboard key and hollow inside. By pressing the respective top side of these keys, this can be shifted so far inward that the finger is sufficiently close to the touch screen in question to trigger a signal.
[0007] U.S. Pat. No. 8,206,047 B1 and U.S. Pat. No. 8,790,025 B2 each describe a keyboard in which the individual keys are also formed by a thin plastic profile, which is modeled on the outside of a conventional alphanumeric keyboard. On the inside, the keys in this case each have a support structure, which is also formed by a thin plastic profile and which perceptibly collapses when pressed on the upper side of the keys to simulate the pressure point of a conventional keyboard as faithfully as possible.
[0008] Digital games generally require a quick change between the available virtual actions of the player character. A rapid change of the thumbs between the existing knobs results from this when controlling such games with game pads of conventional game consoles (e.g., “XBOX 360” or “Playstation 4”). The thumbs thereby exert pressure on the surface of the game pad in order to find the desired knob and where necessary to also immediately activate them with greater pressure. The exertion of pressure in combination with the movement of the thumb thereby generates a relatively high frictional resistance.
[0009] The keys of the keyboards mentioned are configured to be pressed from above for this purpose. A change between keys while exerting pressure, as is demanded by classical game pads would, however, pull the plastic profile of the currently pressed key in the direction of the other key and thus possibly make alternating between the two keys difficult. Such keyboards are also only compatible with certain device models, since they require a certain device width in order to be mounted by means of adhesive regions abutting the side.
[0010] Such keyboards are not practical for most gaming applications due to their shape. Moreover, the production costs of such keyboards are relatively high.
SUMMARY
[0011] The object of the invention is to avoid said disadvantages in a generic operating aid and in particular to enable a differentiated triggering of the control signals as well as a more comfortable attachment and detachment in game applications.
[0012] An improved operating aid has a base element on which an adhesive layer is provided on a display-side surface for removable attachment on the display. In addition, at least one activation area is provided on the base element that can be detected tactilely on a user-side outer side facing away from the display-side surface.
[0013] A signal zone can be acted upon via this activation area, which can be positioned on its display-side surface when attaching the operating aid on the respective display and inside of which, for example, the resistive or capacitive control signal can be generated. The signal zone is thereby generated by the switched-on display and extends, depending on operation of the touch-sensitive display, either only directly on its surface or rather on the display-side surface of the operating aid, such as in the case of a resistive touch screen, or, as in the case of a capacitive touch screen, is formed by an electric field, which extends from the display-side surface to some extent into the operating aid. In particular, the extension of the signal zone can be increased in this case by using a conductive material of the operating aid. A control signal can thereby be generated via the activation zone and the signal zone by touching on the user-side outer side, which can be detected by the display or rather by the electrical equipment and converted into a control command.
[0014] A tactile pressure actuation zone is thereby provided on the activation area, which can be brought in a passive position or is positioned permanently therein, wherein a control signal is not generated or cannot be generated via the signal zone in this passive position. Through this, the pressure actuation zone can be tactilely sensed by the user or rather the user can leave a finger on the pressure actuation zone, which is arranged spaced from the signal zone at least in an unloaded state, so that the transmission of the control signal is inhibited in the pressure actuation zone.
[0015] The activation area on the pressure actuation zone between the display-side surface and the user-side outer side has an elastic material structure. Through this, the pressure actuation zone can be brought into an active position by applying pressure from the passive position in which the pressure actuation zone is arranged spaced to the signal zone, in which the pressure actuation zone is arranged with the finger adjacent to it, for example, partially within the signal zone, and a control signal can be generated through it. In the passive position, the material structure of the activation area, in this case, has a first material thickness surpassing the spatial extension of the signal zone, which ensures that no control signal can be transmitted.
[0016] Through application of pressure to the pressure actuation zone, the elastic material structure can then be brought into the active position in which it has a second material thickness, by which the transmission of the control signal is released. The user can thus keep his fingers ready in the pressure actuation zone of the activation area in gaming applications without a control signal being generated. And only then, when he would like to additionally generate a control signal, he changes his position, for example, in a horizontal or vertical direction toward the signal zone. In this, a change detectable by the electronic device, in particular capacitive or resistive change, is generated or rather an application of pressure to the display surface, which is converted to the desired control signal. In this way, a type of pressure point can be kept on the pressure actuation zone through which a more comfortable and more precise control of the electronic device is possible, in particular with game applications. Here, the transmission of the control signal in the passive position is blocked by the material structure of the activation area, while the transmission of the control signal is released in the active position. Through this vertical adjustability of the material structure, it is possible to tactilely sense the pressure actuation zone in the passive position without a control signal being generated by this. And only then, when he would also like to generate a control signal at this position, the user applies sufficient pressure on the pressure actuation zone in order to displace the pressure actuation zone into the active position. Here, the respective operating finger of the user reaches through the elastic deformation of the material structure in the signal zone, in which he generates a control signal on the display.
[0017] Advantageously, in the active position the pressure actuation zone is thereby arranged at least partially and the second material thickness is arranged completely within the spatial extension of the signal zone, whereby the transmission of the control signal is released. In this way, for example, a detectable change in capacitance can be generated as a consequence of arranging a finger adjacent to the display surface. With this approach, a difference of the material thickness of the structure can be predetermined, which must be achieved by elastic deformation before a control signal is generated on the activation area in question. In this way, it can be ensured that an unwanted control signal is not generated with the mere tactile sensation of the activation area or rather with the mere application of the user's finger, but rather until a certain pressure point must be reached for this. In addition, virtual control elements of the display, which should not be actuated for the respective application, can be covered in this way by means of the material structure in order to not be inadvertently actuated. The soft material structure of the pressure actuation zone also forms a type of material ramp in the pressed-in state which allows the finger to be able to easily leave the pressure actuation zone when pressure is exerted.
[0018] It is thereby advantageous if the material structure is at least formed by the adhesive layer and an elastic backing layer of the base element and the first material thickness is at least 0.8 mm in the passive position. This can reliably prevent the transmission of a control signal in the passive position of the pressure actuation zone, for example, when using a polymer and/or one or more microfiber layers for the material structure of the activation area. The adhesive layer thereby fixes each individual pressure actuation zone in its current position on the touch screen and largely blocks the elasticity of the soft material in the plane parallel to the touch screen. The elasticity is present as a pressure point almost entirely orthogonal to the touch screen plane. Since each pressure actuation zone is self-adhesive, the operating aid can also consist of several, freely combinable parts and requires no specific device width in order to be attached. Thus, the operating aid is compatible with a variety of devices, through which the manufacturing and development costs decrease.
[0019] Advantageously, the adhesive layer is formed by a polymer layer which has a plurality of pores on the display-side surface, by means of which a negative pressure can each be generated on the display surface. The base element can be fastened with particular stability to the display surface in question by such a polymer layer and also be detached from this easily and without residue again after use. Through the plurality of open pores of the polymer layer via which the adhesive effect is generated here, a high number of reuses of the operating aid is possible before the adhesive effect noticeably decreases. Further, such polymer layers also adhere to very dusty or greasy surfaces. In addition, such adhesive layers can be manufactured very soft or very thin, so that they support and do not hinder the pressure point created by the elastic material structure. A corresponding polymer layer is described in more detail, for example, in U.S. Pat. No. 7,431,983 B2.
[0020] Furthermore, it is advantageous if the backing layer is formed by a foamed plastic, such as, for example, foam rubber. This allows the operating aid be produced inexpensively and with a suitable pressure point for game applications. Another possibility for the production of a soft backing layer would be the use of a gel which is enclosed by a smooth membrane, similar to gel inserts of bicycle seats or shoe inserts.
[0021] Advantageously, the base element is also at least partially formed of anti-static material, whereby the occurrence of unwanted electrostatic charges on the operator aid or the touch-sensitive display is prevented. In this manner, electric charges which could briefly block the function of an operating aid are avoided. Such charges can arise while playing, if the control finger often moves back and forth between multiple regions. During changing, the finger is usually thereby held on the operating aid, wherein friction is generated.
[0022] In a particularly advantageous embodiment, the base element is also formed at least transparent over some regions, wherein, for example, the backing layer is formed by a transparent material and the adhesive layer in addition formed so thin that the base element is transparent overall. Through this, parts of the display may be kept visible through the operating aid, which facilitates, for example, the accurate attachment of the operating aid.
[0023] Further, it is advantageous if multiple recesses for the adjustment of a desired pressure point on the respective pressure actuation zone are set in the elastic material structure, such as, in particular, continuous openings. Here, the material recesses have, for example, a plurality of small, continuous recesses or rather perforations on the groove bottom, the knob bottom or troughs, which can be, for example, in the form of circles, squares or hexagons. These recesses can be between 0.2 mm and 4 mm wide. Through the number and size of these recesses, the pressure required for signal generation, on the one hand, can be adjusted, wherein less pressure is required through the reduction of the material. On the other hand, the screen on which the operating aid is attached, is made visible by the perforations through it.
[0024] Moreover, it is advantageous if the pressure actuation zone is formed by a material recess of the activation area, such as a punch out. This enables a particularly simple and inexpensive production of the operating aid with different shapes and different numbers of tactile pressure actuation zones. The material recess can thereby be designed, for example, circular or elliptical, teardrop-shaped, polygonal or slit-like. In addition, they may both be formed the same by a complete opening of the material recess as well as also only by a tangible edge section.
[0025] Advantageously, the material recess is thereby designed as a continuous recess of the base element, such as in the form of a punch out. A relatively free shaping with respect to the activation area is possible in this way.
[0026] Furthermore, it is advantageous if the material recess is designed trough-shaped and the display-side surface forms a closed area, whereby the display surface in question may be particularly well protected against mechanical stresses during operation.
[0027] In addition, the material recess has a maximum extension, such as a diameter of a circular or elliptical recess, from 3 to 10 mm. The pressure actuation zone can be easily tactilely sensed through this without the finger in question coming into direct contact on the display. Instead, the display is only touched through a pressure-induced deformation of the pressure actuation zone or of the fingertip. The maximum extension is thereby thus selected as a function of the shape of the recess, the thickness of the base element and optionally on the user's finger size so that direct contact of the finger via the recess on the display without contact on the material of the operating aid is not possible.
[0028] Advantageously, the material recess forms a first circumferential groove. For example, an easier, more fluid passage of the finger from one direction to another direction is possible through this groove, which, as a result, also has a more fluid movement of the game figure. In particular, free movement without stopping is possible when changing direction.
[0029] It is thereby advantageous if a second circumferential groove arranged concentrically to the first circumferential groove is provided, wherein a tactilely detectable separation element is provided between the two grooves. The speed of the game figure in many game applications can thus be better controlled, for example, if a slower motion is generated via one groove than via the other groove.
[0030] In a particularly advantageous embodiment, the pressure actuation zone is formed by an actuation contour projecting over a user-side surface of the base element, whereby tactile detection of the pressure actuation zone is particularly easy. In addition, the control signal can be generated in a comfortable way by the actuation contour projecting from the base element.
[0031] It is thereby advantageous if the actuating contour is formed by a knob that projects with a tappet section into the material recess of the base element, through which, for example, the control signal can be generated in an especially comfortable way by touching the display surface.
[0032] Advantageously, the knob is, in this case, at least partially electrically conductive, whereby a capacitive change detectable on the display surface can be produced by means of the knob.
[0033] Moreover, it is advantageous if the material recess is formed continuous and the tappet section can be displaced completely through the base element, whereby the operating aid can be used both for capacitive as well as resistive touch screens.
[0034] In an advantageous embodiment, the tappet section can be applied to a bottom of the material recess formed as a trough, whereby the display surface can be particularly well protected against mechanical stresses.
[0035] In a further advantageous embodiment, the actuating contour is formed by a blister, which enables a particularly cost-effective manufacture of the actuating contour.
[0036] It is advantageous if the blister can be everted by applying pressure in the active position. Through this, the active position of the pressure actuation zone can be particularly clearly distinguished from the passive position, which allows a more accurate control of the electronic device.
[0037] In a further advantageous embodiment, the actuating contour is formed by an annular collar made of elastic material, which is placed adjacent to the recess on the base element. A relatively large difference between the thickness of the material structure in the passive position and in the active position can be predetermined through this in order to generate a certain pressure point in a simple manner.
[0038] In an advantageous embodiment, the material recess of the activation area is formed by a first circumferential groove, whereby a flat, continuous actuation region can be generated. The pressure point may thereby be generated either by a soft groove above the signal zone and/or (both together is possible!) a small selected groove width (between 2 mm and 10 mm), which makes it impossible to put the finger on the groove bottom without exerting pressure on the groove edges. In addition, it is favorable if the groove has indentations/recesses (for example, in at least four of the eight cardinal directions), whereby tactile recognition of these positions is facilitated. The tactile recognition of the indentations/positions during the application of pressure can also be reinforced by continuous recesses in the groove bottom (for example, in the form of holes or rounded triangles).
[0039] In a further advantageous embodiment, the first circumferential groove has at least one further circumferential groove, which is arranged concentrically to the first groove and which is delimited by a tactilely detectable separation element. The separation element prevents accidental transition from one groove to the other groove. In some game applications, the speed of game figures can thus be controlled, since the inner grooves might cause slow movements and the outer fast.
[0040] These operating aids are particularly advantageous for the control of game figures in virtual space. An easier, more fluid passage of the finger from the west direction into the northwest direction is, for example, possible through this circumferential groove, which also consequently has a fluid movement of the game figure. Easy movement was actually also possible with the original directional pad, however, the material structure between the west and northwest direction might have created a short stop of the game figure as a result.
[0041] In a very advantageous embodiment, at least one edge of a pressure actuation region or a protruding contour is rounded. Leaving an activation area under application of pressure is thus simplified, since the rounded edge forms a type of ramp, which generates less resistance than an edge. Particularly with grooves, a rounded edge also allows a comfortable (painless) following of the groove while applying pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] An exemplary embodiment of the invention is shown in the figures.
[0043] FIG. 1 is a perspective view of an electronic device with two operating aids according to the invention attached to a display.
[0044] FIG. 2 shows the electronic device according to FIG. 1 with detached operating aids.
[0045] FIG. 3 is an enlarged view of the operating aids according to FIG. 2 .
[0046] FIG. 4 a is a sectional side view of the attached operating aid according to FIG. 3 in a passive position.
[0047] FIG. 4 b is a sectional side view of the operating aid according to FIG. 4 a in an active position.
[0048] FIG. 4 c is a sectional side view of an alternative embodiment of the operating aid according to FIG. 4 a in the active position.
[0049] FIG. 5 a is a perspective view of another embodiment of the operating aid according to the invention with a trough-shaped material recess.
[0050] FIG. 5 b is a sectional side view of the operating aid according to FIG. 5 a in the passive position.
[0051] FIG. 5 c is a sectional side view of the operating aid according to FIG. 5 a in the active position.
[0052] FIG. 6 a is a perspective view of another embodiment of the operating aid according to the invention with an actuating contour formed by a knob.
[0053] FIG. 6 b is a sectional side view of the operating aid according to FIG. 6 a in the passive position.
[0054] FIG. 6 c is a sectional side view of the operating aid according to FIG. 6 a in the active position.
[0055] FIG. 7 a is a perspective view of another embodiment of the operating aid according to the invention with an actuating contour formed by a blister.
[0056] FIG. 7 b is a sectional perspective view of the operating aid according to FIG. 7 a.
[0057] FIG. 7 c is a sectional side view of the operating aid according to FIG. 7 a in the passive position.
[0058] FIG. 7 d is a sectional side view of the operating aid according to FIG. 7 a in the active position.
[0059] FIG. 8 is a perspective view of another embodiment of the operating aid according to the invention with an actuating contour formed by an annular collar,
[0060] FIG. 9 is a perspective view of another embodiment of the operating aid according to the invention with an activation area formed by a circumferential groove.
[0061] FIG. 10 is a perspective view of another embodiment of the operating aid according to the invention with a circumferential groove, which has a plurality of indentations.
[0062] FIG. 11 is a perspective view of another embodiment of the operating aid according to the invention with two concentrically arranged grooves.
[0063] FIG. 12 is a perspective view of another embodiment of the operating aid according to the invention with a groove, whose edges have a raised contour.
[0064] FIG. 13 is a partially sectioned view of an alternative embodiment of a material recess of the operating aid according to the invention, which has a rounded edge.
DETAILED DESCRIPTION
[0065] FIG. 1 shows an electronic device 2 in the form of a smart phone with a touch-sensitive display 4 such as a capacitive or resistive touch screen. The touch-sensitive display 4 displays multiple virtual control fields 6 , which are represented as arrows or numbers. The control fields 6 are used for inputting control signals by a user, by means of which, for example, virtual game figures (not shown) can be moved within an also displayed playing area 8 .
[0066] To thereby enable a more comfortable and more precise actuation of the control elements 6 , two operating aids 10 were subsequently attached to the display 4 , which can be detached from the display after use, as shown in FIG. 2 .
[0067] The operating aids 10 have a flat base element 12 for this purpose whose display-side surface 14 is formed by an adhesive layer 16 in the form of an elastic polymer layer. The polymer layer in this case is, for example, permeated by microscopic air bubbles that form a plurality of open pores on the display-side surface 14 (not shown). When pressing this adhesive layer 16 against the display 4 , a negative pressure is respectively generated by elastic restoring forces in the pores by which the base element 12 can be held on the display 4 .
[0068] In particular, FIG. 3 shows that the elastic polymer layer 16 is held on a backing layer 18 , which forms a user-side surface 22 of the base element 12 on a user-side outer side 20 of the operating aid 10 facing away from the display-side surface 14 and which is, for example, formed from an elastic material, such as a polymer layer, or from a microfiber layer. Alternatively, for this purpose, the backing layer 18 may also be formed by a foamed plastic, such as foam rubber.
[0069] In addition, the base element 12 can be designed anti-static as a whole or at least partially contain anti-static material. In addition, the base element 12 may be formed at least transparent over a region, wherein, for example, the backing layer 18 is formed by transparent material and the adhesive layer 12 is formed so thin that it is even at least partially transparent.
[0070] In order to be able to actuate the control elements 6 of the operating aids 10 in the attached state, several activation areas 24 are provided on the base element 12 . In the embodiment according to FIG. 3 , the activation areas 24 have material recesses 26 in the form of round punch outs. The edges of these material recesses 26 in turn form pressure actuation zones 30 which can be easily felt by the user.
[0071] As can be seen in particular from FIG. 4 a , the touch-sensitive display 4 generates respectively a signal zone 28 of the activation areas 24 on the display-side surface 14 in the attached state of the operating aid 10 . A control signal is generated in these signal zones 28 as soon as a detectable capacitive or resistive change is caused within these, in particular by the entry of a finger F of the user.
[0072] The tactile pressure actuation zones 30 provided on the user-side outer side 20 of the operating aid 10 , which is formed by the edge of the respective material recess 26 , are shown in FIG. 4 a in a passive position, in which they are each arranged spaced to the signal zone 28 . The material recesses 26 in this case preferably have a maximum diameter or rather maximum extension Em, which is between 4 and 8 mm. Through this, the finger F of the user can tactilely sense the activation area 24 and in particular the pressure actuation zone 30 and can be put on these, without him being able to inadvertently put it over the material recesses 26 on the display and thereby generate an unintended control signal.
[0073] Here, the base element 12 has an elastic material structure 32 at least in the activation areas 24 between the display-side surface 14 and the user-side surface 22 or rather the user-side outer side 20 . This material structure 32 forms a first material thickness M 1 in the shown passive position of the pressure actuation zone 30 , which exceeds the vertical extension of the signal zone 28 . Through this, the generation of a control signal by the adjacent finger F is effectively prevented by means of the material structure 32 .
[0074] If a control signal is to be generated now by means of the finger F already adjacent to the activation area 24 , a pressure D is applied to the pressure actuation zone 30 , as shown in FIG. 4 b . The elastic material structure 32 is at least pressed together against an edge section of the pressure actuation zone 30 by this pressure D of the finger F, wherein this shifts in the direction of an active position. In this illustrated active position, the material structure 32 has a significantly lower second material thickness M 2 , which lies entirely within the vertical extension of the signal zone 28 . Through this, the pressure actuation zone 30 lies at least partially inside of the signal zone 28 with the finger F adjacent to it. Consequently, in turn, for example, a capacitive or resistive change to the display-side surface 14 is caused, which is detectable on the part of the display 4 so that a control signal is output to the electronic device 2 .
[0075] The elastic properties of the material structure 32 can thereby be produced both solely by the adhesive layer 16 or the backing layer 18 or rather preferably through the entire layer structure.
[0076] In an alternative embodiment, the operating aid 10 , according to FIG. 4 c , in which the material structure 32 is substantially rigid, the control signal is generated on the other hand so that the finger F adjacent to the pressure actuation zone 30 is so deformed by exerting pressure on his finger tip, that this projects so far into the material recess 26 that it extends into the signal zone 28 , and through it causes a detectable capacitive or resistive change on the part of the display 4 .
[0077] FIG. 5 a shows a further alternative embodiment of the operating aid 10 in which the adhesive layer 16 forms a closed surface and the material recesses 26 are designed trough-shaped, for example, by forming a bottom 34 formed by the adhesive layer 16 .
[0078] In order to also be able to cause a control signal by capacitive change on this operating aid 10 , the signal zone 28 extends either from the display-side surface 14 to above the bottom 34 as shown in FIG. 5 b , or the bottom 34 is embodied elastically such that the finger F extends into the signal zone upon application of pressure to the bottom 34 , as shown in FIG. 5 c . In this case, adjustment recesses 35 can be embedded in the bottom 34 , which are, for example, 0.2 to 0.4 mm wide and through which the pressure force required for signal generation can be adjusted.
[0079] In the following FIGS. 6 to 8 , further embodiments of the operating aids 10 according to the invention are shown, which also has a respective activation area 24 with a signal zone 28 and a pressure actuation zone 30 in the attached state on the display 4 according to the operation described above, which can be brought from a passive position into an active position by applying pressure, in which a control signal can be generated by means of the adjacent finger F.
[0080] In the embodiment of FIG. 6 a , the pressure actuation zone 30 of the activation area 24 of the operating aid 10 is formed by an actuating contour 36 , which projects out on the user-side outer side 20 of the operating aid 10 over the user-side surface 22 of the base element 12 .
[0081] As can be seen in particular from FIG. 6 b , the actuating contour 36 is formed in this case by a knob 38 which projects with a tappet section 40 into the material recess 26 of the activation area 24 . The tappet section 40 is dimensioned so that it is held spaced to the display 4 or rather the signal zone 28 in the illustrated passive position. In addition, the knob 38 is formed of an electrically conductive material, such as, for example, from an electrically conductive plastic or rather from a plastic into which electrically conductive material is embedded. Through this, the entire knob 38 functions as a pressure actuation zone 30 , which can be tactilely sensed in the passive position by the user and on which a finger F can be put without generating a control signal on the display.
[0082] In order to generate a control signal on the display 4 , a pressing force D of the finger F is applied to the knob 38 , whereby this is brought from the passive position into the active position, in which the tappet section 40 reaches into the signal zone 28 , as shown in FIG. 6 c . Due to the conductivity of the knob 38 in this case, a capacitive or resistive change detectable by the display is generated, which can be converted into a control signal.
[0083] Alternatively to the embodiment shown here of the activation area 24 with continuous material recess 26 , the display-side surface 14 may also be formed closed (not shown).
[0084] FIGS. 7 a and 7 b show a further embodiment of an operating aid 10 according to the invention, in which the actuating contour 36 projecting out from the user-side surface 22 is formed by a blister 42 which is affixed, for example, at the edge of the material recess 26 on the backing layer 18 . Here, the entire blister 42 functions as a pressure actuation zone 30 , which can be tactilely sensed in the passive position by the user and on which the finger F, as shown in FIG. 7 c , can be put, without generating a control signal on the display 4 .
[0085] In order to generate a control signal, pressure D of the finger F is applied to the blister 42 , which causes it to evert into the material recess 26 and is thereby brought from the passive position into the active position in which the blister with the finger F adjacent to it reaches into the signal zone 28 as shown in FIG. 7 d . In turn, this generates a capacitive or resistive change detectable from the display 4 , which can be converted into a control signal.
[0086] A closed adhesive layer 16 can also be provided (not shown) here alternatively to the illustrated embodiment of the activation area 24 with continuous material recess 26 on the display-side surface 14 .
[0087] FIG. 8 shows another embodiment of an operating aid 10 according to the invention, in which the actuating contour 36 projecting out from the user-side surface 22 is formed by an annular collar 44 which is affixed, for example, at the edge of the material recess 26 on the backing layer 18 . The operation of the operating aid 10 thereby corresponds to the embodiment according to FIG. 4 a . The additionally attached collar 44 merely provides that the pressure actuation zone 30 of the activation range 24 can be more easily tactilely sensed. In addition, the distance between the actuating pressure zone 30 and the signal zone 28 can be set almost arbitrarily by the collar 44 .
[0088] FIG. 9 shows an embodiment of the operating aid 10 , in which the material recess 26 of the activation area 24 is formed by a first circumferential groove 46 , whereby a flat, continuous activation area 24 can be generated. The pressure point can thereby be generated, for example, by a soft groove bottom 48 reaching over the signal zone 28 , which is either smooth or, as exemplified, has a plurality of adjustment recesses 35 for setting the pressure force required for signal generation.
[0089] Alternatively or additionally, the pressure point may also be generated by the groove edges 50 . For this purpose, the groove has a relatively small groove width bN, such as between 2 mm to 10 mm, whereby putting the finger on the groove bottom 48 is only possible when pressure is exerted on the groove edges 50 .
[0090] In the embodiment according to FIG. 10 , the groove 46 also has several indentations 52 which are directed, for example, in at least four or eight directions, whereby a tactile identification of these positions is facilitated. The tactile detection of the indentations 52 during the application of pressure can also be strengthened by continuous recesses in the groove bottom (not shown).
[0091] In a further advantageous embodiment, at least one additional circumferential groove 54 is provided in addition to the first circumferential groove 46 , as shown in FIG. 11 , which is arranged concentrically to the first groove 46 . Both grooves 46 , 54 are thereby separated from one another by a tactilely detectable separation element 56 . The separation element 56 thereby prevents the unwanted transition from a groove 46 , 54 to the other groove 54 , 46 . The speed of the game figures can thus be better controlled in many game applications if, for example, a slower movement is generated via the inner groove 46 than via the outer groove 54 .
[0092] The operating aids 10 of FIGS. 9 to 11 are particularly advantageous for the control of game figures in virtual space. An easier, more fluid transition of the finger from one direction into another direction is, for example, possible through the respective circumferential groove 46 , 54 , which consequently also results in a more fluid movement of the game figure. In particular, free movement without stopping is possible when changing direction.
[0093] FIG. 12 shows another embodiment of an operating aid 10 with a groove 46 , which has a circumferential raised contour 58 on each of its edges, which may be formed, for example, from hard or soft material and provides an improved guide along the groove 46 . Such a raised contour 58 can of course also be formed on a plurality of grooves 46 , 54 or any other material recess 26 (not shown).
[0094] FIG. 13 shows an advantageous embodiment of a material recess 26 of the activation area 24 , which is exemplified as a groove 46 . This has a rounded recess edge 60 . The rounding thereby enables easier removal of a fingertip from the activation area 24 in question also under the exertion of pressure. The rounded recess edge 60 thereby forms a type of ramp, which generates less resistance than a straight edge. Such a rounded recess edge 60 can thereby be applied on any other material recess 26 or on the raised contour 58 . Particularly with the grooves 46 , 54 , the rounded recess edge 60 thereby enables a more comfortable following, exiting or pressing upon the grooves 46 , 54 or other material recesses also under the exertion of pressure.
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The invention relates to an operating aid ( 10 ) for use on a touch-sensitive display ( 4 ), having a base element ( 12 ) which has an adhesive layer ( 16 ) for removably attaching to the display ( 4 ), said adhesive layer being provided on a display-side surface ( 14 ), and on which at least one activation region ( 24 ) is provided. The activation region can be detected in a tactile manner on a user-side outer face ( 20 ) facing away from the display-side surface ( 14 ), and the activation region can be used to act upon a signal zone ( 28 ) which can be positioned on the display-side surface ( 14 ) in order to generate a control signal that can be detected on the display ( 4 ). A detectable pressure actuation zone ( 30 ) is provided on the activation region ( 24 ). The pressure activation zone can be brought into a passive position, in which no control signals can be generated on the signal zone. The activation region ( 24 ) has an elastic material design ( 32 ) on the pressure actuation zone ( 30 ) between the display-side surface ( 14 ) and the user-side outer face ( 20 ). The material design has a first material thickness (M 1 ) which exceeds the signal zone ( 28 ) in a passive position and a smaller second material thickness (M 2 ) in an active position, and the pressure actuation zone ( 30 ) can be moved from the passive position, in which the pressure actuation zone is arranged at a distance from the signal zone ( 28 ), into the active position, in which the control signal is generated, by applying pressure.
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TECHNICAL FIELD OF THE INVENTION
Embodiments of the present invention relates to a method and apparatus for avoiding erosion and high friction loss for power cable deployed electric submersible pump (ESP) systems.
BACKGROUND OF THE INVENTION
For certain production wells, artificial lift systems can become necessary when the natural pressure within the underground reservoir is no longer adequate to naturally push produced fluids to the surface. Electric submersible pumps (ESPs) are often used in these situations. Electric power is transmitted from the surface via an umbilical power cable to the downhole ESP. Conventionally, ESPs were deployed at the end of production tubing, with the power cable installed outside the production tubing. However, electrical failures were often associated with this type of setup, and anytime there was an electrical failure, a rig had to be brought in to pull out the production tubing and the ESP.
In an effort to overcome this problem, alternative ESP systems were developed. One such system is a power cable deployed ESP system. In this system, the power cable is used to transmit power, as well as to support the ESP itself. In this alternate setup, both the power cable and the ESP are installed inside the production tubing.
In order to improve overall safety for a power cable deployed ESP system, well control can employ a deep set surface controlled subsurface safety valve (SCSSV). The SCSSV is installed in the production tubing below the ESP. The SCSSV is designed to be fail-safe, so that the wellbore is isolated in the event of any system failure or damage to the surface production-control facilities. An example of a prior art setup is shown in FIG. 1 .
In FIG. 1 , production tubing 40 is disposed within casing 20 . ESP 90 is supported by power cable 100 , as well as production tubing 40 via isolation member 120 . Casing 20 has perforations 22 in a producing region 30 of an underground reservoir. Produced fluids enter casing 20 through perforations 22 . The produced fluids then travel through the safety valve 80 into an inner volume 105 of production tubing 40 , and flow through a narrow gap between ESP 90 and production tubing 40 . The produced fluid then enters ESP 90 via intake slots 97 , travels through medial pump body portion 98 , and exits ESP 90 above isolation member 120 via discharge slots 111 . The produced fluid is now back within production tubing 40 (at a point above isolation member 120 ), where it can be pumped to the surface. Lower packer 50 prevents produced fluids from traveling up the annular region formed between production tubing 40 and casing 20 .
In these types of setups, the fluid velocity of the production fluids can get quite high due to the narrow gap between the production tubing and the ESP. In typical installations, the narrow gap can range from 0.079 inch to 0.225 inch, depending on the size of the production tubing and chosen ESP. For a typical target rate of 6,000 barrels per day (bpd) production using production tubing of 4½ inch, the fluid velocity of the produced fluid coming through this gap can be 70 ft/s. For 5½ inch tubing, the velocity can still reach 40 ft/s. However, at fluid velocities in this range, the ESP system can fail quickly due to erosion. Additionally, at high velocities such as these, the frictional losses are quite significant. Overcoming frictional losses is usually achieved using longer motors and longer pumps; however, doing this increases the capital costs. Additionally, longer equipment increases installation difficulties, particularly for live well deployment with a surface lubricator. As such, ESP systems are typically only operated at 1,000 to 2,000 bpd.
Therefore, it would be advantageous to provide an ESP system that did not suffer from erosion or high friction losses at production rates higher than 2,000 bpd.
SUMMARY OF THE INVENTION
The present invention is directed to a method and apparatus that provides one or more of these benefits. In one embodiment, the invention provides for an ESP assembly for use in a wellbore, wherein the ESP assembly includes a pump and a tubing section adapted for insertion within casing of the wellbore thereby defining an annulus between the tubing section and the casing. The tubing section circumferentially surrounds a portion of the pump. The tubing section includes fluid openings that are operable to allow fluid from the wellbore to flow radially outward, thereby occupying a greater volume, and therein reducing the bulk fluid velocity of the fluid. The pump can include a fluid inlet, a seal section, a pump discharge and a pump motor coupled to the pump.
In one embodiment, the tubing section can be integral within a string of production tubing that is adapted for insertion into the wellbore. In another embodiment, the ESP assembly further includes a safety valve positioned at a lower end of the tubing section. The safety valve has an open and closed position, and the safety valve is positioned such that fluid from the wellbore enters the tubing section through the safety valve when the safety valve is in an open position. In another embodiment, the ESP assembly can further include a safety valve control line that is in communication with the safety valve.
In one embodiment, the fluid openings are selected from the group consisting of slots, holes, perforations, and combinations thereof. Those of ordinary skill in the art will recognize that the fluid openings can be of any size, shape, and pattern so long as the integrity of the production tubing is maintained. In one embodiment, the fluid openings are perforations having diameters in the range of ¼ inch to ½ inch. In another embodiment, the ESP assembly can include a lower packer and an upper packer, wherein the lower packer is connected to the casing and the production tubing, the lower packer being positioned proximate the lower end of the production tubing, the lower packer being operable to support the positioning of the production tubing within the casing. The upper packer is connected to the casing and the production tubing, and the upper packer is positioned at a point above the lower packer thereby forming a first interstitial space in the annulus between the upper packer and the lower packer. A second interstitial space is also formed in the annulus between the upper packer and the surface.
In another embodiment, the ESP assembly for use in a wellbore can include casing, production tubing, the lower packer, the upper packer, the safety valve, and the safety valve control line in communication with the safety valve. The casing is positioned within a hydrocarbon wellbore and is in fluid communication with a producing region of a reservoir such that produced fluid can enter the casing. The production tubing is positioned within the casing to provide a pathway for produced fluids dispersed from the hydrocarbon well. The production tubing has a diameter that is less than the diameter of the casing such that an annulus is formed between an outer wall of the production tubing and an inner wall of the casing, wherein the production tubing has a lower end that is distal from the surface. The lower packer is connected to the casing and the production tubing and is positioned proximate the lower end of the production tubing. The lower packer is operable to support the positioning of the production tubing within the casing. The upper packer is connected to the casing and the production tubing. The upper packer is positioned at a point above the lower packer, thereby forming the first interstitial space in the annulus between the upper packer and the lower packer. The second interstitial space is formed in the annulus between the upper packer and the surface. The safety valve is positioned on an inner wall of the production tubing proximate the lower packer, and the safety valve has an open position and a closed position. The first interstitial space is in fluid communication with the production tubing, such that the assembly is operable to allow produced fluid from the producing region of the reservoir to flow from the production tubing into the first interstitial space. This causes the fluid velocity of the produced fluid to be less than the fluid velocity of the produced fluid if the first interstitial space was not in fluid communication with the production tubing.
In another embodiment, the ESP assembly can also include an absence of perforations in the casing in areas other than proximate the producing region of the reservoir. In another embodiment, the casing does not allow produced fluids to reenter the reservoir. In another embodiment, the second interstitial space is not in fluid communication with the production tubing.
In another embodiment, the assembly is operable to house an ESP within the production tubing. The ESP can include a pump intake, a pump discharge, a medial pump body portion, an isolation member, a motor, and a seal section. The pump intake can be positioned above the safety valve so that the produced fluids enter the pump intake. The pump discharge can be positioned above the upper packer and within the production tubing so that the produced fluids are discharged within inner walls of the production tubing and sent to the surface. The medial pump body portion can extend between the pump intake and the pump discharge and can also provide a pathway through which the produced fluids flow from the pump intake to the pump discharge. The isolation member can be positioned at an upper portion of the ESP, and the isolation member is operable to isolate the pump intake from the pump discharge. The motor is connected to the ESP and provides power to the ESP. The seal section can be connected between the motor and a distal end portion of the pump intake, with the seal section being operable to prevent produced fluids from entering the motor. In another embodiment, the second interstitial space is not in fluid communication with the ESP.
In another embodiment, the portion of the tubing between the upper packer and safety valve can include fluid openings for allowing the produced fluids to enter the first interstitial space. In another embodiment, the perforations fluid openings can have diameters in the range from ¼ inch to ½ inch. In another embodiment, the casing can extend through the producing region of the reservoir. In one embodiment, the fluid velocity of the produced fluid can be maintained below 20 fps when producing more than 2,000 bpd. In another embodiment, the fluid velocity of the produced fluid is maintained between 10 to 20 fps when producing up to 6,000 bpd. In another embodiment, the fluid velocity of the produced fluid is maintained below 20 fps when producing up to 32,000 bpd for 4½ inch tubing (7 inch casing). In another embodiment, the fluid velocity of the produced fluid is maintained below 20 fps when producing up to 45,000 bpd for 7 inch tubing (9⅝ inch casing).
Embodiments of the present invention also include a method for enhanced well control of high fluid velocity wells. In one embodiment, the method can include providing any ESP assembly discussed herein, inserting the ESP assembly into a wellbore that is in fluid communication with an underground hydrocarbon reservoir, and flowing fluid from the underground hydrocarbon reservoir through the fluid openings of the tubing string and radially outward, such that the fluid occupies a greater volume of space, thereby lowering the fluid velocity of the fluid.
In another embodiment, the invention can include a method for enhanced well control for high fluid velocity wells can include the steps of positioning casing into a bore of a hydrocarbon well, positioning production tubing at least partially within the casing, connecting a lower packer to the casing and the production tubing, connecting an upper packer to the casing and the production tubing, positioning a safety valve on an inner wall of the production tubing proximate the lower packer, communicating with the safety valve, and allowing produced fluids to flow from the reservoir through the opening of the safety valve to the production tubing and the first interstitial space, such that the fluid velocity of the produced fluid is less than the fluid velocity of the produced fluid if the first interstitial space was not in fluid communication with the production tubing.
In another embodiment, the method can also include the step of operating the ESP so that the produced fluids enter the ESP, flow through the ESP, and discharge from the ESP back into the production tubing above the isolation member and then travel on to the surface. In another embodiment, the second interstitial space is not in fluid communication with the ESP. In another embodiment, the hydrocarbon well is located offshore.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it can admit to other equally effective embodiments.
FIG. 1 is a front elevational view of an apparatus in accordance with an apparatus known in the prior art.
FIG. 2 is a front elevational view of an apparatus in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
While the invention will be described in connection with several embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all the alternatives, modifications and equivalents as may be included within the spirit and scope of the invention defined by the appended claims. Like numbers refer to like elements throughout.
Embodiments of the present invention can improve ESP performance in most any reservoir; however, the embodiments are most advantageous in wells that typically experience higher than normal friction losses or erosion damage to an ESP. Pressure losses at or above 50 psi are generally regarded as high friction losses. As will be understood by those skilled in the art, embodiments of the present invention, for example, also can allow produced fluids to more readily flow when pumped by use of an ESP. While the embodiments shown in the figures generally show vertical bores, those of ordinary skill in the art will understand that embodiments of the present invention can also apply to horizontal bores. Therefore, embodiments of the present invention are useful for pumping produced fluids from either a horizontal bore or vertical bore of a hydrocarbon well to the surface.
High fluid velocity can result in premature failure of down hole components such as an ESP due to erosion damage. Accordingly, embodiments of the present invention can enhance well control, for example, by improving production rates and reducing the rate of premature failure of an ESP.
Now turning to FIG. 2 . Embodiments of the present invention include positioning casing 20 within wellbore 10 . The bottom of the well can be an open-hole, cased-hole completion, or any other bottom hole completion, as will be understood by those skilled in the art, to be suitable for embodiments of the present invention. For example, an open-hole, top set, or barefoot completion can be made by drilling down producing region 30 and subsequently casing wellbore 10 . According to this embodiment, wellbore 10 is drilled through producing region 30 leaving the bottom of wellbore 10 open. Casing 20 in a cased-hole completion, according to another embodiment of the present invention, is run through the producing region 30 , and cemented in place. As illustrated in FIG. 2 , according to this embodiment, perforations 22 are made in casing 20 to allow produced fluids to fluidly travel from producing region 30 of the underground reservoir to within casing 20 and eventually onward to the surface.
After casing 20 is positioned within wellbore 10 , cement is pushed between the outer walls of casing 20 and the inner walls of wellbore 10 to set casing 20 thereto. Casing 20 , for example, can prevent the contamination of fresh water zones. Casing 20 can be made out of steel pipe to support wellbore 10 , and in accordance the American Petroleum Institute specifications and standards as understood by those skilled in the art.
To further support wellbore 10 , and to provide a pathway for produced fluids dispersed from wellbore 10 to the surface, embodiments of the present invention include production tubing 40 . Production tubing 40 has an outside diameter that is less than the inside diameter of casing 20 . Lower packer 50 is positioned between outer walls of production tubing 40 and inner walls of casing 20 and is also positioned proximate the lower end of production tubing 40 . Lower packer 50 is adapted to support the positioning of production tubing 40 within casing 20 , as well as also to prevent produced fluids from entering first interstitial space 70 without first passing through safety valve 80 when safety valve 80 is in an open biased position. When safety valve 80 is in a closed biased position, lower packer 50 , in conjunction with safety valve 80 , prevents produced fluids from entering first interstitial space 70 .
As illustrated in FIG. 2 , embodiments of the present invention include ESP 90 being operable to pump produced fluids from wellbore 10 and thereby fluidly travel to the surface. In the embodiment shown in FIG. 2 , ESP 90 is positioned entirely within production tubing 40 , with a portion of ESP 90 extending below isolation member 120 and a portion extending above isolation member 120 . The portion of ESP 90 disposed below isolation member 120 , e.g., further down hole. can include, for example, motor 92 , seal sections 94 , pump intake 96 , and at least a region of medial pump body portion 98 . The outer diameter of ESP 90 has a smaller diameter than the inner diameter of production tubing 40 .
During operation, according to certain embodiments of the present invention, motor 92 receives power through power cable 100 . In one embodiment, ESP 90 can include one or more centrifugal pumps (not shown) within medial pump body portion 98 . The one or more centrifugal pumps suction produced fluids from inner volume 105 within production tubing 40 . The produced fluids are suctioned from inner volume 105 through a plurality of intake slots 97 , and pumped by the one or more centrifugal pumps to increase the pressure and flow of the produced fluids that entered pump intake 96 . The produced fluids are then sent to pump discharge 110 and discharged through a plurality of discharge slots 111 to a proximal region within the inner walls of the production tubing 40 and onward to the surface. The outer areas of pump discharge 110 and pump intake 96 are separated by isolation member 120 . During operation, isolation member 120 provides a barrier to allow for a pressure differential to form across isolation member 120 due to the produced fluids being pumped from pump intake 96 to pump discharge 110 .
In one embodiment, ESP 90 includes motor 92 to drive one or more centrifugal pumps within medial pump body portion 98 . Motor 92 , for example, can be the most down hole major component of ESP 90 . During operation, motor 92 runs in the range of speed of about 2,500 to 3,500 rev/min. In some embodiments, motors that are operable to run at about 10,000 RPM could be used. Those of ordinary skill in the art will recognize that the speed is related to the exact equipment used. As will be understood by those skilled in the art, during operation, the flow of produced fluids that pass the outer surfaces of the motor also can act as a coolant to reduce heat associated with operation of ESP 90 to thereby assist in preventing ESP 90 from overheating.
Embodiments of ESP 90 further include one or more seal sections 94 to prevent produced fluids from entering within inside surfaces of motor 92 . In addition to preventing produced fluids from entering the inside surfaces of motor 92 , the one or more seal sections 94 equalizes external bottom hole pressures and internal pressures of the motor 92 . Moreover, as will be understood by those skilled in the art, the one or more seal sections 94 allows lubricant associated with motor 92 to thermally expand and contract.
ESP 90 can also include pump intake 96 whereby produced fluids enter ESP 90 . Pump intake 96 includes a plurality of intake slots 97 that are preferably evenly spaced in a location where the produced fluids are suctioned therethrough. The plurality of intake slots 97 can be a variety of uniform shapes including, but not limited to, spherical, ellipsoidal, or rectangular as understood by those skilled in the art. Pump intake 96 preferably is connected between a proximal end portion of the one or more seal sections 94 and a distal end portion of medial pump body portion 98 as illustrated in FIG. 2 .
Medial pump body portion 98 can include one or more centrifugal pumps to pump the produced fluids that enter ESP 90 . The horsepower of the one or more centrifugal pumps ranges from about 75 to 300 during operation. The one or more centrifugal pumps increase the flow rate of the produced fluids entering ESP 90 to artificially lift the produced fluids to the surface. In a preferred embodiment of ESP 90 , the one or more centrifugal pumps have a large number of stages, each stage having an impeller and a diffuser. Medial pump body portion 98 extends between pump intake 96 and pump discharge 110 so that produced fluids flow therebetween from pump intake 96 to pump discharge 110 .
Embodiments of the present invention can also include isolation member 120 disposed between pump discharge 110 and medial pump body portion 98 . According to embodiments of the present invention, isolation member 120 connects to the inner walls of production tubing 40 to support the positioning of ESP 90 .
ESP 90 can include pump discharge 110 to discharge the produced fluids for onward transfer within production tubing 40 to the surface. Pump discharge 110 , for example in one embodiment, includes a plurality of discharge slots 111 that can be evenly spaced in a location where the produced fluids are discharged to a proximal region within the inner walls of production tubing 40 . The plurality of discharge slots 111 , as will be understood by those skilled in the art, can be a variety of uniform shapes including, but not limited to, spherical, ellipsoidal, or rectangular. As illustrated by the arrows in FIG. 2 , for example, pump discharge 110 is positioned within production tubing 40 so that produced fluids discharge through discharge slots 111 and fluidly travel through production tubing 40 and onward to the surface.
Embodiments of the present invention can include, for example, safety valve 80 being operable to prevent produced fluids from flowing into inner volume 105 of production tubing 40 when safety valve 80 is in the closed position. Safety valve 80 selectively, or in the case of an emergency, assists to prevent produced fluids from dispersing to the surface. Safety valve 80 , according to an embodiment of the present invention, is connected to the inner walls of production tubing 40 and is distally disposed from ESP 90 within production tubing 40 . In one embodiment, safety valve 80 can be a deep set surface controlled subsurface safety valve (SCSSV). Industry well control policy requires all wells that are in close proximity to people or facilities to be equipped with an SCSSV. Conventionally, the SCSSV is shallow set (e.g. about 200-300 It below the wellhead). However, in embodiments of the present invention, safety valve 80 is deep set (e.g. located below ESP 90 ).
Embodiments of the present invention also include upper packer 60 and first interstitial space 70 . First interstitial space 70 being the annular volume created between casing 20 and production tubing 40 , and lower packer 50 and upper packer 60 . In one embodiment, a portion of production tubing 40 below isolation member 120 and above safety valve 80 contains fluid openings 140 , such that first interstitial space 70 is in fluid communication with inner volume 105 of production tubing 40 . The produced fluid can now travel all the way to casing 20 , affectively increasing the available volume, which in turn reduces the fluid velocity of the produced fluids.
Upper packer 60 is adapted to prevent produced fluids from flowing in the annular area between the inner walls of casing 20 and the outer walls of production tubing 40 above upper packer 60 , hereby defined as second interstitial space 130 .
During operation, produced fluids are produced from producing region 30 and flow through perforations 22 to the inner walls of casing 20 distal from safety valve 80 . According to an embodiment of the present invention, power and communication are transmitted to safety valve 80 through safety valve control line 82 connected to a proximal end of safety valve 80 . In one embodiment, safety valve control line 82 receives power from the surface. In another embodiment (not shown), safety valve control line 82 can receive power directly from the ESP. When safety valve 80 is in the “open” position, produced fluids flow safety valve 80 to inner volume 105 of production tubing 40 before entering first interstitial space 70 . When safety valve 80 is in the “closed” position, produced fluids are prevented from traveling to inner volume 105 of production tubing 40 or first interstitial space 70 . Safety valve 80 , as will be understood by those skilled in the art, preferably is in a fall-back mode so that any interruption or malfunction should result in safety valve 80 being in the closed position.
In another embodiment, safety valve control line 82 can be removed and replaced with a wireless communication device that is operable to communicate with safety valve 80 wirelessly. Moreover, as will be understood by those skilled in the art, embodiments of the present invention can include communicating by hydraulic or pneumatic methods as well.
While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed.
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A method and apparatus for reducing erosion and friction losses in a wellbore using a power cabled deployed electric submersible pump (ESP). The apparatus can include an ESP disposed within production tubing, wherein a portion of the production tubing surrounding the ESP contains fluid openings that are operable to allow produced fluids to flow outward, thereby increasing the available volume for the produced fluids. The increased volume results in lower fluid velocities of the produced fluid, which advantageously reduces erosion and friction loss.
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BACKGROUND OF THE INVENTION
The invention relates to an observation and target system that can be raised for combat vehicles, consisting of a platform capable of being run out and/or pivoted in relation to the vehicle, on which at least one television camera is located, said camera being connected by means of a cable with at least one monitor provided in the combat compartment of the vehicle.
Observation and target systems of this type permit a substantial simplification of conventional observation platforms because the installations herertofore required for the housing and protection of the observer are eliminated.
SUMMARY OF THE INVENTION
The object of the present invention is to develop an elevatable observation and target system of the abovementioned type to improve significantly near and long range field observation and thus make possible increased reaction velocity, and to simplify the entire weapons system and thus obtain a higher operating safety.
This object is attained because the television camera is an attitude stabilized panoramic camera, which can be remotely controlled in elevation and azimuth and has a focal range that is adjustable from the combat compartment. The camera is equipped with angle indicators to generate the prevailing line-of-sight coordinates. In particular, the platform supporting the panorama camera can pivot and is capable of following the azimuth.
The panoramic camera permits not only angular field of vision adjustments as a function of distance and sector observation, but it also makes possible a decisive increase in reaction time by means of functional coupling with the moving mechanism of the platform.
The panoramic camera with its zoom lens or its interchangeable objective lenses is preferably rigidly mounted on the platform and is equipped with a stabilized mirror head, that is adjustable in azimuth and elevation, with which the angle indicators for the generation of line-of-vision coordinates are correlated.
This configuration contributes to high operating safety and high adjusting velocities.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE shows a schematic of a system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The panoramic camera preferably comprises a high resolution television camera 1, the field-of-vision to resolution ratio of which approaches that of pure optical systems, and which in a particularly advantageous manner, may be combined with monitors 6 located in the combat compartment 10 in the form of small image flying spot tubes equipped with a binocular optical viewing device. Flying spot tubes of this type have screen diagonals of approximately 3 to 5 cm and in view of their low inertia masses are especially resistant to interference, even in rough operations. The binocular viewing device contributes to the increased concentration of the observer, provides an impression of direct viewing in a fully protected position, and contributes to the shortening of reaction times because of the possibility of rapid and accurate near and long range detection.
Appropriately, a thermal imaging device is integrated in the panorama camera and means are provided to display the images of the panorama camera and the thermal imaging device selectively on the monitors provided in the combat compartment. The observer or observers are thus able to select the optimum means of information based on the prevailing conditions, including a pivotable residual light amplifier, or to merge alternative information from the different image generators within the shortest possible period of time, thereby increasing the security of a decision to be made.
A further essential advantage of the invention is that electronic units 4, 8 to modify signals may be inserted in the signal path between the panorama camera and the monitor. Such signal modifications may comprise, for example, a variation of contrast, or a special optical target identification, by brightening or marking.
The insertion of an intermediate memory, which significantly facilitates or automates the detection of motion, is particularly advantageous. Image areas in which motion is to be detected may be programmed, preferably by position and magnitude, while image lines on which conditions are to be recognized may be programmed by the scanning of a scenical contour by a line of vision.
According to a further appropriate embodiment of the invention, it is possible with a slight electronic effort to combine information into the existing monitor image, particularly in the form of data and/or markings.
Items that may be combined for example, are the NATO cross-hairs, a measured distance and readiness for action. In a corresponding manner, data concerning the prevailing runout height and the firing direction of the platform, or the like, may also be blended in.
According to a further advantageous embodiment of the invention, the azimuthal movement may be effected by sectors, and the sector angle adapted to the angular coverage of the camera so that the sectors are always overlapping. During the change of sectors, the monitor being scanned is dark in keeping with a further characteristic of the invention, with the dark phase being chosen to be shorter than the ability of the human eye to react.
The platform 20 carrying the observation and target system is preferably in the form of a weapons platform, in particular for elevatably supported launchers. The platform is capable of following the targeting means in elevation.
Because the structural volume of the weapons platform is small in comparison with that of manned combat or observation platforms, this configuration is advantageous since in the retracted position a correspondingly smaller storage space is required for the housing of the weapons platform. Furthermore, it is advantageous that the system according to the invention is immediately ready for operation and may be used in any position between the retracted and fully extended state, both during the day and at night.
As the result of the sequence controls 7 provided according to the invention, the overall system is particularly user friendly and thus also safe in operation. This becomes apparent from the description of the process of attaching a target. For example: the gunner, observing the environment through the binocular viewing device 11 on the monitor 6, controls the primarily stabilized mirror head of the panorama camera 1 in azimuth and elevation by means of a gunner instrument 7. When the gunner discovers a target on his monitor 6, he is able to lock the weapons platform onto the target. In the process, the line-of-vision coordinates are transferred, whereupon the platform 20 may run in onto the line of vision of the panorama camera. The platform 20 follows the panoramic camera in the azimuth, while the launchers 9 provided on the platform follow in elevation. Once the gunner has identified the target, he may initiate the surveying of the target and the transfer of the target data to the fire control computer by actuating a target designation key. Once the platform and the launchers are run in on the target and the target is within the range of the launchers, the fire control computer clears the weapons for firing and the gunner is able to fire.
The use in the present invention of a high resolution panorama camera is of essential importance. The characteristics of such a camera given below represent a nonlimiting example used essentially to define the type of camera:
Number of lines: 1249
Objective lens: f=50 . . . 250 mm
Field of vision: 156 m at 4000 m, f=250 m
Angle of vision: 2.3°-11.5°
Directional range: azimuth n×360°
Directional range: elevation+20°, -10°.
The panoramic camera preferably is of a modular construction. In a first module the camera housing is combined with the pick-up tube and the video electronics; in a second module the objective housing with the objective lens and zoom adjusting mechanism; in a third module the stabilized, orientable mirror head with the angle indicators to transfer the location coordinates to the fire control computer; and a fourth module the stabilizing electronics and the signal processing unit.
The imaging capacity and the resolution of a camera used according to the invention make it possible with an objective lens having a focus of f=250 mm, to resolve objects with a dimension of 120 mm (120 mm=1 line) at a distance of 4000 m. As the identification of an object in the shape of an armored vehicle requires eight pairs of lines, objects larger than 1920 mm may be identified with a camera system described above as an example.
It is possible, however, to increase the imaging capacity in the target field by enlarging the zoom range to greater focal widths.
In summary, the most important advantages of the system according to the invention may be described as a significant simplification of the entire weapons system because the observer, who is located in the chassis and fully protected by armor, is able to observe and analyze near and target areas with a quality equivalent to direct observation and under unfavorable conditions, obtain even higher quality than direct observation by means of the binocular viewing device; that a high reaction velocity may be obtained by sector observation and distance dependent angle of vision settings, which may be further enhanced by the blending of data into the field of vision of the observer; and that the observer may be aided in the detection and tracking of targets by electronic image processing, which again has a positive effect on the reaction velocity.
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An elevatable observation and target for combat vehicles increases safety and the reaction velocity by a stabilized vision line camera, that is remotely controlled from the combat compartment with an adjustable focal width prepared on an elevatable platform, with the camera comprising angle indicators for the generation of the prevailing sight line coordinates and the platform being capable of following the sight line of the panoramic camera as a function of the angle indicator signals.
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REFERENCE TO RELATED APPLICATIONS
This is a U.S. national stage of application No. PCT/EP2013/053247 filed 19 Feb. 2013. Priority is claimed on German Application No. 10 2012 202 893.5 filed 27 Feb. 2012, the content of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to laser spectrometers and, more particularly, to a laser spectrometer and method for measuring the concentration of a gas component in a measurement gas.
2. Description of the Related Art
Laser spectrometers are particularly used for optical gas analysis in process measurement technology. Here, a laser diode generates light in the infrared range, which is guided through the process gas to be measured (the measurement gas) and is subsequently detected. The wavelength of the light is tuned to a specific absorption line of the gas component respectively to be measured, the laser diode periodically sampling the absorption line. To this end, the laser diode is driven periodically with a ramp-shaped or triangular (increasing and decreasing ramp) current signal. The concentration of the gas component of interest can be determined from the absorption detected at the position of the absorption line.
The intensity and wavelength of the light generated are nonlinear functions of the injection current and of the operating temperature of the laser diode. As a result, wavelength referencing is necessary in many cases. To this end, a reference gas is additionally introduced in a known concentration into the light path, and an absorption line of the reference gas is measured. The temperature of the laser diode can then be regulated via the position of the absorption line of the reference gas, such that the absorption line of the gas compared to be measured always lies at a particular position of the ramp of the current signal. In this case, the current ramp must be large enough for the laser diode sampling range resulting therefrom to cover both the absorption line of the gas component to be measured and that of the reference gas.
When shining through the measurement gas and reference gas, besides the wavelength-dependent absorption by infrared-active gas components, wavelength-independent absorption also takes place by optical components (e.g., windows) or aerosols (e.g., smoke particles). This makes normalization of the measurement necessary. To this end, the laser diode can be driven regularly with at least one burst current signal, the amplitude of which lies outside the value range of the ramp-shaped or triangular current signal, so that the light wavelengths generated with the burst current signal lie outside the wavelength ranges of the absorption lines of the gas components to be measured and other infrared-active gas components. This makes it possible to normalize the light intensity detected at the position of the absorption line to be measured, by division by the light intensity detected at the position of the burst current signal (EP 2 072 979 A1).
As explained above, in contemporary laser spectrometers a wavelength range that covers both the absorption lines of the gas components to be measured and the absorption lines for the wavelength referencing is sampled. In addition, a time window is required for the normalization of the measurement. Each sampling period therefore claims much more time than is necessary for the detection of a single absorption line. The time resolution of the measurement, in the case of rapidly varying gas concentrations, is thereby limited.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to increase the measurement speed in the laser-spectrometric determination of the concentration of a gas component in a measurement gas.
This and other objects and advantages are achieved by the method and the laser spectrometer in accordance with the invention by providing a method for measuring the concentration of a gas component in a measurement gas, by detecting the intensity of the light of a wavelength-tunable laser diode after shining through the measurement gas and a reference gas and determining the concentration of the gas component with the aid of the reduction in the light intensity due to the absorption of the light at the position of a selected absorption line of the gas component, the position of the absorption line of the gas component being referenced with the aid of a selected absorption line of the reference gas. In accordance with the method of the invention, the laser diode is driven periodically with a first increasing and/or decreasing current signal to sample the absorption line of the gas component wavelength-dependently in a sampling range which lies outside the absorption line of the reference gas and which is restricted to the immediate vicinity of the absorption line of the gas component. Next, the laser diode is driven regularly with a second increasing and/or decreasing current signal to sample the absorption line of the reference gas wavelength-dependently in a sampling range which either contains the two absorption lines of the gas component and of the reference gas or lies outside the absorption line of the gas component and is restricted to the immediate vicinity of the absorption line of the reference gas. The laser diode is then driven regularly with at least one burst current signal having an amplitude lying outside the value ranges of the first and second current signals to normalize the light intensity detected at the position of the absorption line with the intensity detected at the position of the at least one burst current signal. Finally the first current signal, the second current signal and the burst current signal are generated successively such that individual or a few, generated directly after one another, second current signals and burst current signals alternate with a multiplicity of first current signals generated directly after one another.
It is also an object of the invention to provide a laser spectrometer for measuring the concentration of a gas component in a measurement gas, where the laser spectrometer includes a wavelength-tunable laser diode, the light of which, after shining through the measurement gas and a reference gas, strikes a detector having a downstream evaluation device in which the concentration of the gas component is determined with the aid of the reduction in the light intensity due to the absorption of the light at the position of a selected absorption line of the gas component, the position of the absorption line of the gas component being referenced with the aid of an absorption line of the reference gas.
The spectrometer also includes a first signal generator for periodic driving of the laser diode with a first increasing and/or decreasing current signal to sample the absorption line of the gas component wavelength-dependently in a sampling range that lies outside the absorption line of the reference gas and which is restricted to the immediate vicinity of the absorption line of the gas component, a second signal generator for regular driving of the laser diode with a second increasing and/or decreasing current signal to sample the absorption line of the reference gas wavelength-dependently in a sampling range which either contains the two absorption lines of the gas component and of the reference gas or lies outside the absorption line of the gas component and is restricted to the immediate vicinity of the absorption line of the reference gas, at least one third signal generator for regular driving of the laser diode with at least one burst current signal having an amplitude lying outside the value ranges of the first and second current signals to normalize the light intensity detected at the position of the absorption line with the intensity detected at the position of the at least one burst current signal, and a time generator which controls the signal generators such that the first current signal, the second current signal and the burst current signal are generated successively, with individual or a few, generated directly after one another, second current signals and burst current signals alternating with a multiplicity of first current signals generated directly after one another.
With the method in accordance with the invention, or in the laser spectrometer in accordance with the invention, mixed operation occurs, consisting of the actual measurement (periodic microscan) of rapid concentration changes of the gas component to be measured and a short reference/normalization phase for the wavelength referencing, the line locking and the normalization. The duration of the continuous measurement must be dimensioned such that the measurement conditions remain constant and do not deviate from those during the reference/normalization phase. This applies above all to the transmission conditions, as well as the temperature and pressure.
Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims. It should be further understood that the drawings are not necessarily drawn to scale and that, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained below with reference to the figures of the drawing with the aid of exemplary embodiments, in which:
FIG. 1 shows a schematic representation of an exemplary spectrometer in accordance with the invention having a laser diode;
FIGS. 2 to 6 show various examples of driving the laser diode; and
FIG. 7 is a flowchart of the method in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a laser spectrometer for measuring the concentration of at least one gas component of interest of a measurement gas 1 , which is contained in a measurement volume 2 , such as a measurement cuvette or a process gas line. The spectrometer contains a laser diode 3 , the light 4 of which strikes, through the measurement gas 1 and a downstream reference gas cuvette 6 filled with a reference gas 5 , a detector 7 with a downstream evaluation device 8 for delivering the measurement result 9 . The laser diode 3 is driven by a controllable current source 10 with an injection current i, the intensity I and the wavelength λ of the light 4 generated depending on the current i and the operating temperature of the laser diode 3 . The injection current i is generated in the form of different current signals. To this end, the current source 10 is driven via an adder 11 by different signal generators 12 , 13 , 14 , 15 , 16 , of which a first signal generator 12 generates a first ramp-shaped or triangular signal 17 , a second signal generator 13 generates a second ramp-shaped or triangular signal 18 , a third signal generator 14 generates a first burst signal 19 , a fourth signal generator 15 generates a second burst signal 20 , and a fifth signal generator 16 generates a sine signal 21 . A digital/analog converter 22 generates a bias signal 23 , with the aid of which the current source 10 generates a bias current for the laser diode 3 . The signal generators 12 , 13 , 14 , 15 , 16 are controlled by a time generator 24 in accordance with a table 25 , in which it is established which of the signal generators 12 , 13 , 14 , 15 , 16 generates the relevant signal 17 , 18 , 19 , 20 or 21 when and how often directly in succession, i.e. with which number of periods. The generation of the ramp-shaped or triangular signals 17 , 18 and the burst signals 19 , 20 is carried out alternately, i.e., not simultaneously, while the sine signal 21 can only be generated together with the respective ramp-shaped or triangular signals 17 , 18 . The table 25 is programmable and, as shown, may be implemented in the time generator 24 or, for example, in a superordinate control device 26 of the laser spectrometer.
The driving of the laser diode may be performed in different ways in the scope of the invention. For example, the adder 11 may be replaced with a switching device (multiplexer), controlled by the time generator 24 , which converts the signals 17 , 18 , 19 , 20 into a signal sequence in accordance with the table 25 , and thereby drives the current source 10 . The signals 17 , 18 may also have other increasing and/or decreasing signal profiles, such as a sine profile.
FIG. 2 shows a first example of the driving of the laser diode with the injection current i. In its time profile, the injection current i consists of different current signals 17 ′, 18 ′, 19 ′, 20 ′, 21 ′, which result from the driving of the current source 10 with the signals 17 , 18 , 19 , 20 , 21 . The wavelength λ of the light 4 generated follows the profile of the current i more or less linearly. The absorption line of the gas component to be measured lies at the position i abs , or λ abs , and that of the reference gas at the position i ref , or λ ref .
With the first ramp-shaped or triangular current signal 17 ′, the absorption line of the gas component is sampled in a sampling range that lies outside the absorption line of the reference gas 5 and is restricted to the immediate vicinity of the absorption line of the gas component. The sampling is performed over a prolonged time, such as one minute, with a multiplicity of sampling periods following one another directly. Owing to the relatively low amplitude of the current signal 17 ′, the period duration is correspondingly short, so that the measurement of the absorption line of the gas component can even follow rapid concentration changes of the gas component to be measured.
The sampling of the absorption line of the gas component is interrupted regularly, here for example at minute intervals, by a measurement of the absorption line of the reference gas 5 . To this end, the laser diode 3 is driven with the second ramp-shaped or triangular current signal 18 ′, the amplitude of which, in the example shown in FIG. 2 , is large enough for the resulting sampling range to contain the two absorption lines of the gas component and the reference gas 5 . This second current signal 18 ′ is generated only for a short duration in the second range or less, for a single period or very few periods.
Before and/or after the second current signal 18 ′, the burst signals 19 ′ and 20 ′, respectively, used for the normalization of the measurement are generated.
In order to increase the measurement accuracy, the ramp-shaped or triangular current signals 17 ′ and 18 ′ may be modulated in a known way with the sine current signal 21 ′ with the frequency f. Owing to the nonlinearity of the absorption lines, the modulation of the injection current i with the frequency f results in a corresponding variation of the detected light intensity I with more less pronounced harmonic distortions. At the extreme position (absorption maximum) in the middle of the absorption line, the first harmonic with the frequency 2 f dominates, while the proportion of the first harmonic in the intensity I decreases greatly in wavelength ranges outside the absorption maximum. The absorption occurring at the position of the absorption maximum can therefore be determined very accurately and free from interference in the evaluation device 8 by evaluating the 2 f signal component.
FIGS. 3 to 6 show other exemplary embodiments of the driving of the laser diode 3 , in which the second current signal 18 ′ and/or the burst current signals 19 ′, 20 ′, or only one burst current signal, are generated in a different sequence. The second current signal 18 ′ may also be generated in the shape of a ramp ( FIGS. 4 and 6 ) instead of triangularly and/or with a small amplitude, restricting the sampling to the immediate vicinity of the absorption line of the reference gas 5 ( FIG. 3 ), in order to keep the interruption of the rapid periodic sampling of the absorption line of the gas component of interest as short as possible. A ramp-shaped signal form is naturally also possible for the first current signal 17 ′.
FIG. 7 is a flowchart of a method for measuring a concentration of a gas component in a measurement gas ( 1 ), by detecting an intensity (I) of light ( 4 ) of a wavelength-tunable laser diode ( 3 ) after shining the light through the measurement gas ( 1 ) and a reference gas ( 5 ), and by determining the concentration of the gas component aided by a reduction in the intensity (I) of the light due to absorption of the light ( 4 ) at a position (iabs, λabs) of a selected absorption line of the gas component, the position (iabs, λabs) of the absorption line of the gas component being referenced with aided by a selected absorption line of the reference gas ( 5 ). The method comprises driving the laser diode ( 3 ) periodically with at least one of (i) a first increasing current signal ( 17 ′) and (ii) a first decreasing current signal ( 17 ′) to sample the absorption line of the gas component wavelength-dependently in a sampling range which reside outside the absorption line of the reference gas ( 5 ) and which is restricted to an immediate vicinity of the absorption line of the gas component, as indicated in step 710 .
The laser diode ( 3 ) is then driven regularly with at least one of a second increasing current signal ( 18 ′) and (ii) a second decreasing current signal ( 18 ′) to sample an absorption line of the reference gas ( 5 ) wavelength-dependently in a sampling range which one of (i) contains two absorption lines of the gas component and the reference gas ( 5 ) and (ii) lies outside the absorption line of the gas component and which is restricted to the immediate vicinity of the absorption line of the reference gas ( 5 ), as indicated in step 720 .
Next, the laser diode ( 3 ) is driven regularly with at least one burst current signal ( 19 ′, 20 ′) having an amplitude lying outside the value ranges of the first and second current signals ( 17 ′, 18 ′) to normalize the light intensity (I) detected at the position (iabs, λabs) of the absorption line with the intensity (I) detected at the position of the at least one burst current signal ( 19 ′, 20 ′), as indicated in step 730 .
The first current signal ( 17 ′), the second current signal ( 18 ′) and the at least one burst current signal ( 19 ′, 20 ′) are generated successively such that individual or a few, generated directly after one another, second current signals ( 18 ′) and the at least one burst current signal ( 19 ′, 20 ′) alternate with a multiplicity of first current signals ( 17 ′) generated directly after one another as indicated in step 740 .
The method according to the invention is suitable for spectrometers in all bands (UV, VIS, IR).
While there have been shown, described, and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the methods described and the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.
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A laser spectrometer and method for measuring gas component concentration in a measurement gas, wherein light intensity from a wavelength-tunable laser diode is detected after irradiation of the measurement gas and a reference gas, and the concentration of the gas component is determined based on reduction of the light intensity by the absorption of light at the position of a selected absorption line of the gas component, and the position of the absorption line of the gas component is referenced based on a selected absorption line of the reference gas, and wherein there is a mixed operation consisting of actual measurements of fast concentration changes of the gas component to be measured and a short reference/standardization phase for wavelength referencing, line locking and standardization, where the duration of the actual measurement is measured such that measuring conditions remain constant and do not deviate from those during the reference/standardization phase.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application entitled “Remotely Locating and Commanding a Mobile Device,” U.S. patent application Ser. No. 12/434,586, filed May 1, 2009, the disclosure of which is herein incorporated by reference in its entirety. This application also is related to co-pending U.S. patent application entitled “Securely Locating a Device,” U.S. patent application Ser. No. 11/938,745, filed Nov. 12, 2007 and to co-pending U.S. patent application entitled “Remotely Locating and Commanding a Mobile Device,” U.S. patent application Ser. No. 12/434,582, filed May 1, 2009.
TECHNICAL FIELD
[0002] The present disclosure relates to remotely communicating with a mobile device, such as a mobile telephone or a media player, and to causing the mobile device to perform a function through the transmission of one or more remote commands.
BACKGROUND
[0003] Mobile devices have been adapted to a wide variety of applications, including computing, communication, and entertainment. For example, mobile telephones permit users to freely initiate and receive voice communications. Similarly, mobile media devices have been developed to permit users to take electronic entertainment, including audio, video, and electronic games, to even the most remote location. Further, mobile computing devices have been developed to provide users with remote access to data communications through wireless connectivity, such as over IEEE 802.11 or 3G networks. Some mobile devices, such as smart phones, support a combination of voice communications, entertainment, and mobile computing.
[0004] Because mobile devices are sized for portability, they easily can be misplaced. Also, because mobile devices often are carried to many different locations, they can be forgotten or lost. Further, because of their convenience and portability, mobile devices often are used to store a large amount of personal data. For example, a mobile device can be used to store an entire address book of contact information, electronic mail and text messages relating to business and personal matters, account information, one or more galleries of images, and a library of music. Thus, the loss of a mobile device also can incur the loss of a substantial amount of data, including sensitive personal data.
[0005] Ownership of a mobile device can be indicated in a number of ways. For example, owners can mark a mobile device with identifying information, such as a name, address, or telephone number. The mobile device can be marked physically, such as through a label or an engraving, or electronically, such as through registration information stored on the mobile device. Further, with respect to mobile telephones, an attempt can be made to recover a lost device. For example, a user can call a lost mobile telephone to speak with a finder who is willing to answer. If the finder is honest, the mobile telephone can be returned to the rightful owner. However, mobile devices and the services they provide access to often are valuable and a mobile device thus may not be returned if lost or may be intentionally stolen.
[0006] To prevent the data stored on a lost mobile device from being compromised, the data can be protected against unauthorized access in a variety of ways. For example, access to the data and/or applications can be protected through login credentials, such as a system password. The mobile device can block any access or functionality until the correct login information is supplied. Further, file encryption can be linked to a security password, such that files remain encrypted until the correct login information is supplied. A mobile device also can be locked after multiple unsuccessful attempts at access to prevent hacking. For example, a mobile device can be configured such that repeated password failures lock the mobile device to prevent any further use. Alternatively, a service provider can be contacted to disable further use of the mobile device, such as by deactivating a corresponding account.
SUMMARY
[0007] A mobile device can be remotely contacted and commanded to perform one or more operations, such as through the transmission of a message to the device. Further, before the mobile device is lost, it can be configured to support one or more remote commands. The remote commands supported can be selectively enabled by the mobile device owner. A mobile device also can support one or more remote commands by default.
[0008] The transmission of one or more remote commands to the mobile device can be initiated from a networked computing device, such as through a web service. The mobile device also can confirm receipt of one or more remote commands and can acknowledge that an associated operation or instruction has been or will be executed. For example, messages can be transmitted to and from the mobile device through a notification service implemented using a publish-subscribe (“PubSub”) framework.
[0009] The present inventors recognized a need to allow a mobile device owner to remotely issue one or more commands to the mobile device, including commands used to present a message or sound on the mobile device, to lock the mobile device, to wipe the contents of the mobile device, or to locate the mobile device. Further, the need to receive one or more messages from the mobile device acknowledging and/or responding to a remote command also was recognized. The present inventors also recognized the need to provide a web-based application configured to facilitate remote management of one or more mobile devices.
[0010] Additionally, the present inventors recognized the need to permit an existing passcode associated with a mobile device to be changed or a new passcode to be set. The present inventors further recognized the need to provide an acknowledgement indicating that a mobile device has been locked in accordance with a newly specified passcode. It also was recognized that an error message can be presented indicating that the passcode for a mobile device was not changed, such as in response to one or more predetermined conditions.
[0011] The present inventors also recognized the need to allow reconfiguring a mobile device to alter or disable support for one or more remote commands. Further, the need for the mobile device to automatically retrieve command messages also was recognized. Also, the present inventors recognized the need to permit transmitting multiple remote commands to a mobile device, such as a locate command and a message command. Additionally, the present inventors recognized the need to permit disassociating a mobile device from a remote management account, such as when ownership of the mobile device changes. Accordingly, the techniques and apparatus described here implement algorithms for remotely communicating with a mobile device to cause the mobile device to perform functions through the transmission of one or more remote commands.
[0012] In general, in one aspect, the techniques can be implemented to include receiving, by a mobile device, a remote lock command message comprising a lock command and specifying a passcode to be set, locking the mobile device in response to the received remote lock command message, setting an unlock passcode associated with the mobile device to the specified passcode, and generating an acknowledgement message in response to the remote lock command message.
[0013] The techniques also can be implemented such that receiving further includes accessing a subscribed topic hosted on a notification service, the subscribed topic being associated with a lock command, and retrieving the remote lock command message from the subscribed topic. Further, the techniques can be implemented such that the subscribed topic is uniquely associated with the mobile device. Additionally, the techniques can be implemented to further include determining, prior to setting the unlock passcode, that the specified passcode complies with an implemented security constraint of the mobile device.
[0014] The techniques also can be implemented to further include publishing the acknowledgement message to a notification service in substantially real time. Further, the techniques can be implemented such that generating an acknowledgement message further involves including a time stamp indicating a time at which the remote lock command message was received. Also, the techniques can be implemented such that locking the mobile device further includes locking a display associated with the mobile device such that access to one or more of information stored on the mobile device and functionality of the mobile device is blocked. Additionally, the techniques can be implemented such that setting an unlock passcode further includes initializing an unlock passcode associated with the mobile device.
[0015] In general, in another aspect, the techniques can be implemented as a computer-readable medium, tangibly encoding a computer program product comprising instructions operable to cause data processing apparatus to perform operations including accessing a subscribed topic hosted on a notification service, the subscribed topic corresponding to a mobile device, retrieving a remote lock command message included in the subscribed topic, locking the mobile device in response to the remote lock command message, and publishing an acknowledgement message to the notification service.
[0016] The techniques also can be implemented to be further operable to cause data processing apparatus to perform operations including identifying a passcode specified by the remote lock command message, detecting that the specified passcode does not comply with a security constraint implemented by the mobile device, and determining, in response to the detecting, not to reset an unlock passcode associated with the mobile device. Additionally the techniques can be implemented to be further operable to cause data processing apparatus to perform operations involving including a passcode error message in the acknowledgement message. Further, the techniques can be implemented to be further operable to include locking the mobile device by locking a display such that access to one or more of information stored on the mobile device and functionality of the mobile device is blocked. Additionally, the techniques can be implemented to be further operable to cause data processing apparatus to perform operations including establishing a connection to the notification service over a wireless data connection.
[0017] The techniques also can be implemented to be further operable to cause data processing apparatus to perform operations involving including a time stamp in the acknowledgement message indicating a time at which the remote lock command message was executed and including an indication that the mobile device was locked in the acknowledgement message. Further, the techniques can be implemented such that the subscribed topic is included in a command collection associated with the notification service that uniquely corresponds to the mobile device. Additionally, the techniques can be implemented to be further operable to cause data processing apparatus to perform operations including resetting an unlock password associated with the mobile device based on the specified passcode.
[0018] In general, in another aspect, the subject matter can be implemented as a system including a server hosting a notification service including a plurality of topics and a mobile device including processor electronics configured to perform operations including accessing a subscribed topic hosted on the notification service, the subscribed topic corresponding to the mobile device, opening a remote lock command message included in the subscribed topic, the remote lock command message comprising a lock command and a specified passcode, locking the mobile device in response to the remote lock command message, setting an unlock passcode associated with the mobile device to the specified passcode, and publishing an acknowledgement message to the notification service.
[0019] The system also can be implemented such that the processor electronics are further configured to perform operations involving including in the acknowledgement message an indication confirming that the unlock passcode has been set to the specified passcode and a time stamp identifying a time at which the remote lock command message was received.
[0020] The techniques described in this specification can be implemented to realize one or more of the following advantages. For example, the techniques can be implemented such that the location of a lost mobile device can be remotely requested and acquired. The techniques also can be implemented to permit transmitting one or more remote commands to a mobile device using a store and forward message framework. The remote commands can include a message command, a locate command, a sound command, a lock command, and a wipe command. Further, a PubSub model can be employed to facilitate communications between a command application and a mobile device, such that the mobile device can access a subscribed node when data communications are available. Additionally, the techniques can be implemented to permit transmitting information and/or acknowledgement messages from the mobile device in response to a remote command. The techniques also can be implemented such that a communication node monitored by a mobile device can be automatically created when the associated mobile device account is created. The techniques further can be implemented to permit delivering a remote command to a mobile device and receiving a response from the mobile device in near real-time.
[0021] The techniques also can be implemented to permit specifying a new passcode in conjunction with a remote lock command. Further, the techniques can be implemented such that the passcode is not changed by a lock command if a more complex passcode constraint has been specified on the device. The techniques also can be implemented such that one or more other remote commands can be executed after a remote lock command. Additionally, the techniques can be implemented such that the device always enters a locked state in response to receiving a remote lock command.
[0022] The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows an exemplary computing environment that includes mobile devices and a notification server.
[0024] FIG. 2 shows a flow diagram describing an exemplary process for linking a mobile device with a remote management account.
[0025] FIG. 3 shows a flow diagram describing an exemplary process for remotely commanding a mobile device.
[0026] FIG. 4 shows a flow diagram describing an exemplary process for receiving a remote command by a mobile device.
[0027] FIGS. 5-9 show flow diagrams describing exemplary processes for executing remote commands by a mobile device.
[0028] FIGS. 10-11 show exemplary user interfaces depicting the location reported by a mobile device in response to a locate command.
[0029] FIG. 12 shows a mobile device displaying an exemplary message in response to a message command.
[0030] FIGS. 13A and B show exemplary mobile device interfaces presented in response to an executed remote lock command.
[0031] FIG. 14 shows a flow diagram describing an exemplary process for processing a remote command message by a mobile device.
[0032] Like reference symbols indicate like elements throughout the specification and drawings.
DETAILED DESCRIPTION
[0033] FIG. 1 shows an exemplary computing environment that includes mobile devices and a notification server. A communication network 105 connects the devices and applications hosted in the computing environment 100 . The communication network 105 can be any type of network, including a local area network (“LAN”), such as an intranet, and a wide area network (“WAN”), such as the internet. Further, the communication network 105 can be a public network, a private network, or a combination thereof. The communication network 105 also can be implemented using any type or types of physical media, including wired communication paths and wireless communication paths associated with multiple service providers. Additionally, the communication network 105 can be configured to support the transmission of messages formatted using a variety of protocols.
[0034] A user station 110 can be configured to operate in the computing environment 100 . The user station 110 can be any computing device that can be configured to communicate with a web-enabled application, such as through a web browser. For example, the user station 110 can be a personal computing device, such as a desktop or workstation, or a portable computing device, such as a laptop or smart phone. The user station 110 can include an input interface through which one or more inputs can be received. For example, the input interface can include one or more of a keyboard, a mouse, a joystick, a trackball, a touch pad, a touch screen, and a microphone. The user station 110 also can include an output interface through which output can be presented, including one or more of a display, one or more speakers, and a haptic interface.
[0035] The user station 110 further can include a network connection to the communication network 105 . The network connection can be implemented through a wired or wireless interface, and can support bi-directional communication between the user station 110 and one or more other computing devices over the communication network 105 . Also, the user station 110 includes an interface application, such as a web browser or custom application, for communicating with a web-enabled application.
[0036] An application server 115 also can be configured to operate in the computing environment 100 . The application server 115 can be any computing device that can be configured to host one or more applications. For example, the application server 115 can be a server, a workstation, or a personal computer. In some implementations, the application server 115 can be configured as a collection of computing devices, e.g. servers, sited in one or more locations. The application server 115 can include an input interface through which one or more inputs can be received. For example, the input interface can include one or more of a keyboard, a mouse, a joystick, a trackball, a touch pad, a touch screen, and a microphone. The application server 115 also can include an output interface through which output can be presented, including one or more of a display, a haptic interface, and one or more speakers.
[0037] The application server 115 further can include a network connection to the communication network 105 . The network connection can be implemented through a wired or wireless interface, and can support bi-directional communication between the application server 115 and one or more other computing devices over the communication network 105 . Further, the application server 115 can be configured to host one or more applications. For example, the application server 115 can be configured to host a remote management application that facilitates communication with one or more mobile devices associated with an account. The mobile devices and the application server 115 can operate within a remote management framework to execute remote management functions. The application server 115 also can be configured to host a notification service application configured to support bi-directional communication over the communication network 105 between multiple communication devices included in the computing system 100 . For example, the notification service application can permit a variety of messages to be transmitted and received by multiple computing devices.
[0038] In some implementations, the notification service can include a defined namespace, in which a unique command collection topic can be created for each subscribing mobile device. A unique identifier can be used to associate a subscribing mobile device with the corresponding command collection topic, such as an assigned number or address. The unique identifier also can be embedded in a Uniform Resource Identifier (URI) that is associated with a subscribed command collection topic. Further, one or more command nodes can be created below a command collection topic, such that each command node corresponds to a particular remote command type. For example, a command collection topic can include a separate command node for each of: locate commands, message commands, sound commands, directory listing commands, file retrieval commands, lock commands, and wipe commands.
[0039] Through the use of separate command nodes, multiple commands can be transmitted to a mobile device substantially simultaneously. In some implementations, if multiple commands are received in a command collection topic, server time stamps can be compared to determine an order of execution. In some other implementations, an order of command execution can be determined based on command type. For example, if a wipe command is received in conjunction with one or more other remote commands, the wipe command can be performed last.
[0040] Through the notification service, a publisher, such as a remote management application, can publish a remote command message to a command collection topic that is associated with a particular mobile device. When a remote command message is published to the command collection topic, a notification message can be transmitted to the subscribing mobile device. The mobile device can then access the subscribed topic and retrieve one or more published messages. Thus, communication between the publisher and the mobile device can be decoupled. Further, the remote command message can be published to the appropriate command node of the command collection topic. Additionally, a mobile device receiving a remote command message can publish a response to a result topic hosted by the notification service. A publisher, such as a remote management application, can subscribe to the result topic and can receive any published response messages.
[0041] Further, the computing environment 100 can include one or more mobile devices, such as a mobile telephone 120 , a digital media player 125 , and a laptop computer 130 . Each of the mobile devices included in the computing environment 100 can include a network interface configured to establish a connection to the communication network 105 . For example, the mobile telephone 120 can establish a cellular (e.g., 3G or 4G) network connection that provides data access to the communication network 105 . Further, the digital media player 125 can establish an IEEE 802.11 (i.e., Wi-Fi or WLAN) network connection to the communication network 105 . Also, the laptop computer 130 can be configured to establish a connection to the communication network 105 based on either or both of the IEEE 802.16 (i.e., wireless broadband or WiBB) and the IEEE 802.11 standards.
[0042] Each of the mobile devices 120 , 125 , and 130 also can be configured to communicate with the notification service application hosted by the application server 115 to publish and receive messages. Further, each of the mobile devices 120 , 125 , and 130 can be configured to execute a remote management application or a remote management function responsive to a remote command received through the notification service application. In some implementations, the remote management application can be integrated with the operating system of the mobile device.
[0043] A mobile device can execute a remote command to perform one or more associated functions. For example, the remote commands can include locate commands, message commands, sound commands, directory listing commands, file retrieval commands, lock commands, and wipe commands. Some remote commands can be used to output a notification from a mobile device. For example, a sound command can cause a mobile device to output an auditory alert. Further, a message command can be used to present a text-based message on the display of a mobile device. Some other remote commands can be used to perform file-based functions. For example, a wipe command can be used to delete one or more items of data stored on the mobile device. A directory listing command can cause a mobile device to return data identifying all, or a portion of, the file directory structure associated with the storage of the mobile device. Additionally, a file retrieval command can be used to retrieve a copy of one or more files from a mobile device. Still other remote commands can be used to monitor a mobile device. For example, a locate command can cause a mobile device to transmit a message indicating its location at the time the locate command is executed. Further, a usage command can cause a mobile device to transmit a message identifying usage data for a period of time, such as calls placed or received. The period of time can be predetermined or can be specified in the usage command. Additionally, a lock command can be used to remotely secure a mobile device, such as to prevent access to functions and/or stored information by an unauthorized individual.
[0044] Additionally, each of the mobile devices 120 , 125 , and 130 can include an input interface through which one or more inputs can be received. For example, the input interface can include one or more of a keyboard, a mouse, a joystick, a trackball, a touch pad, a keypad, a touch screen, a scroll wheel, general and special purpose buttons, a stylus, and a microphone. Each of the mobile devices 120 , 125 , and 130 also can include an output interface through which output can be presented, including one or more of a display, one or more speakers, and a haptic interface. Further, a location interface, such as a Global Positioning System (GPS) processor, also can be included in one or more of the mobile devices 120 , 125 , and 130 to provide location information, e.g., an indication of current location. In some implementations, general or special purpose processors included in one or more of the mobile devices 120 , 125 , and 130 can be configured to perform location estimation, such as through base station triangulation.
[0045] FIG. 2 shows a flow diagram describing an exemplary process for linking a mobile device with a remote management account. A mobile device can be linked with any remote management account to which the mobile device owner has access. In some implementations, a mobile device can be linked with only one remote management account at a time. Thus, in order to establish a link between a mobile device and a remote management account, any previous link with a different remote management account must be broken. Alternatively, the act of linking a mobile device with a remote management account can cause any previous link with a different remote management account to be broken. In some implementations, a link between a mobile device and a corresponding remote management account also can be broken without establishing a link with a new remote management account. For example, if a mobile device is being sold or otherwise transferred to a new owner, the link between the mobile device and the existing remote management account can be broken. The mobile device subsequently can be linked to a remote management account associated with the new owner. However, a mobile device cannot be remotely managed when it is not linked with a remote management account.
[0046] In order to establish a link with a remote management account, a remote management application can be initialized on the mobile device ( 205 ). A remote management application can be included on the mobile device as part of the operating system or as a preinstalled application. Alternatively, the remote management application can be downloaded and installed by a user. Once initialized, the remote management application can cause the mobile device to establish a connection to a corresponding remote management server.
[0047] Access information can be provided to the remote management server to identify the remote management account to which the mobile device is to be linked ( 210 ). For example, a username and password corresponding to a remote management account can be entered, such as in response to a prompt by the server. The username and password can uniquely identify a remote management account hosted by the remote management server. Any unique identifier can be used to indicate a specific remote management account hosted by the remote management server.
[0048] Information uniquely identifying the mobile device further can be obtained by the remote management server ( 215 ). In some implementations, a serial number, a telephone number, a Subscriber Identity Module (SIM) card, a Media Access Control (MAC) address, an International Mobile Equipment Identity (IMEI), or other such identifier can be used to identify the mobile device. In some other implementations, the information identifying the mobile device can be a unique device identifier (UDID), which can be a hash, e.g. generated using a Secure Hash Algorithm, of hardware identifiers associated with the mobile device. Further, the unique identifier can be obtained from the mobile device automatically. Thus, data entry errors can be avoided. Once identified, the mobile device can be associated with the remote management account ( 220 ).
[0049] Further, the mobile device can subscribe to a command collection topic ( 225 ). The command collection topic can be specific to the mobile device, such that only messages intended for the mobile device are published to the command collection topic. Also, access to the command channel topic can be granted only to the mobile device, which can authenticate with the notification service based on the previously determined unique identifier. In some implementations, the notification service can be hosted on the remote management server. In other implementations, the notification service can be hosted on one or more servers separate from the remote management server. When the mobile device subscribes to the command collection topic, one or more command nodes (or child nodes) can be created to receive messages published by the notification service. For example, the command collection topic can include a command node for each type of remote command message that the mobile device can receive, such as locate commands, sound commands, message commands, screen lock commands, directory listing commands, file retrieval commands, and wipe commands.
[0050] Additionally, it can be determined whether one or more remote management settings associated with the mobile device are to be changed ( 230 ). The remote management functions associated with the mobile device initially can be configured in accordance with default settings. For example, one or more of the remote management commands, such as the wipe and sound commands, can be enabled by default, while one or more other remote management commands, such as the locate command, can be disabled by default. A remote management command will not be executed by the mobile device unless it has been enabled. Accordingly, the mobile device owner's privacy can be protected in the default mobile device configuration because location information cannot be remotely obtained from the mobile device. Further, in some implementations, one or more of the remote management commands, e.g. the message command, can be permanently enabled, such that a mobile device owner cannot disable the command.
[0051] At the time the mobile device is associated with a remote management account, the mobile device owner can be prompted to review the remote command settings. If the mobile device owner elects not to change the remote command settings, the initialization process can be terminated. Alternatively, if the mobile device owner elects to change the remote command settings, the current remote command settings can be displayed so that the mobile device owner can alter one or more of the remote management settings ( 235 ). For example, the mobile device owner can provide input to enable the locate command so that the mobile device can be remotely located.
[0052] In some implementations, the remote command settings can be accessed at any time through an operating system menu item, such as preferences or contacts. Alternatively or additionally, the remote command settings can be accessed through the remote management application. Once the remote command settings have been set, the initialization process can be terminated.
[0053] FIG. 3 shows a flow diagram describing an exemplary process for remotely commanding a mobile device. A remote management application can be configured to remotely command one or more linked mobile devices by publishing remote command messages to a notification service. In some implementations, the remote management application can be a web-based application hosted on one or more servers.
[0054] A remote management account owner can login to a remote management account by accessing the remote management application and providing login credentials, such as a username and password ( 305 ). A remote management account can be established through a registration process at any time, even if no mobile devices are being linked with the account. In some implementations, the login process can be secured, such as by encrypting one or more items of login information or by establishing a secured connection. Further, in some implementations, additional or different login credentials can be required in order to access a remote management account.
[0055] Once access to a remote management account has been granted, a list of mobile devices linked with the remote management account can be presented ( 310 ). The list of mobile devices identifies each of the managed devices associated with the remote management account. Each mobile device can be uniquely identified through one or more items of information, including one or more of an icon identifying the device, a device type, a model, a serial number, a telephone number, and a nickname. Further, the list of mobile devices also can indicate, for each device, whether the device is currently reachable or online. If a mobile device associated with the account has been wiped, the mobile device can be displayed in the list of mobile devices with an indication that the device can no longer be managed. In some implementations, a mobile device also can be associated with a remote management account through the account interface, such as during account registration.
[0056] A mobile device can be selected from the list of managed devices ( 315 ). For example, the account owner can select a mobile device that has been misplaced. The mobile device can be selected by clicking on a corresponding icon or item of information included in the list of managed devices. One or more remote commands available for the selected mobile device also can be presented ( 320 ). In some implementations, all remote commands can be presented along with indicators identifying which remote commands have been enabled for the mobile device. In some other implementations, only the remote commands that have been enable are presented. Further, in some implementations, one or more remote commands also can be enabled at the account level, i.e. through the remote management account, for execution on a mobile device. For example, the mobile device and remote management application can be configured to permit one or more remote commands to be enabled through the remote management account if additional authentication information can be verified. Additionally, one or more remote commands, e.g. the locate command, can be enabled only at the device level, i.e. from the mobile device. Thus, the privacy of the mobile device owner can be safeguarded.
[0057] A remote command to be executed by the mobile device can be selected from the available remote commands ( 325 ). Based on the remote command selected, the remote management application can prompt the account owner for one or more items of information. For example, if the message command is selected, the remote management application can prompt the account owner to provide a message to be displayed on the mobile device. Alternatively, if the wipe command is selected, the remote management application can prompt the account owner to confirm that a wipe command is to be sent to the mobile device. Other remote commands can be initiated upon selection, without prompting the account owner for additional information. For example, the locate command can be initiated in response to its selection.
[0058] The remote management application can generate and transmit the selected remote command to the notification service. For example, the remote management application can have an Extensible Messaging and Presence Protocol (XMPP) connection to the notification service and can send a publish message to the corresponding command node of the command collection topic associated with the mobile device. The notification service can publish the remote command and send a notification message to the mobile device subscribing to the command collection topic.
[0059] After a remote command has been initiated, it can be determined whether another command is to be generated ( 330 ). Any number of commands can be sent to a mobile device. For example, a message command can be sent to present a message on the display of the mobile device and a sound command can be sent to provide an audible alert so that the mobile device may be noticed. However, after a wipe command has been executed, no additional commands can be sent to a mobile device until it has been reconfigured. If another command is to be generated, it further can be determined whether the command is intended for the same mobile device ( 335 ). If another command is to be generated for the same mobile device, the remote command can be selected from the available remote commands for that mobile device ( 325 ). Alternately, if the next command is intended for a different mobile device, the list of mobile devices associated with the remote management account can be presented ( 310 ).
[0060] If another command is not desired, any result messages associated with the remote management account can be accessed ( 340 ). A mobile device receiving a remote command can publish a result message indicating that the command is being executed and providing any information requested by the command. Further, the remote management account can specify a result topic with the remote command to which the mobile device is to publish the result message. If the mobile device is connected to a data network when the remote command message is published, the corresponding result message can be published by the mobile device to the result topic in real-time or near real-time. Alternatively, if the mobile device is powered off or not connected to a data network when the remote command message is published, a result message will not be published until after the mobile device establishes a connection to a data network and retrieves the remote command for execution.
[0061] FIG. 4 shows a flow diagram describing an exemplary processes for receiving a remote command by a mobile device. Some mobile devices, such as mobile telephones, can have a persistent wireless network connection, such as a (TCP) connection, whenever they are powered on and in a service area. Some other mobile devices, such as digital media players, can have a wireless network connection only when they are within range of an access point, such as a Wi-Fi base station, and the wireless network connection has been enabled. Further, push services for a mobile device can be turned off, e.g. to preserve battery life. Thus, a mobile device can be configured to establish a network connection at a predetermined interval, such as every thirty minutes, to receive remote management commands. Additionally, in the event a mobile device is configured to establish a network connection only in response to a manual command, the mobile device nonetheless can be configured to automatically establish a network connection in support of remote management. For example, a network connection can be established once an hour to check for remote command messages and then torn down. Thus, if the mobile device is lost and a network connection cannot be manually triggered, it is still possible for one or more remote management commands to be received by the mobile device.
[0062] A mobile device can access a notification service hosting a command collection topic to which the mobile device subscribes ( 405 ). For example, the mobile device can access a URI associated with the notification service and can perform an authentication process. Once authenticated, the mobile device can access a subscribed command collection topic. The command collection topic can be uniquely associated with the mobile device and can include one or more command nodes, each of which can receive a particular type of command message. The mobile device can be configured to access the notification service upon reestablishing a data network connection, such as when the mobile device is first powered on in an area in which data network access is available. Additionally, the mobile device can be configured to access the notification service in response to receiving a notification that a message has been published to a subscribed command topic.
[0063] Once the mobile device has accessed the command collection topic, each of the command nodes included in the topic can be polled to determine whether one or more new remote command messages have been received ( 410 ). In some implementations, the mobile device can be configured to compare any remote command messages included in the command collection topic to remote command messages cached by the mobile device. If a remote command message does not exist in the cache, the mobile device can treat the message as new. If no new remote command messages have been received, the mobile device can disconnect from the notification service ( 415 ).
[0064] Alternatively, if a new remote command message is detected in the command collection topic, the mobile device can retrieve the new remote command message ( 420 ). In some implementations, if more than one new remote command message exists in the command collection topic, the remote command messages can be retrieved in order based on server time stamps, command message type, or a combination thereof. For example, the mobile device can be configured to retrieve a wipe command last, as execution of the wipe command will preclude the execution of any remaining commands.
[0065] The remote command message can include general parameters to be used in executing the command and response, such as a server time stamp, a result topic to which a result message is to be published, and a command identifier. One or more command specific parameters also can be included for a particular command type. For example, a message command can include parameters identifying the message to be displayed. The parameters can be expressed using any data construct, including a delineated list, data fields, or key-value pairs. In some implementations, the server time stamp can be an XMPP standard time stamp in the format yyyy-MM-dd'T′HH:mm:ss.SSS′Z. Further, the server time stamp can be used to calculate the duration between transmission of the remote command message and execution of the associated command.
[0066] The mobile device can evaluate a retrieved remote command message to determine whether the associated command is understood ( 425 ). For example, a mobile device may not understand a command that is associated with a more recent version of an operating system or that requires functionality not included in the mobile device. If the mobile device does not understand the command associated with the retrieved remote command message, the mobile device can publish a message to a result topic indicating that the command was not understood ( 430 ). The result topic can be a predetermined result topic associated with the mobile device or a result topic identified in the remote command message. The mobile device further can determine whether the command collection topic includes a new command message ( 410 ).
[0067] If the command associated with the retrieved remote command message is understood, the mobile device can determine whether the command also is enabled ( 435 ). For example, one or more of the commands that can be executed by a mobile device can be disabled, either through user action or in accordance with default settings. If the command has been disabled, the mobile device can publish a message to the result topic indicating that the command has been disabled ( 440 ). The mobile device further can determine whether the command collection topic includes a new command message ( 410 ).
[0068] If the mobile device determines that the command is enabled, the mobile device can publish an acknowledgement message to the result topic ( 445 ). The result topic can be specified in the command message or can be a predetermined result topic. The acknowledgement message can indicate the result of the command and the time at which command execution was initiated. Also, the acknowledgement message can be published before command execution for some commands, such as the wipe command, the sound command, and the message command, to indicate that the command will be executed. For other commands, such as the location command and the lock command, the acknowledgement message can be published after the command has been executed. For example, the acknowledgement message corresponding to the location command includes data generated during command execution that identifies the location of the mobile device.
[0069] The mobile device also can execute the command identified by the remote command message ( 450 ). For example, the sound command can be executed by outputting an audible alert, such as one or more sounds played at a specified volume for a specified duration. In some implementations, the audible alert also can be delayed, e.g. for a predetermined time after the command is transmitted, and/or repeated one or more times. The message command can be executed by outputting a message, such as text, to a display included in the mobile device. The lock command can be executed to lock the screen of the mobile device and also to permit changing the passcode that must be entered to unlock the device. Further, execution of the wipe command can cause one or more items of data to be deleted from the mobile device. In some implementations, the type of data or level of wipe can be selected by the mobile device owner. In other implementations, executing the wipe command can cause the mobile device to be restored to a default state. Additionally, execution of the locate command can cause the mobile device to identify its location, based on the geographic reference information available to the mobile device at the time the command is executed. Except in the case of a wipe command, after the command has been executed the mobile device can determine whether another new message exists in the command collection topic ( 410 ).
[0070] FIG. 5 shows a flow diagram describing an exemplary process for executing a sound command by a mobile device. The mobile device can receive a sound command indicating that an audible alert is to be output ( 510 ). As described above, a remote command message corresponding to the sound command can be retrieved from a sound command node of a command collection topic subscribed to by the mobile device. Further, the mobile device can determine that the sound command is both recognized and enabled on the mobile device. If the mobile device determines that the sound command is not recognized or is not enabled, the command is ignored.
[0071] In response to the sound command, the mobile device can determine the sound to be played ( 515 ). In some implementations, the sound command can indicate that a predetermined audible alert is to be played. The predetermined audible alert can be characterized by one or more predetermined sounds and a predetermined duration. In some other implementations, the sound command can include one or more parameters specifying characteristics of the audible alert, such as one or more sounds to be played, a volume, a duration, whether the audible alert is to be repeated, and whether the audible alert is to be output continuously or periodically.
[0072] The one or more sounds representing the audible alert can then be output by the mobile device ( 520 ). Further, the mobile device can publish a result message to the notification service ( 525 ). The result message can be published to a result topic, e.g. a result topic specified by the command message, indicating that the audible alert has been or will be output. In some implementations, the result message can include one or more items of data, such as the time at which the command was executed and the characteristics of the audible alert.
[0073] FIG. 6 shows a flow diagram describing an exemplary process for executing a message command by a mobile device. The mobile device can receive a message command indicating that a message is to be presented on a display of the mobile device ( 605 ). For example, the message can indicate contact information that can be used to coordinate the return of the mobile device. As described above, a remote command message corresponding to the message command can be retrieved from a message command node of a command collection topic subscribed to by the mobile device. Further, the mobile device can determine that the message command is both recognized and enabled on the mobile device. If the mobile device determines that the message command is not recognized or is not enabled, the command is ignored.
[0074] The mobile device can determine the message to be displayed ( 610 ). For example, the received message command can include the text of the message to be presented. In some implementations, the message command also can specify the message format, including one or more of font, font size, text color, background, and graphics. Further, one or more restrictions can be placed on the message, such as the number of characters or message size, to ensure that the message can be displayed in its entirety on a single screen and to reduce the overhead associated with the message command. The message identified by the message command can be presented on the display of the mobile device ( 615 ). The message can be displayed above all other items presented on the display, such that the entire message is visible and uninterrupted. Further, the message can be displayed even if the mobile device is locked or if a screensaver is active.
[0075] The mobile device also can publish a result message to a result topic associated with the notification service ( 620 ). For example, a result topic can be specified by the message command. The result message can indicate that the message was displayed on the mobile device and the time at which the message was displayed. Further, the result message also can echo back the message that was displayed on the mobile device. After the message is displayed, input can be received by the mobile device to cancel the message ( 625 ). For example, when the mobile device is found, the message can be turned off in response to an action, such as a button push.
[0076] FIG. 7 shows a flow diagram describing an exemplary process for executing a wipe command by a mobile device. The mobile device can receive a wipe command indicating that one or more items of data are to be deleted from the mobile device ( 705 ). As described above, a remote command message including the wipe command can be retrieved from a wipe command node of a command collection topic subscribed to by the mobile device. Further, the mobile device can determine that the wipe command is both recognized and enabled on the mobile device. If the mobile device determines that the wipe command is not recognized or is not enabled, the command is ignored.
[0077] In response to the wipe command, the mobile device can request to unsubscribe from the command collection topic ( 710 ). As a result of unsubscribing, all of the messages in the command nodes corresponding to the command collection topic can be deleted. In some implementations, the mobile device also can be removed from the device listing of the remote management account. In some other implementations, the mobile device can be presented in the device listing as no longer being able to be managed (or as a dead device). The mobile device can determine whether the attempt to unsubscribe from the command collection topic was successful ( 715 ). If the mobile device did not successfully unsubscribe from the command collection topic, the mobile device can repeat the request to unsubscribe ( 710 ).
[0078] If the mobile device successfully unsubscribed from the command collection topic, the mobile device can publish a response to the result topic ( 720 ). The response can indicate that the wipe process has been initiated. Further, the response also can indicate when the wipe process was initiated. In some implementations, an electronic mail (email) message also can be generated by the remote management application to indicate that the wipe process has been initiated. For example, an email message announcing the wipe procedure can be addressed to an email account associated with the remote management account owner. Once the response has been published, the mobile device can execute the wipe command ( 725 ).
[0079] In some implementations, the level of wipe to be performed can be specified in the wipe command. For example, the mobile device can be wiped to return it to the original factory settings and to delete all user data. In one alternative, the mobile device can be wiped to render it inert, such that system data must be restored before the mobile device is once again functional. In another alternative, the wipe command can specify one or more types of data to be wiped, such as electronic mail messages, images, and contacts. Any number of categories can be specified for deletion using a custom wipe command. Once the wipe procedure has been performed, the mobile device is no longer subscribed to the command collection topic and thus cannot receive any additional remote commands.
[0080] FIG. 8 shows a flow diagram describing an exemplary process for executing a lock command by a mobile device. Upon receiving a lock command message, a mobile device enters a locked state, such as by locking the screen and requiring the entry of a valid passcode before access to device functionality or stored information is once again permitted. As with other commands, the mobile device that is to receive the remote lock command can be selected in the remote management application. A lock command can be specified in the interface corresponding to the mobile device to initiate sending the remote lock command message ( 805 ). For instance, a lock button or other such interface command tool can be selected, e.g. using a mouse or touch input, to initiate the lock operation.
[0081] A lock command interface can be presented to facilitate execution of the remote lock command ( 810 ). For instance, the lock command interface can prompt the user to input and confirm a new passcode, e.g. a four-digit personal identification number (PIN), that will be required to unlock the mobile device after the lock command is executed. The new passcode can be used to set an initial passcode if one was not previously required to access the mobile device or to reset the current passcode. The new passcode can be configured in accordance with a simple (or base) security constraint utilized as a default by the mobile device. In some implementations, the lock command interface also can be configured to prompt the user to enter the current passcode for validation. The information entered into the lock command interface can be used to generate the remote lock command message.
[0082] In some other implementations, the lock command interface can indicate that a complex security constraint has been implemented on the mobile device. For instance, the mobile device can publish a message indicating that the default security constraint, e.g. a simple constraint, has been replaced by a more complex security constraint intended to provide a higher standard of security for the mobile device. In some implementations, the lock command interface can indicate that, as a result of the more complex security constraint implemented on the mobile device, the passcode cannot be changed remotely. For instance, a lock button or other such binary command tool can be presented in the lock command interface in place of the prompt for a new passcode. Alternatively, the lock command interface can be adapted to prompt the user to input a new passcode that conforms to the more complex security constraint that has been enacted. If the security constraint is known, the new passcode can be validated against the constraint and included in the remote lock command message for use in resetting the passcode on the mobile device.
[0083] Further, the remote lock command message can be published ( 815 ). For instance, the remote management application can be configured to transmit the remote lock command message to a remote lock topic associated with a command collection of a notification service that corresponds to the mobile device. Once published, the remote lock command message can be delivered to the mobile device ( 820 ). If the mobile device is on-line, i.e., has a current data connection that permits communication with the notification service, the remote lock command message can be transferred to the mobile device substantially in real-time. Otherwise, the remote lock command message can be queued at the notification service and delivered to the mobile device upon the restoration of communication with the notification service.
[0084] The passcode specified by the remote lock command message can be evaluated to determine whether it complies with the presently implemented security constraint ( 825 ). For instance, if a more complex security constraint has been implemented, the remote management application may not have been updated to reflect the change and the specified passcode could fail to meet the requirements of the more complex constraint. If a more complex security constraint has not been implemented, the remote lock command can be executed to lock the mobile device and to reset the passcode ( 830 ). For instance, a private framework on the mobile device can be accessed to cause the mobile device passcode to be reset to the passcode specified in the remote lock command message. Once the passcode has been reset and the mobile device has been locked, the newly specified password must be entered to unlock the device. Alternatively, if a more complex security constraint has been implemented, the lock command specified in the remote lock command message can be executed without resetting the passcode ( 835 ). Thus, the mobile device can be locked and the existing passcode, which conforms to the more complex constraint, is required to unlock the device.
[0085] Additionally, a message acknowledging the remote lock command message can be published to the notification service ( 840 ). The acknowledgement message can be published before or after the lock command is executed by the mobile device. If no errors are encountered, the acknowledgment message can confirm that the mobile device, e.g. the screen, was locked and that the passcode was set to the passcode specified by the lock command. Further, the acknowledgement can include a time stamp, e.g. indicating the time at which the mobile device received the remote lock command message or the time at which the mobile device was locked. In some implementations, an email message can be generated based on the published acknowledgement and can be transmitted to an email account associated with the user.
[0086] Alternatively, if one or more errors are encountered during the lock operation, the acknowledgement message can indicate whether the mobile device was locked and can include a time stamp, e.g. indicating the time at which the lock command was received. Further, the acknowledgement message can indicate the type of error encountered, e.g. passcode reset failure, and the reason for the error. For instance, the passcode reset can fail if the passcode included in the remote lock command message fails the security (or passcode) constraint that has been implemented by the mobile device. If a more complex or rigorous constraint has been implemented, the security level of the mobile device can be maintained by preventing a change to the passcode specified by the remote lock command message. In some implementations, details regarding the currently enacted security constraint can be transmitted to the user, such as in the published acknowledgement message, or in a separate published message or email. An error also can arise in response to other circumstances, such as if the remote lock command message fails to specify a new passcode, if the previous passcode used for validation was incorrect, or if the message is partially or entirely corrupted. Despite the detection of one or more errors, the mobile device can be locked in response to the remote lock command message.
[0087] FIG. 9 shows a flow diagram describing an exemplary process for executing a locate command by a mobile device. The mobile device can receive a locate command requesting the present location of the mobile device ( 905 ). As described above, a remote command message including the locate command can be retrieved from a locate command node of a command collection topic subscribed to by the mobile device. Further, the mobile device can determine that the locate command is both recognized and enabled on the mobile device. If the mobile device determines that the locate command is not recognized or is not enabled, the command is ignored.
[0088] In response to receiving the locate command, the mobile device can determine its present location ( 910 ). For example, the mobile device can use a location process or application programming interface (API) to retrieve the available data that most accurately describes its location. If the mobile device includes a Global Positioning System (GPS) chip, the mobile device can retrieve the GPS coordinates identifying its present location. If the mobile device does not include a GPS chip, or if GPS coordinates are not available, the mobile device can determine its location through other means. For example, if the mobile device is configured to communicate on a wireless telecommunications network, the mobile device can estimate its location using cellular tower triangulation. Alternatively, if the mobile device is configured to communicate using a Wi-Fi connection, the mobile device can estimate its location in accordance the nearest Wi-Fi base station. The mobile device also can use any other technique known in the art for determining or estimating its location.
[0089] The mobile device also can be configured to determine one or more times associated with the locate command ( 915 ). For example, the mobile device can determine the time at which the locate command was received. Further, the mobile device can determine the time at which the locate command was processed to determine the location information.
[0090] Once the mobile device has determined the location information, the mobile device can publish a result message to the result topic ( 920 ). The result message can include one or more items of location data. For example, the result message can include key-value pairs specifying geographic data, such as longitude, latitude, vertical accuracy, and horizontal accuracy. Further, the result message can include one or more items of time data. For example, the result message can include a time stamp indicating the time at which the location data was retrieved and a time stamp indicating the time at which the locate message was received. Accordingly, the accuracy of the location data can be at least partially assessed based on the reported time data.
[0091] FIG. 10 shows an exemplary user interface depicting the location reported by a mobile device in response to a locate command. The user interface 1000 can be configured for presentation on any display device, including a display associated with a mobile device. A map 1005 can be presented in the user interface 1000 , depicting a region that includes the location reported by the mobile device in response to a locate command. In some implementations, the map 1005 can be interactive and can include a resolution control 1008 for receiving input to increase or decrease the scale of the map 1005 .
[0092] The user interface 1000 also can include an address field 1010 that displays an address corresponding to the location reported by the mobile device. The address most closely corresponding to the reported location of the mobile device can be selected. For example, if the location reported by the mobile device is outside of an existing address, such as in a parking lot or greenbelt, the nearest available address to that location can be presented. A location indicator 1015 also can be presented on the map 1005 in the position corresponding to the location reported by the mobile device. Further, a legend 1020 can be displayed in conjunction with the location indictor 1015 . In some implementations, the legend 1020 can identify the mobile device reporting the displayed location. In some other implementations, the legend 1020 can indicate a geographic reference, such as the street address, location name, or geographic coordinates of the reported location.
[0093] FIG. 11 shows an exemplary user interface depicting an estimated location of a mobile device based on a response to a locate command. The user interface 1105 can be configured for presentation on any display device, including a display associated with a mobile device. A map 1110 can be presented in the user interface 1105 , depicting a region that includes the estimated location of the mobile device. In some implementations, the map 1110 can be interactive and can include a resolution control 1115 for receiving input to increase or decrease the scale of the map 1110 .
[0094] The user interface 1105 also can include an address field 1120 that displays an address corresponding to the estimated location of the mobile device. The address most closely corresponding to the estimated location of the mobile device can be selected. For example, if the estimated location is based on a Wi-Fi base station, the address associated with the Wi-Fi base station can be included in the address field 1120 . A location indicator 1125 also can be presented on the map 1110 . The location indicator 1125 can be centered on the estimated position, such as the location of the associated Wi-Fi base station. The location indicator 1125 also can be sized to approximate the area in which the mobile device can be located, such as in accordance with the approximate effective range of the associated Wi-Fi base station. Further, a legend 1130 can be displayed in conjunction with the location indictor 1125 . In some implementations, the legend 1130 can identify the mobile device reporting the estimated location. In some other implementations, the legend 1130 can indicate a geographic reference, such as an address, a location name, or the geographic coordinates corresponding to the estimated location.
[0095] FIG. 12 shows a mobile device displaying an exemplary message in response to a message command. The digital media player 125 includes a display 1205 , such as a touch screen. In response to receiving a remote command to display a message, the digital media player 125 can present a message window 1210 on the display 1205 . The message window 1210 can include a text message, such as contact information identifying the owner of the digital media player 125 . For example, the remote command sent to the digital media player 125 can include a text message, such as “If found, please call Jake at 866.555.1234.” In some implementations, the message window 1210 can include one or more images, graphics, effects, or links. The one or more images, graphics, effects, or links can be content transmitted in conjunction with the message command, content retrieved by the digital media player 125 , or content stored on the digital media player 125 . The message window 1210 can be presented using any arrangement of colors and fonts. Further, the message window 1210 can include an action button 1215 to permit closing the message window 1210 . In some implementations, the message window 1210 can be persistently displayed until the action button 1215 is actuated or other input canceling presentation of the message is received. Additionally, the message window 1210 can be displayed above any other screen content, such that it is viewable even if the mobile device is locked or displaying a screen saver.
[0096] FIGS. 13A and 13B show exemplary mobile device interfaces presented in response to an executed remote lock command. After a lock command has been executed by a mobile device, e.g. mobile telephone 120 , lock interface 1305 , shown in FIG. 13A , can be presented on an associated device display. When lock interface 1305 is presented, functionality associated with the mobile device can be inaccessible. In some implementations, one or more exceptions can exist through which functionality can remain accessible. For instance, an incoming telephone call can be answered even when the mobile device is locked. Also, a message can be presented on the device display and/or a sound can be output from a device speaker, such as in response to one or more mobile commands. Lock interface 1305 can include one or more graphical elements configured to permit unlocking the mobile device. For instance, slider 1310 can be manipulated, e.g. through a touch screen interface, to enter an unlock input that initiates unlocking of the mobile device.
[0097] FIG. 13B shows an example passcode entry interface 1315 , which can be presented on the mobile device display in response to received unlock input. Passcode entry interface 1315 can be configured to prompt a user to enter the passcode required to unlock the mobile device. In some implementations, passcode entry interface 1315 can include separate passcode entry boxes 1320 , such that an individual passcode entry box 1320 is presented for each character (e.g., letter, number, or symbol) included in the required passcode. In other implementations, passcode entry interface 1315 can include a single passcode entry box, which can be of any size, or no passcode entry box.
[0098] Further, passcode entry interface 1315 can include one or more character interfaces 1325 , which can be adapted to receive user input specifying a passcode. For instance, character interfaces 1325 can be arranged as a keypad in passcode entry interface 1315 , and can be actuated through corresponding input to a touch screen. Other configurations can be used in other interfaces. For instance, character interfaces also can be implemented as scrollable wheels, drop-down menus, or virtual keyboards. Additionally or alternatively, one or more physical controls included in the mobile device also can be used to enter one or more characters associated with a passcode.
[0099] FIG. 14 shows a flow diagram describing an exemplary process for processing a remote command message by a mobile device. Initially, a subscribed topic hosted on a notification service can be accessed, the subscribed topic corresponding to a mobile device ( 1405 ). A remote command message included in the subscribed topic that identifies a command to be executed by the mobile device can be retrieved ( 1410 ). Further, it can be determined whether the command can be executed by the mobile device ( 1415 ). Once it is determined that the command can be executed by the mobile device, a result message associated with the command can be published ( 1420 ). Further, the command can be executed by the mobile device based on the determining ( 1425 ). In some implementations, the result message can be published before, after, or in conjunction with execution of the command.
[0100] The techniques and functional operations described in this disclosure can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structural means described in this disclosure and structural equivalents thereof, or in combinations of them. The techniques can be implemented using one or more computer program products, e.g., machine-readable instructions tangibly stored on computer-readable media, for execution by, or to control the operation of one or more programmable processors or computers. Further, programmable processors and computers can be included in or packaged as mobile devices.
[0101] The processes and logic flows described in this disclosure can be performed by one or more programmable processors executing one or more instructions to receive, manipulate, and/or output data. The processes and logic flows also can be performed by programmable logic circuitry, including one or more FPGAs (field programmable gate array), PLDs (programmable logic devices), and/or ASICs (application-specific integrated circuit). General and/or special purpose processors, including processors of any kind of digital computer, can be used to execute computer programs and other programmed instructions stored in computer-readable media, including nonvolatile memory, such as read-only memory, volatile memory, such as random access memory, or both. Additionally, data and computer programs can be received from and transferred to one or more mass storage devices, including hard drives, flash drives, and optical storage devices. Further, general and special purpose computing devices and storage devices can be interconnected through communications networks. The communications networks can include wired and wireless infrastructure. The communications networks further can be public, private, or a combination thereof.
[0102] A number of implementations have been disclosed herein. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claims. Accordingly, other implementations are within the scope of the following claims.
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Methods, systems, and apparatus are presented for processing a remote lock command message. In one aspect, a method includes receiving, by a mobile device, a remote lock command message comprising a lock command and specifying a passcode to be set by the mobile device, locking the mobile device in response to the received remote lock command message, setting an unlock passcode associated with the mobile device to the specified passcode, and generating an acknowledgement message in response to the remote lock command message. Further, receiving the remote lock command message can include accessing a subscribed topic hosted on a notification service, the subscribed topic being associated with a lock command, and retrieving the remote lock command message from the subscribed topic. Additionally, locking the mobile device can include locking a display such that access to information stored on the mobile device and device functionality are blocked.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a printing press with a plurality of in-line printing units, with a transport system for the rectilinear transport of substrates to be printed through the printing units, and with a feeder at which the substrates are stacked for transferring the substrates to the transport system, and to suitable turning devices therefor.
In conventional printing presses, the transport path of the substrates or sheets through the printing press is, for structure-inherent reasons, often a curved path. A desirable side effect is thereby that the sheets, during their being transported along the path, are stabilized.
There has become known from German patent DE-PS 19 30 317 a printing press of the above-noted type in which the sheets are transported in a single gripper closure in a horizontal plane through a plurality of consecutive printing units. That type of sheet transport is partially based on the requirement that the transport system for transporting the sheets through the printing units should operate so as to be as free as possible from inertial forces.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a printing press with rectilinear sheet transport and turning devices therefor, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which is more versatile in use than conventional printing presses.
With the foregoing and other objects in view there is provided, in accordance with the invention, a printing press, comprising:
a plurality of in-line printing units defining a substantially rectilinear transport path;
a transport system for transporting substrates for printing in the printing units along the transport path;
a feeder assembly for feeding the substrates to be printed to the transport system, the feeder assembly including a feeder for transferring individual substrates from a feeder pile on which the substrates to be printed are stacked to the transport system, the feeder defining a feeder transport path of the substrates from the feeder pile to the transport system, the feeder transport path being rectilinear and substantially coplanar with the transport path in the printing units.
In accordance with an added feature of the invention, the feeder for transferring the substrates to the transport system comprises a substrate-removal device and at least one pair of transfer rollers, the substrate-removal device and the transfer rollers being disposed directly adjacent the feeder transport path.
In accordance with an additional feature of the invention, the printing press further comprises a delivery defining a delivery transport path along which the substrates enter the delivery, the delivery including at least one of a pair of transfer rollers and a braking apparatus disposed immediately adjacent the delivery transport path, the delivery transport path being substantially coplanar with the transport path of the substrates through the printing units.
In other words, the objects of the invention are achieved in a printing press of the above-mentioned kind in that the transfer of the substrates from the feeder pile to the transport system is rectilinear and is in the same plane as the transport path of the substrates into the printing units.
With the printing press according to the invention it is possible to print not only flexible materials such as paper, but also materials such as cardboard, plastic, sheet metal, glass etc., which, owing to their thickness or their material properties, cannot or must not be deformed. With conventional printing presses it was not possible to print non-deformable substrates; nor was this possible with the above-mentioned printing press known from DE-PS 19 30 317. It is essentially important in that printing press only that the sheets be transported along a flat transport path through the printing units. It can therefore be presumed that use will be made of conventional feeders in which, normally, there is at least a slight deformation of the sheet.
According to the invention, the feeder is incorporated into the flat transport path in that the substrates are, in one plane, removed from the feeder pile, accelerated and sent on the transport path through the printing units. The delivery may, in a similar manner, be incorporated into the flat transport path in that the substrates are deposited rectilinearly on the delivery pile, which is kept at a suitable height. Alternatively, the top side of the delivery pile may be lower than the exit point of the substrates from the printing units. The substrates--after having been braked, where appropriate, by a braking apparatus--thereby drop onto the delivery pile.
The system according to the invention therefore allows substrates of any thickness and even very stiff or even brittle substrates to be printed quickly and in large numbers, e.g. in offset printing. The prior art has accepted as self-evident that such printing is not possible with conventional printing presses, and such substrates have been printed using other, economically less efficient printing processes.
In accordance with a further feature of the invention, the plurality of printing units includes a series of recto printing units and a series of verso printing units, and the transport system includes a first transport apparatus for transporting the substrates from the feeder through the series of recto printing units, and a second transport apparatus disposed behind the first transport apparatus as seen along the transport path for transporting the substrates through the series of verso printing units.
In accordance with again a further feature of the invention, transfer rollers of the recto printing units and transfer rollers of the verso printing units are disposed on mutually opposite sides of the transport path, and the first and second transport apparatus adjoin each other at a transfer point for transferring the substrates from the first transport apparatus to the second transport apparatus, the transfer point lying on the transport path of the substrates between the recto printing units and the verso printing units. Conversely, the transfer rollers of the recto printing units and of the verso printing units may be disposed on the same side of the transport path of the substrates through the printing units, and including a turning apparatus for turning the substrates disposed between the first transport apparatus and the second transport apparatus.
In accordance with a further feature of the invention, each of the transport apparatus encompasses at least one endless conveyor belt, each of the endless conveyor belts comprising a rectilinear strand extending along the transport path of the substrates through the printing units, the substrates lying in flat contact on the rectilinear strand during transport through the printing units.
If digital printing units are used, then endless conveyor belts are most suitably employed as the transport system.
In order to be able to carry out multicolor perfecting with the printing press according to the invention, a number of printing units for recto printing (first-side print) and a number of printing units for verso printing (back-side print) are disposed inline along the sheet transport path. The verso-printing units are disposed on a different side of the substrates from the printing units for recto printing.
In order to permit the use of identical printing units, it may be necessary for the recto and verso printing units to be disposed on the same side of the substrates. This can be accomplished through the interposition of a suitable turning device. The transport paths from the feeder to the turning apparatus and from the turning apparatus to the delivery each extend rectilinearly in the same plane.
According to the invention, various turning devices for turning the substrates in the printing press are provided which do not deform the substrates when they are turned. Turning devices according to the invention comprise a turning unit being rotatable about a center axis thereof, the turning unit having two mutually parallel rollers, the rollers being spaced apart by a distance being greater than a maximum length of a substrate to be turned, and an endless turning belt for the substrates, the turning belt being guided around the rollers.
In accordance with further features of the invention, the turning unit is rotatable through 180° or it is indexable in increments of 180°.
Another turning device according to the invention includes a rotatable turning pocket defining at least one substantially rectangular compartment, the compartment being slightly larger than a maximum size of a substrate to be turned and having three essentially open sides and one closed side, the closed side extending along an axis about which the turning pocket is rotatable.
In accordance with another feature of the invention, the at least one compartment is one of a plurality of compartments, the compartments being disposed in a star-shape about the axis about which the turning pocket is rotatable. Furthermore, the at least one compartment may be formed with one or more stops for holding substrates that are transported into the turning pocket, and including a plurality of grippers for ejecting the substrates from the turning pocket, the grippers being disposed along an open side of the compartment disposed opposite the closed side. The grippers preferably revolve around mutually spaced-apart gripper shafts and project into consecutive the compartments when the gripper shafts are rotated in synchronism with the turning pocket.
In an alternative embodiment of the turning device, there are provided a plurality of mutually parallel pairs of driveable transport rollers, the transport-roller pairs being mutually spaced apart by respective distances being smaller than a length of the substrates to be turned, all of the transport-roller pairs being commonly rotatable about an axis passing through each of the transport-roller pairs perpendicularly the transport-roller pairs.
In a preferred embodiment, the turning apparatus further comprises a drum-shaped housing having ends and defining a longitudinal axis, the transport-roller pairs being driveably held in the housing, the housing being open at the ends and being rotatable about the longitudinal axis, the longitudinal axis being coaxial with the axis passing perpendicularly through each of the transport-roller pairs.
In yet another embodiment of the turning device there are provided a plurality of pairs of driven transport rollers, the transport-roller pairs being disposed behind each other and being spaced apart by distances being smaller than a length of the substrates to be turned, mutually adjacent transport-roller pairs being offset with respect to each other by an angle being a fraction of 180°, the plurality of with the result that there is formed a spiral transport path of the substrates through the turning apparatus with a total angle of rotation of 180°.
In accordance with concomitant features of the invention, the above-described turning devices are incorporated in printing machines with rectilinear sheet transport as described above.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a printing press with rectilinear substrate transport and turning devices therefor, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a printing press for flat substrate transport with distributed printing units for recto and verso printing;
FIG. 2 is a similar view of a printing press with flat substrate transport and identical printing units for recto and verso printing and a turning apparatus for turning the substrates;
FIG. 3 is a schematic perspective view of a printing press for flat substrate transport with printing units for recto and verso printing and with a further embodiment of a turning apparatus;
FIG. 4 is a partial perspective view illustrating another embodiment of a turning apparatus; and
FIG. 5 is a diagrammatic perspective view of an alternative embodiment of a turning apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen a printing press which includes a feeder 1 with a height-adjustable feeder pile 2 on which the substrates or sheets to be printed are stacked. The terms substrates and sheets will be used indiscriminately herein, each referring to materials to be printed and formed of paper, sheet metal, glass panes, etc. The feeder of the printing press further includes substrate-removal rollers 3 and a pair of transfer rollers 4. A delivery 5 includes a height-adjustable delivery pile 6, a pair of transfer rollers 7 and a non-illustrated braking apparatus. In its simplest form, the braking apparatus may be a stop at the rear end of the delivery pile 6 in the longitudinal direction of the print press.
Disposed one behind the other-between the feeder 1 and the delivery 5 are a first endless conveyor belt 8 which is deflected around guide pulleys 9 and 10, and a second endless conveyor belt 11, which is deflected around guide pulleys 12 and 13. The upper strand of the conveyor belt 8 and the lower strand of the conveyor belt 11 lie one behind the other in the same plane, the conveyor belts 8, 11 contacting each other at a point on the circumference of the guide pulleys 10, 12. Four printing units 14 for recto printing are disposed one behind the other above the first conveyor belt 8; and four printing units 15 for verso printing are disposed one behind the other below the second conveyor belt 11. The printing units 14, 15 are schematically shown merely in the form of cylinders that transfer the inks from the printing units 14, 15 onto substrates. The substrates thereby lie on the upper strand of the conveyor belt 8 or on the lower strand of the conveyor belt 11
In operation, the substrates are removed consecutively from the feeder pile 2 by the substrate-removal rollers 3, are accelerated by the transfer rollers 4 and are conveyed onto the first conveyor belt 8, which runs around the guide pulleys 9, 10 in a counter-clockwise direction in FIG. 1. The substrates are transported along the printing units 14 by friction between the cylinders of the printing units 14 and the conveyor belt 8 and are printed on one side. At the point of contact between the conveyor belts 8, 11, the substrates part from the conveyor belt 8 and pass to the conveyor belt 11. The conveyor belt 11 conveys the substrates along the printing units 15 in the direction of the arrow, for example, by friction between the cylinders of the printing units 15 and the conveyor belt 11, the substrates being printed on the other side. On reaching the guide pulley 13, the substrates part from the conveyor belt 11 and pass between the pair of transfer rollers 7 in order to be deposited on the delivery pile 6.
With the exception of a possible slight offset which may be required in the case of thicker substrates, the surface of the upper strand of the conveyor belt 8 and the surface of the lower strand of the conveyor belt 11 lie in the same plane. The feeder pile 2 is moved during operation in such a manner that the uppermost substrate always lies in that same plane. At the delivery end it is merely necessary for the two transfer rollers 7 to adjoin that plane (where appropriate, a substrate brake will also suitably be disposed), and the released substrates are able to drop onto the delivery pile 6, the top side of which is kept, during operation, slightly below the plane of the transport of the substrates through the printing units 14, 15.
In this manner, the substrates undergo the printing process without any deformation. As a result, it is also possible for very thick, very stiff, or very fragile materials to be printed on both sides in multicolor in one operation.
If the printing units 14, 15 and the transfer rollers 4, 7 are disposed one behind the other at a distance smaller than the length of the substrates, thick or stiff substrates are kept on the transport path without the need for further measures. In order also to allow the printing of shorter or flexible substrates using the same printing press, the conveyor belts 8, 11 may be provided with means that, for example, produce electrostatic forces or vacuum, with the result that the substrates adhere to the rectilinear strands of the conveyor belts 8, 11, yet again detach themselves from the conveyor belts 8, 11 when they reach the guide pulleys 10/13. If required, the substrates may be held on the belts 8 and 11, respectively, by electrostatic charge forces, suction grippers, mechanical grippers, clamps, or the like.
Should it be the case that only recto printing is required, the printing units 15 and the conveyor belt 11 are omitted and the delivery 5 is disposed directly at the end of the conveyor belt 8. Furthermore, it is possible for the number of printing units to be varied at will for each substrate side.
The printing units 14, 15 may be any conventional printing units, e.g. offset printing units; alternatively, they may be digital printing units. In digital printing, endless belts are particularly suitable for the sheet transport. Alternatively, conventional substrate-transport apparatus employing chains and grippers also enter into consideration for the transport system.
Frequently, it is desirable to employ printing units of precisely identical construction, the printing parts of which are all disposed on one side of the substrate-transport path. This case is shown in FIG. 2, in which elements that conform to the printing press of FIG. 1 are identified by identical reference numerals.
In FIG. 2, four printing units 16 are used for verso printing, said printing units 1S being disposed above a conveyor belt 17, i.e. in the reverse orientation to FIG. 1. In FIG. 2, the upper strand of the conveyor belt 17 lies in the same plane as the pair of transfer rollers 7 of the delivery 5. The conveyor belt 8 and the conveyor belt 17 are disposed at a distance apart in the direction of the length of the printing press, a turning unit 18 is disposed in the space formed between the guide rollers 10 and 12. The turning unit 18 consists of two rollers 19, 20, which are disposed at a distance apart that is greater than the maximum proposed substrate length, and of an endless turning belt 21, which runs around the rollers 19, 20. The turning unit 18 is rotatable as a whole about an axis 22 extending between the rollers 19, 20 and parallel to the rotational axes thereof. The upper strand of the conveyor belt 8 and the upper strand of the conveyor belt 17 are parallel, but are offset with respect to each other in the direction of the height of the printing press by a distance corresponding to the thickness of the turning unit 18, i.e. essentially to the diameter of the rollers 19, 20.
With the printing press shown in FIG. 2 in operation, the substrates are first of all printed on their first sides by the printing units 14, as has been described in conjunction with FIG. 1, and they then pass onto the turning belt 21, which is driven in synchronism with the conveyor belt 14 (arrow S) by a non-illustrated drive. Once the substrate is in contact over its entire length with the turning belt 21, the substrate, for example, adhering to the turning belt 21 through electrostatic forces or through vacuum, the turning belt 21 stops and the turning unit 18 as a whole is rotated through 180° about the axis 22 by a non-illustrated drive, as is indicated by arrows P. Subsequently, the turning belt 21 restarts in the opposite direction (arrow W) and transfers the substrate to the conveyor belt 17 with the printing units 16. The delivery of the substrates is identical to that described in conjunction with FIG. 1.
The particular design of the turning unit 18 makes it possible for the substrates to pass without deformation through a printing press of the kind shown in FIG. 2, i.e. with identical printing units.
A further turning apparatus which leaves the substrates flat when they are turned is shown in FIG. 3, which provides a perspective view of a printing press similar to that in FIG. 2 and in which elements that conform to elements in FIG. 2 are identified by identical reference numerals.
The printing press shown in FIG. 3 encompasses the conveyor belt 8 and the printing units 14 for recto printing--which, in conjunction with the feeder 1, form a first transport path--and a conveyor belt 23 and printing units 24 for verso printing--which, in conjunction with a delivery 25 for verso printing, form a second transport path. The first and second transport paths extend parallel to each other at the same height; however, in a sideways direction (transversely to the first and second transport paths), they are offset with respect to each other by slightly more than the width of a substrate.
A turning pocket 26 is disposed in a space between the conveyor belt 8 and the conveyor belt 23. The schematically represented turning pocket 26 is a rotationally symmetrical element with a number of compartments 27, which are disposed in star-like manner around an axis 28. The axis 28 extends parallel to the first and second transport paths and in the center therebetween. The turning pocket 26 is rotatable about the axis 28. Each compartment 27 comprises essentially rectangular sides corresponding to the maximum size of substrate to be accepted and--with the exception of one side that adjoins the axis 28--is open on all sides. With the turning pocket 26 in a defined position, a compartment 27 lies in an extension of the first transport path through the printing units 14 for recto printing and a compartment 27 opposite with respect to the axis 28 lies in an extension of the second transport path through the printing units 24. Each compartment 27 of the turning pocket 26 comprises schematically represented stops 29 on the side towards the second transport path.
Situated on the circumference of the turning pocket 26 and slightly outside of the radius of rotation thereof are, at the level of the first transport path through the printing units 14 two gripper shafts 30 and, at the level of the second transport path through the printing units 24, two gripper shafts 31. The gripper shafts 30, 31 are each spaced apart from each other in the direction of the axis 28 and are drivable about axes that are parallel to each other and perpendicular with respect to the axis 28. An endless transport apparatus (not separately shown) runs around each of the gripper shafts 30 and 31. Attached to each of the transport apparatus at intervals are a plurality of grippers 32, which, with the turning pocket 26 in a defined position, are each able to reach into and grip a sheet in one of the compartments 27 thereof. The gripper shafts 30, 31 and the grippers 32 comprise driving means (not shown) for rotation and for gripping.
A further delivery 33 for recto printing is disposed behind the turning pocket 26 in an extension of the first transport path through the printing units 14.
With the printing press and turning apparatus shown in FIG. 3 in operation, a substrate that has been singled from the feeder 1 is printed on one side by the printing units 14 for recto printing and is then inserted against the stops 29 into a compartment 27 of the turning pocket 26, said compartment 27 lying on a straight line with the first transport path through the printing units 14. Should it be desired that the respective substrate be printed only on the first side, the grippers 32, revolving around the gripper shafts 30, grip the substrate and convey it to the delivery 33. Should it be desired that the substrate be printed on both the first and back sides, the turning pocket 26 rotates further in phase with the printing press. For this purpose, the turning pocket 26 has a timed drive (not shown), which stops respective compartments 27 in an extension of the respective transport paths while the substrates are inserted or ejected. Once the substrate (to be printed on the first and back sides) lies on a straight line with the second transport path for verso printing, it is gripped by the grippers 32, which revolve around the gripper shafts 31, and is transferred to the printing units 24 for verso printing, which then print the second side of the substrate and convey the substrate to the delivery 25.
The gripper shafts 30, 31 rotate in synchronism with the turning pocket 26, with the result that, on one cycle, two successive grippers 32 engage a compartment 27 of the turning pocket 26 and, on the next cycle two other grippers 32 engage the following compartment 27 of the turning pocket 26.
With the turning pocket 26 shown in FIG. 3, the substrates are able to pass through the printing press without deformation, just as in the case of the preceding embodiment.
Furthermore, the exemplary embodiment shown in FIG. 3 has the advantage that there are different substrate-transport paths for recto and verso printing, this permitting substrates to be removed separately according to recto printing and verso printing. Moreover, a modular construction of the printing press is possible. Finally, the printing press and/or the turning apparatus can be incorporated in a most advantageous manner into on-line operation with pre- or post-processing machines of many different kinds.
A further turning apparatus which leaves the substrates flat when they are turned is shown in FIG. 4, which is a perspective view of a portion of a printing press similar to that of FIG. 2.
The turning apparatus shown in FIG. 4 comprises a drum-shaped housing 34 with open ends. The longitudinal axis of the housing 34 extends through the center of a transport path of substrates 35 through a plurality of printing units 36 for recto printing and through a plurality of printing units 37 for verso printing. Between the printing units 36 and the printing units 37 there is a space that is greater than the length of a substrate 35. The housing 34 is disposed in the space.
A plurality of pairs of transport rollers 38 are located inside the drum-shaped housing 34. The rollers extend from wall to wall and perpendicularly with respect to the longitudinal axis thereof are. The pairs of transport rollers 38 are disposed one behind the other in the direction of the longitudinal axis of the housing 34 and are separated from each other and from the nearest printing unit 36, 37 by distances that are smaller than the length of the substrates 35. In the position shown in FIG. 4, the transport-roller pairs 38 lie in the same plane as the printing units 35, 37.
The drum-shaped housing 34 is rotatable about its longitudinal axis and is connected to a non-illustrated drive, through which drive the housing 34 is rotated through 180° backwards and forwards or indexed in increments of 180° in one direction. The transport rollers 38 are either connected in their horizontal positions to a non-illustrated drive disposed outside of the housing 34, or they have one or more drives that are disposed inside the housing 34 and are rotatable together therewith.
In operation, the substrates 35 are printed on one side by the printing units 36 and are then transported into the housing 34 by friction between the cylinders of the printing units 36. After a substrate 35 has been gripped by the first transport-roller pair 38 and has been released by the printing units 36, the housing 34 rotates through 180° about the transport direction of the substrate 35, the transport rollers 38 continuing to rotate inside the housing 34. The housing 34 may included non-illustrated guides that guide the substrates 35 on their path between the transport-roller pairs 38. The rotation speed of the housing 34 is designed such that, at the end of the 180° rotation, at which the housing 34 stands still for a moment, the substrate 35 is precisely at the end of the housing 34 or between the last transport-roller pair 38, from where it is then transferred to the printing units 37, which print it on the other side.
The timing of the rotation of the housing is controlled in such a manner that there is only one substrate 35 in the housing 34 at a time while said housing 34 rotates. The housing 34 is either always rotated in the same direction or is rotated backwards and forwards. In the latter case, the transmission of driving motions to the housing 34 is facilitated.
The specimen embodiment in FIG. 4 has the advantage that the substrates 35 can be turned without acceleration or deceleration in the substrate-transport direction. This makes it possible also for very sensitive substrates to be turned essentially in a force-free manner, such as thin glass plates, and, just as in the above-described exemplary embodiments, for them to be printed without deformation if the feeder and the delivery are disposed, as also described above, in such a manner as to ensure a rectilinear substrate-transport path. Furthermore, the embodiment shown in FIG. 4 allows very high speeds to be achieved.
A modification of the turning apparatus from FIG. 4 is schematically represented in FIG. 5. In FIG. 5, five transport-roller pairs 39 are disposed one behind the other along a substrate-transport path indicated at the start and end by arrows, each two successive transport-roller pairs 39 being offset with respect to each other by an angle of approx. 45°, with the result that there is formed a spiral transport path with a total rotation angle of 180°. The relative offset angle between mutually adjacent rollers depends on the number of such roller pairs 39 provided between the mutually parallel roller pairs at the beginning and at the end of the turning device, i.e. the relative offset corresponds to 180° divided by the number of roller pairs plus one. Non-illustrated guides at the edge 40 of the transport path through the turning apparatus ensure that the substrates are not deformed or are deformed only insignificantly during transport and at transfer between the individual transport-roller pairs 39. This exemplary embodiment is distinguished in that only few moving parts are required.
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A printing press has a plurality of in-line printing units in which substrates are transported along a rectilinear transport path. The printing units include several recto printing units and several verso printing units disposed along the transport path. A transport system, which transports the substrates through the printing units along the straight transport path, includes a first transport apparatus through the recto printing units, and a second transport apparatus through the verso printing units. A feeder assembly feeds the substrates to be printed from a feeder pile to the transport system. The feed by the feeder also follows a straight path which is coplanar with the path through the printing units. It is thus possible to print not only bendable substrates, but also rigid and stiff substrates such as carton, plastic, sheet metal, glass, and the like. The system further includes a turning apparatus for turning the substrates between the recto printing units and the verso printing units.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of Application Ser. No. PCT/EP96/04080, filed Sep. 18, 1996 which claims the priority of Belgian Application No. 9500769, filed Sep. 19, 1995, and each of which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a steel wire element for mixing into subsequently hardening soft materials, said element consisting of hook-shaped ends and a middle portion the length/diameter ratio of which is between 20 and 100.
BACKGROUND OF THE INVENTION
Such wire elements for reinforcing subsequently hardening materials, such as concrete are known from the Dutch patent 160,628 and the corresponding U.S.A. Pat. Nos. 3,900,667 and 3,942,955 of the applicant N.V. BEKAERT S.A. and are marketed worldwide by the applicant under the brand name DRAMIX®. The technical characteristics of the DRAMIX steel wire fibers are described in Bekaert specifications AS-20-01 (4 pages) and AS-20-02 (3 pages) of April 1995.
Each one of Dutch Patent 160,628, U.S. Pat. Nos. 3,900,667 and 3,942,955, Bekaert specifications AS-20-01 and AS-20-02 is incorporated herein by reference.
By steel wire fibers or elements with hook-shaped ends is to be understood, on the one hand, steel wire fibers with L-shaped or bent ends, such as described, for example, in Dutch patent 160,628, and, on the other hand, steel wire fibers with Z-shaped ends, such as described in Bekaert specifications AS-20-01 and AS-20-02. In what follows, steel wire fibers with L-shaped and Z-shaped ends are described in greater detail in the sections specifically dealing with the figures.
An important aim of adding steel wire fibers to concrete is to improve the bending strength of the steel fiber reinforced concrete. The determination of the bending tensile strength, the bending strength and the equivalent bending tensile strength of steel fiber reinforced concrete is described in Dutch Recommendation 35 of the Civil-Technical Center for the Implementation of Research and Regulations (in brief, CUR35) and in the Belgian standards NBN B15-238 and NBN B15-239.
With the addition of steel wire fibers to concrete, it has been found that the bending strength and the equivalent bending tensile strength increase considerably with increasing amounts of steel wire fibers.
One disadvantage of this, however, is that the cost price of the steel fiber reinforced concrete thus obtained increases with the increasing amounts of steel wire fibers. It is for this and other reasons that many new types of steel wire fibers have been developed with a great variety of different possible embodiments in which the aim has always been to obtain an equal improvement of the technical characteristics of the steel fiber reinforced concrete with the addition of smaller amounts of steel wire fiber to the concrete.
One important group of steel wire fibers that gives rise to a considerable improvement of the technical characteristics of the steel fiber reinforced concrete thus obtained is the group of steel wire fibers having hook-shaped ends, such as already mentioned above.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the invention to provide a new type of steel wire element in which the technical characteristics of the steel fiber reinforced concrete thus obtained are even further improved, or in which it is possible to lower the cost price of the steel fiber reinforced concrete thus obtained due to the fact that the desired technical characteristics of the steel fiber reinforced concrete can be obtained with the addition of smaller amounts of steel wire elements to the concrete.
For this purpose, the invention proposes a steel wire element of the type mentioned in the introduction in which the middle portion of the steel wire element displays a substantially circular cross-section over essentially its entire length and in which the hook-shaped ends of the steel wire element are deformed by flattening.
It should be noted that the idea of flattening the steel wire fibers over their entire length is already known from Japanese patent 6-294017 (deposited for examination on Oct. 21, 1994). From German patent G9207598 the idea is also already known of flattening only the middle portion of a steel wire fiber with hook-shaped ends. Furthermore, from U.S. Pat. No. 4,233,364 the idea is already known of using straight steel wire fibers without L or Z hook-shaped ends: the ends of these fibers are flattened and provided with a flange in a plane essentially perpendicular to the flattened ends.
Each one of Japanese Patent No. 6-294017, German Patent No. G 9207598, and U.S. Pat. No. 4,233,364 is incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in further detail in the following description on the basis of the accompanying drawing.
In the drawing:
FIG. 1 shows in perspective a first embodiment of a steel wire element according to the invention, in which the Z-shaped ends are flattened in a plane which is parallel with the plane of the wire element,
FIG. 2 shows in perspective a second embodiment of a steel wire element according to the invention, in which the Z-shaped ends are flattened in a plane perpendicular to the plane of the wire element,
FIGS. 3a and 3b show in perspective two variants of a third embodiment of a steel wire element according to the invention, in which the Z-shaped ends are flattened in a plane perpendicular to the plane of the wire element, but with a degree of flattening that varies over the length of the flattened ends,
FIGS. 4 through 7 are longitudinal cross-sections of four different embodiments of steel wire elements with L-shaped ends.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a first embodiment of a steel wire element or fiber 1 according to the invention. The fiber 1 consists of a middle portion 2 and Z-shaped ends 3. The Z-shaped ends 3 are obtained by bending, or crimping, the original ends of length 1 at an angle α to a crimping depth of h. The fiber 1 consists preferably of drawn steel wire, and the diameter of the fiber 1 can vary from 0.2 mm to 1.5 mm, depending on the use to which the steel wire fiber is being put. The length of the middle portion 2 is preferably equal to between 20 and 100 times the diameter of the fiber.
According to the invention, the middle portion 2 of the fiber 1 shows a substantially circular cross-section over essentially its entire length and the hook-shaped ends 3 of the fiber 1 are deformed by flattening. With the embodiment shown in FIG. 1, the Z-shaped ends 3 are flattened in the plane of the drawing or in a plane which is parallel with the plane of the wire element.
At least a portion 4 of the hook-shaped ends 3 of fiber 1 immediately adjacent middle portion 2 may be deformed by flattening, as shown in this embodiment and the other embodiments described in detail below. A tip or outer free end 5 of Z-shaped ends 3 may be deformed by flattening as shown in this embodiment and the others described below.
The cross-section of the flattened ends 3 can be substantially rectangular or ovular in shape. Hence the ends 3 of a wire element 1 having a substantially circular cross-section with a diameter of 1.05 mm can be flattened to a rectangular cross-section with a breadth of roughly 0.65 mm and a height of 1.33 mm. By degree of flattening is meant here the ratio of the original diameter to the breadth of the rectangular cross-section or the small axis of the oval-shaped cross-section. In the aforementioned example, the degree of flattening is 1.05: 0.65=1.62. It has been determined that the degree of flattening is preferably greater than 1.10 and less than 3.50. With too low a degree of flattening, the enhancement of the bending strength of the steel fiber reinforced concrete is less great; this is also the case with too high a degree of flattening and, moreover, great deforming forces are needed to obtain the desired degree of flattening. In the embodiment of the wire element 1 shown in FIG. 1, the degree of flattening of the flattened ends 3 is essentially constant over their entire length.
FIG. 2 shows a second embodiment of a steel wire element 1 according to the invention. The difference between the embodiment shown in FIG. 1 and the embodiment shown in FIG. 2 consists in the fact that in the second instance the Z-shaped ends 3 are flattened in a plane perpendicular to the plane of the wire element 1.
FIG. 3a shows a first variant of a third embodiment of a steel wire element 1 according to the invention, in which the Z-shaped ends 3, just as in FIG. 2. are flattened in a plane perpendicular to the plane of the wire element 1. but in which the degree of flattening of the flattened ends 3 varies over their length.
FIG. 3b shows a second variant of the third embodiment, in which the degree of flattening of the flattened ends 3 varies over their length. The degree of flattening is smaller at the bending points or bends of the Z-shaped ends 3 than in the immediately adjacent portions of the bends.
FIGS. 4 through 7 show longitudinal cross-sections of four different embodiments of steel wire elements 1 with L-shaped ends 3.
FIG. 4 shows a fourth embodiment of a steel wire element 1 according to the invention. The difference between the embodiment shown in FIG. 1 and the embodiment shown in FIG. 4 consists in the fact that the Z-shaped ends 3 are now replaced by L-shaped ends 3, in which the L-shaped ends 3 are bent in opposite directions.
FIGS. 5, 6 and 7 show further embodiments of steel wire elements 1 with flattened L-shaped ends 3, in which, however, the flattened L-shaped ends 3 are provided with additional end structures to further increase the bonding in the concrete. It is clear that numerous other variants are also possible within the scope of the invention.
The invention will now be further explained on the basis of the tests that have been carried out on four different types of steel wire fibers 1 with Z-shaped ends. The four types are: basic type B or steel wire fiber with Z-shaped ends (non-flattened) according to the prior state of the art; type T1: steel wire fiber according to FIG. 1; type T2: steel wire fiber according to FIG. 2; type T3: steel wire fiber according to FIG. 3b.
The most important mechanical properties of the four types of fibers are shown in Table 1:
TABLE 1______________________________________dia- length tensilemeter L strength α l h(mm) (mm) (Newton/mm.sup.2) degrees (mm) (mm)______________________________________B 1.05 49 1180 40-50 2.1 2.0T1 1.05 51 1100 40-50 2.1 2.3T2 1.05 51 1100 40-50 2.5 2.0T3 1.05 51 1100 50-60 2.4 2.1______________________________________
the values reported here are the average values of 10 measurements.
length L is the total length of the fiber (in mm).
diameter d: the nominal wire diameter in mm.
tensile strength of the straight middle portion in N/mm 2 .
α: the angle at which the wire element 1 is bent.
l: the length in mm of the bent ends.
h: the crimping depth in mm.
the degree of flattening of types T1 and T2 is approximately 1.62 and is constant over the entire length; the degree of flattening of type T3 is also 1.62 on average, though it varies over the length.
Concrete test beams (length L=500 mm, height H=150 mm, breadth B=150 mm) were formed with fiber amounts of 20, 30, 40 and 50 kg/m 3 for each type of fiber and then subjected to a four-point stress test as described in CUR 35 or the NBN B15-238 and NBN B15-239 standards.
The testing conditions for the test beams are: test basis L=450 mm and l=150 mm. The equivalent bending tensile strength fe 300 (with deflection j=1.5 mm) (in N/mm 2 ) is given below in Table 2, in which n indicates the number of test beams per type and amount. The increase of the equivalent bending tensile strength fe 300 (j=1.5 mm) for types T1, T2 and T3 in relation to the basic type B is given in each case as a % (in parentheses).
TABLE 2______________________________________Fibers(kg/mm.sup.3) B T1 T2 T3______________________________________20 2.2 2.3 (+5%) 2.6 (+18) 2.6 (+18) (n = 6) (n = 6) (n = 6) (n = 6)30 2.9 2.9 (0) 3.3 (+14) 3.6 (24) (n = 5) (n = 6) (n = 6) (n = 5)40 3.2 3.6 (13) 3.9 (22) 4.2 (31) (n = 6) (n = 6) (n = 6) (n - 6)50 3.8 4.0 (5) 4.4 (16) 5.0 (32) (n = 6) (n = 6) (n = 6) (n = 6)______________________________________
The test results in Table 2 clearly indicate that the equivalent bending tensile strength fe 300 (j=1.5 mm) increases considerably with steel wire elements (types T1, T2 and T3) according to the invention. This means that to obtain a particular equivalent bending tensile strength in a steel fiber reinforced concrete construction--as, for example, a concrete floor--it will suffice to add a smaller amount of steel fibers according to the invention to the concrete.
It can further be concluded from the test results that the type T2 steel wire fibers produce better results than the type T1 fibers, and that the type T3 fibers produce still better results than the type T2 fibers.
While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, uses and/or adaptations of the invention following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention and of the limits of the appended claims.
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Steel wire element for mixing into subsequently hardening soft materials includes hook-shaped ends and a middle portion the length/diameter ratio of which is between 20 and 100. The middle portion of the element displays a substantially circular cross section over essentially its entire length and the hook-shaped ends of the element are deformed by flattening.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application Ser. No. 12/855,426 filed Aug. 12, 2010, the disclosure of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an electronic color display comprising a color filter. The invention further relates to an electronic device comprising an electronic color display provided with a color filter.
[0004] 2. Description of the Related Art
[0005] An embodiment of an electronic display provided with a color filter is known from WO2007/063440. The known electronic display comprises a display effect layer, which may be arranged to reflect or to emit light with a broad spectrum (white light) over which a color filter layer is superposed. The color filter layer is arranged to change the white light into colored light by intercepting specific wavelengths. The display effect layer and the color filter layer need to be properly aligned, for example to prevent parallax or aperture problems.
BRIEF SUMMARY OF THE INVENTION
[0006] In some instances, a compromise between brightness and color saturation has to be made in color displays. Display effects such as reflective electrophoretic or reflective/transmissive LCD enable good black and white brightness. Color is usually implemented by combining these black and white displays with an array of color filters. In order to produce saturated colors, the color filters need a substantially high absorption for wavelengths of a different color. This may decrease the brightness of white by 50-70% compared to the original black/white pixel brightness.
[0007] Handheld, display-based devices, such as e-readers, mobile phones, PDA's, or the like are used for a great variety of applications. For reading, usually a black and white display is preferable, while for picture or graphics viewing, a full-color display may be needed. In addition, the display has to have sufficient brightness and/or contrast for a variety of ambient lighting conditions, for example for an indoor and outdoor use.
[0008] It is an object of at least one invention contemplated herein to provide a color display enabling substantially optimized brightness and/or contrast for a variety of ambient lighting conditions and/or use modes.
[0009] To this end the electronic color display according to one contemplated invention comprises a color filter arranged with a plurality of color filter elements, said color filter being overlaid on an illuminating area of the display, said illuminating area being arranged to emit, transmit or reflect light in a range of wavelengths, wherein respective transmission of the color filter elements is adjustable.
[0010] The technical measure of one contemplated invention is based on the insight that by allowing a purposeful adjustment of the transmission of a color filter element either transmission of part of the said range of wavelengths, or transmission of substantially the full said range of wavelengths may easily be enabled in a reproducible way.
[0011] The technical measure of one contemplated invention is based on a further insight that by providing the filter elements of the color filter with adjustable transmission, preferably with adjustable transmission and saturation, the electronic display properties, like brightness and/or contrast and/or saturation do not have to be optimized for a given application, but, instead, these display properties may be tuned on demand based upon a currently used application or ambient conditions.
[0012] In accordance with one contemplated invention respective transmissions of the color filter elements are modified for a selected wavelength or wavelengths. Such modification or adjustment may be carried out pursuant to an envisaged utilization mode of the device, or pursuant to ambient parameters, like ambient lighting conditions.
[0013] In particular, the illumination unit may be arranged to produce white or black pixels. The illumination unit may relate to a reflective active-matrix display, although this embodiment is not limiting. The filter elements of the color filter may advantageously be arranged to enable high or maximum transmission to wavelengths corresponding to a substantially white spectrum. In this way displaying of a black/white picture is enabled. It will be appreciated that grey shades are seen as intermediate levels between black and white. Alternatively, when the pixels of the color filter are adjusted to enable high or maximum transmission only for part of the visible-light spectrum, for example, for red, blue or green color, a colored displaying mode is enabled. As a result, a versatile color display is provided, which has optimum brightness or, optionally optimum brightness and contrast, in particular for black and white displaying. Furthermore, it is noted that the lowest reflectance in black can be obtained by displaying black using the illumination unit and switching the pixels of the color filter to pass only part of the visible-light spectrum, thereby roughly reducing the overall black reflectance by a factor of three. However, for this black level to be used in conjunction with other shades of grey or colors, the color filter pixels need to be individually addressable.
[0014] In an embodiment of the color display according to one contemplated invention the color filter comprises an array of switchable elements, the switching state of these elements determining the part of the visible-light spectrum that is transmitted by the switchable elements.
[0015] It is found to be particularly preferable to provide the color filter with filter elements operating using the electrowetting principle, because in this way a substantially instantaneous and independent adjustment of the filter elements is possible. Implementation of red, blue or green filter elements may be provided by using respectively colored liquids arranged within such filter elements. The principle of electrowetting is known in the art. An example of an apparatus arranged with actuatable fluid is known from US 2007/0243110.
[0016] It will be appreciated that although in the US 2007/0243110 reference is made to a macroscopic device, manufacturing of a filter array comprising substantially microscopic filter elements operating using the electrowetting principle lies within ordinary skill of the artisan. However, it will be appreciated that for enabling operating of the adjustable filter elements filled with the actuatable fluid, each cell comprising the actuatable fluid should have electrodes fed by a power supply. The power supply, electrically connected to a common unpatterned electrode, may be controllable by a suitable processor for setting a desired voltage across the cell for altering spatial filling of the cell by the actuatable fluid. More details on this embodiment will be presented with reference to FIG. 3 a.
[0017] In a further embodiment of the color display according to one contemplated invention the illuminating area is arranged with black and white pixels, the filter elements of the color filter dimensionally correspond to and are aligned with said black and white pixels.
[0018] It is found to be advantageous that the elements of the color filter correspond to the pixels of the illumination area. In this way a one-to-one translation of envisaged display mode requirements to suitable filter characteristics can be made.
[0019] In a particular embodiment color display brightness and/or resolution of the color display are adjustable.
[0020] It is found that the respective resolutions of the display and the controllable color filter comprising color filter elements do not have to be the same. For example, should the resolution of the display be 2 times higher in x- and y-directions than the resolution of the color filter, in the color mode, such difference in resolution may be used to generate extra colors and/or adjust brightness. Should the resolution of the color filter be higher than the resolution of the display, this difference may be used to optimize use of the white channel in color mode.
[0021] In a still further embodiment of the color display according to one contemplated invention the color filter comprises a first display portion and at least a second display portion, the filter elements of the first display portion and the at least second display portion being controlled independently from each other.
[0022] It is found to be advantageous instead of having one area to provide a suitable plurality of such areas. This may result in enabling different settings with respect to color saturation and brightness for different areas of the color filter. Such functionality may be advantageous, for example, when different viewing areas of the display have different purposes. Such embodiment may be enabled by replacing the unpatterned common electrode in the switchable filter element stack by two or more patterned electrodes. In this case a provision of a suitable plurality of independent power sources may be required. This embodiment is discussed in further details with reference to FIG. 3 c.
[0023] In a still further embodiment of the color display according to one contemplated invention a substrate has a display counter electrode for controlling the illumination area and a color filter electrode for controlling the color filter, the display counter electrode and the color filter electrode being joined. This feature has an advantage that by choosing a suitable material for a substrate layer normally separating the display counter electrode and a color filter electrode, said electrodes may be joined. As a result the overall brightness of the illumination unit may increase. This feature will be further discussed with reference to FIG. 1 .
[0024] In a still further embodiment of the color display according to one contemplated invention the illumination area comprises an array of transmissive elements.
[0025] It is found to be advantageous to combine the color filter with an illumination unit having a transmissive display effect. In this case the color filter may be combined either with a backlight, or with reflective pixel pads. For such arrangements, it is possible to position the color filter in front of the illumination unit, or between the illumination unit and backlight or reflection layer.
[0026] One contemplated invention further relates to an electronic portable device comprising an electronic color display as is described with reference to the foregoing. The electronic portable device relates, by way of example, to a mobile phone, an e-reader, an organizer, a palm-top or the like. Advantageously, the color display may be settable in a first mode and in a second mode, wherein said transmission for the selected wavelength and for said wavelength range may be adjustable based on the first mode and the second mode. Preferably, the first mode corresponds to a reading mode and the second mode corresponds to a picture viewing mode. In an exemplary case, said first mode is arranged for enabling monochromic displaying, said second mode is arranged for enabling polychromic displaying.
[0027] For example, for e-reading, the color display may be set into a high-resolution, high-brightness monochrome mode. For picture viewing, the display can be put in color mode. In the color mode, color saturation may be increased while somewhat decreasing brightness. Mode selection of the display may be carried out by a single power source to which the display is connected. It will be appreciated that the illumination unit may comprise electrophoretic material and may be driven in accordance with conventional driving used for actuating an electrophoretic display.
[0028] These and other aspects of the invention will be discussed in further detail with reference to drawings, wherein like reference signs represent like elements. It will be appreciated that the drawings are provided for illustrative purposes only and may not be used for limiting the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The appended claims set forth the features of the present invention with particularity. The invention, together with its objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:
[0030] FIG. 1 presents schematic cross-sectional views of an embodiment of a color display provided with an adjustable color filter according to the invention;
[0031] FIG. 2 is an illustrative depiction of an embodiment of an electronic device incorporating a color display according to the invention;
[0032] FIG. 3 a presents a schematic view of an embodiment of a color display according to the invention provided with a single power source for switching the filter elements;
[0033] FIG. 3 b schematically depicts a top view of the electrodes 1 a and 2 b (of FIG. 3 a ) required for implementing such operation of the device; and
[0034] FIG. 3 c schematically depicts an embodiment of a color display according to the invention provided with a plurality of power sources adapted for switching filter elements in different areas of the display separately.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
[0036] FIG. 1 presents a schematic view of an embodiment of a color display provided with an adjustable color filter according to an embodiment of the invention. The color display 15 according to the embodiment comprises an illumination unit 14 implemented as a display feature comprising a lower substrate 3 provided with a suitable pixel pad 4 arranged to control suitable electrophoretic capsules 5 . The electrophoretic capsules 5 comprise, for example, charged white particles 5 a and black particles 5 b dispersed in a clear fluid (or white particles dispersed in for example black or colored fluid, not shown) and may be arranged to operate in a reflective way. In order to actuate the electrophoretic capsules the illumination unit 14 comprises a display counter electrode 2 a arranged on a further substrate 2 , wherein a suitable actuation voltage may be applied between electrodes 4 and 2 a. In accordance with the illustrative embodiment the illuminating unit 14 is overlaid with a color filter arranged with a plurality of color filter elements 16 a, 16 b, 16 c, wherein respective transmissions of the color filter elements 16 a , 16 b, 16 c are adjustable to allow either transmission for a selected wavelength emanating from elements 7 b, 8 b, 9 b in said range of wavelengths, or transmission for a number of or all the wavelengths from said range of wavelengths.
[0037] In the illustrative embodiment of the color display 15 , the color filter comprises an array of filter elements 16 a, 16 b, 16 c comprising respective fluids 7 b, 8 b, 9 b, wherein said fluids are actuated using electrowetting principle using among others suitable control means 7 a, 8 a, 9 a arranged for implementing the electrowetting principle. Preferably, the color filter 16 is arranged with basic red-green-blue filters, which may be implemented by providing suitably colored oil 7 b, 8 b, 9 b in a suitable coupling medium 17 , for example water, which may at least partially fill respective color filter elements 16 a, 16 b, 16 c. In order to actuate the color oils, the color filter comprises a filter counter electrode 1 a arranged to apply a suitable actuating voltage on a wall of the filter element corresponding to the filter elements 16 a, 16 b, 16 c. The filter counter electrode 1 a is preferably positioned on a still further substrate 1 . Finally, the color display 15 may comprise a black matrix 6 arranged either on top of the substrate 1 as shown in FIG. 1 or on the bottom side of the substrate 1 (not shown). An embodiment of an actuation mode of the color filter will be discussed with reference to views 10 a, 10 b and 10 c.
[0038] In view 10 a an actuation mode is shown wherein the color filter elements are set for allowing high or maximum transmission to a wide range of light wavelengths emanating from the illumination unit 14 . By way of example, substantially whole white light spectrum is transmitted. For this purpose a first actuating voltage is applied to the respective walls of the color filter elements 16 a, 16 b, 16 c so that the colored oil is substantially limited to an area below the black matrix 6 . The actuation voltage may be applied between the electrodes 2 b and 1 a . It will be appreciated that the colored oil 7 b, 8 b , 9 b may be fed to the respective pixels from corresponding reservoirs. It is possible that, alternatively, the filter elements 16 a, 16 b, 16 c are actuated in such way that the respective colored oils are transported away from the filter elements 16 a, 16 b, 16 c towards the reservoir.
[0039] A corresponding image resulting from such actuation mode may be represented by a series of black and white pixels 11 a, 11 b, 11 c. It can also represent grey tones. This image may have high resolution, high brightness and is substantially monochrome, which may correspond to a reading mode of the color display 15 .
[0040] In view 10 b a further mode is given, wherein the filter elements 16 a, 16 b, 16 c are actuated in such way that the respective color oils 7 b, 8 b, 9 b partially cover respective area of the color filter elements. A corresponding image is represented by a series of polychrome pixels 12 a, 12 b, 12 c which may have a normal resolution, medium brightness and medium color saturation. The color of the pixels 12 a, 12 b, 12 c correspond to the color of the respective liquids, for example oils 7 b, 8 b, 9 b. Those skilled in the art would readily appreciate, in view of the disclosure pateherein, which class of liquids is suitable for electrowetting.
[0041] In view 10 c a still further mode is given, wherein the filter elements 16 a, 16 b , 16 c are actuated in such way that respective area of the color filter elements are fully filled with the respective color oils. The resulting image is represented by a sequence of pixels 13 a, 13 b, 13 c which may have normal resolution, low brightness and high color saturation.
[0042] It will be appreciated that instead of providing non-patterned electrodes 2 b and 1 a , either one of the electrodes may be patterned resulting in different portions of the color filter having different settings, for example with respect to color saturation and brightness. In this way, however, each filter portion must have its own power source. This further embodiment is discussed in further detail with reference to FIG. 3 c.
[0043] In addition or alternatively, the substrate 2 may be arranged for joining electrodes 2 a and 2 b. Omission of one electrode layer may result in an increase of an overall brightness.
[0044] It will be appreciated that the color display 15 , instead of using display effect based on electrowetting effect, other display effects may be used, like for example a display effect based on Ch-LC (Cholesteric Liquid Crystal), GH-LC (Guest-Host Liquid Crystal), based on PDLC (Polymer Dispersed Liquid Crystal) or based on MEMS (Micro Electro-Mechanical Systems).
[0045] FIG. 2 presents an embodiment of an electronic device according to an illustrative example of the invention. The electronic device 20 comprises a housing 22 and a retractable, notably wrappable display 25 , preferably arranged on a rigid cover 22 a. The display 25 is provided with the adjustable color filter as is described with reference to the foregoing. The display 25 may be arranged in accordance with the embodiment described with reference to FIG. 1 . Alternatively, the display 25 may be arranged with other suitable means to enable due adjustment of the filter elements transmission for one or more wavelengths. The rigid cover 22 a may be arranged to be wound together with the display 25 around the housing 22 to a position 21 a. The rigid cover 22 a may comprise an edge member 23 provided with rigid areas 23 a and flexible areas 24 a, 24 b cooperating with hinges 26 a, 26 b of the cover 22 a. When the display 25 is being retracted to the position wound about the housing 22 , the surface of the display 25 may abut the housing 22 . Preferably, the housing 22 or display 25 comprise means (not shown) for enabling selection of the mode for controlling transmission settings of the individual color filter elements for providing optimum viewing mode with regard to at least brightness and resolution. Selection of the viewing mode can be on the initiative of the user or it can be coupled to metadata of the image to be displayed. Alternatively, if no metadata is available, the properties of the image to be displayed can be determined by image analysis or be controlled by the application (computer program executing on the device 20 ) that is used to render the image. It will be appreciated that instead of a wrappable display the electronic apparatus may comprise a rollable display, so that the flexible display 25 is arranged to be rolled over a suitable roller upon storage, preferably inside a portion of a housing, or a rigid display, arranged on the outside of a device housing.
[0046] FIG. 3 a schematically presents an embodiment of a color display according to an embodiment of the invention provided with a single power source for switching the filter elements.
[0047] The color display 15 , according to an aspect of the illustrative embodiment of the invention, is arranged for enabling a unified response from all filter elements 16 a, 16 b , 16 c, as the respective actuatable fluids 7 b, 8 b and 9 b are controlled by a common power supply 30 via the respective control means 7 a, 8 a and 9 a. When a trigger voltage is provided across a cell corresponding to liquids, using electrodes 1 a and 2 b, respective spatial distribution of the actuatable fluids across the filter elements 16 a, 16 b, 16 c may be changed, see views 10 a, 10 b and 10 c presented in FIG. 1 .
[0048] It will be appreciated that other items depicted in FIG. 3 a may be substantially the same as items discussed with reference to FIG. 1 . Accordingly, respective electrophoretic capsules 5 may comprise charged white particles 5 a and black particles 5 b dispersed in a clear fluid (or white particles dispersed in for example black or colored fluid, not shown) and may be arranged to operate in a reflective way. In order to actuate the electrophoretic capsules the illumination unit 14 comprises a display counter electrode 2 a arranged on a further substrate 2 , wherein a suitable actuation voltage may be applied between electrodes 4 and 2 a. In accordance with the invention the illuminating unit 14 is overlaid with a color filter arranged with a plurality of color filter elements 16 a, 16 b , 16 c, wherein respective transmissions of the color filter elements 16 a, 16 b, 16 c are adjustable to allow either transmission for a selected wavelength emanating from elements 7 b, 8 b, 9 b in said range of wavelengths, or transmission for a number of, or all, the wavelengths from said range of wavelengths. FIG. 3 b schematically presents a top view of the electrodes 1 a and 2 b required for implementing such operation of the device.
[0049] FIG. 3 c presents in a schematic way an embodiment of a color display according to the invention provided with a plurality of power sources adapted for switching filter elements in different areas of the display separately. In this embodiment instead of having one electrode area as shown in FIG. 3 b a plurality of electrode areas is patterned, 101 a, 101 a ′, 101 a ″, 101 a ″″. The bottom electrode 2 b may be left common for all filter elements 16 a, 16 b, 16 c.
[0050] In order to implement regional switching, each patterned electrode 101 a, 101 a ′, 101 a ″, 101 a ′″ is connected to a dedicated power source 30 a, 30 b, 30 c, 30 d. each of such power sources is arranged to apply a control voltage between an unpatterned bottom electrode 2 b and a respective patterned sub-electrode 101 a, 101 a ′, 101 a ″, 101 a ″′. Such functionality is advantageous as it supports area-related switching of the display, allowing for presenting information on specifically designated display areas. For example, one area may be designated for control menu's, while another area may be designated for reading, e-mailing and so on.
[0051] Such sub-areas may even enable definition of different settings with respect to color saturation and brightness for different areas of the color filter. Such functionality may be advantageous, for example, when different viewing areas of the display have different purposes.
[0052] It will be appreciated that although specific embodiments of the color display and the electronic apparatus according to the invention are discussed separately for clarity purposes, interchangeability of compatible features discussed with reference to isolated figures is envisaged.
[0053] It will further be appreciated that in the present application the following terms shall have the following meaning:
[0054] “illuminating area” relates to a reflective, emissive and/or transmissive area of a display;
[0055] “brightness” relates to luminance in an emissive or backlit transmissive display; and reflectance in a reflective display;
[0056] “selected wavelength” relates to a part of the visible-light spectrum; can be associated with a certain color;
[0057] “filter element” relates to an element that passes selected wavelengths and suppresses other wavelengths.
[0058] While specific embodiments have been described above, it will be appreciated that the invention may be practiced otherwise than as described. The descriptions above are intended to be illustrative, not limiting. Thus, it will be apparent to one skilled in the art that modifications may be made to the invention as described in the foregoing without departing from the scope of the claims set out below.
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A color display and an electronic apparatus including the color display are described herein. The color display includes a first substrate having an illuminating area, a color filter unit, a plurality of power sources and a colored fluid. The color filter unit has a first and second electrode on the illuminating area, wherein the first electrode includes a plurality of patterned electrodes. Each of the patterned electrodes of the first electrode is connected to one of the power sources, whereby different voltages are applied on the patterned electrodes. The colored fluid disposed between the first and second electrodes and partially covering the surface of the illuminating area, wherein a covered area of the illuminating area by the colored fluid is controlled by the voltage applied on the first and second electrodes
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This is a division of application Ser. No. 589,493 filed Mar. 14, 1984.
FIELD AND BACKGROUND OF THE INVENTION
This invention relates in general to sewing machines and in particular to a new and useful sewing machine having a magazine containing a plurality of separate thread supply needles in needle holders which may be selectively coupled and decoupled to a needle bar.
A thread changing mechanism is disclosed in the German OS No. 29 27 142. This mechanism, intended for small embroidering machines having a plurality of needle bars, provides for each needle bar a magazine which is displaceable in its longitudinal direction, transversely to the longitudinal axis of the needle bar. The magazine accommodates a plurality of needle holders, each carrying a needle, with only one of these holders of the magazine being operable to the needle bar at a time. To change the thread, the embroidering machine must be stopped and the needle bar is lifted above its upper dead center position, whereby the needle holder just connected to the needle bar is retracted into its magazine and thereby uncoupled from the needle bar. As soon as needle bar at the end of this lifting motion has entirely been withdrawn from the magazine, the magazine is displaced and the next needle holder needed for the embroidering operation is brought into a standby position. The needle bar is then lowered again whereby it is coupled to the new needle holder.
Since the regular working stroke of the needle bar is extended by the additional lifting, the total height of displacement is relatively very large and requires correspondingly spaced apart bearings. Further, since another drive, different from the normal one for the working stroke, is needed for the additional lifting of the needle bar, the supporting structure of the needle drive enlarges to dimensions which call for an accommodating housing correspondingly voluminous. This does not raise problems in a development of an embroidering machine, where the size of the housing can easily be adapted. Great difficulties would be encountered however, with an attempt to proceed similarly in connection with a conventional sewing machine.
SUMMARY OF THE INVENTION
The invention is directed to a thread changing mechanism occupying such a small space that it can be used not only in embroidering machines, but also in conventional sewing machines.
By providing that the needle holder is coupled to, or uncoupled from, the needle bar by vertically moving the magazine in which the needle holders are received and that when the magazine is moved from its transfer position laterally into a rest position, the thread changing mechanism can be used particularly also for sewing machines having normally driven needle bars, in being sure that the magazine will not hinder the motion of the wheel holder coupled to the needle bar.
The invention includes an arrangement for effecting a positive and thus accurate and safe connection between the needle holder and the needle bar.
In accordance with the invention, the sewing machine includes a reciprocating needle bar which cooperates with a rotary hook and includes a mechanism for stopping the needle bar in a selected position for example a top dead center position and for moving a magazine into association with the needle bar to remove the previous needle holder and its associated thread, and to position a new holder with its associated thread into coupled engagement with the needle bar and which will be operated therewith while the remaining threads are maintained out of operative positions. The magazine is advantageously supported on a slide which moves along a line which is parallel to the reciprocation plane of the needle bar so as to position a selective needle holder in alignment with the bar. The holder is shifted into engagement with the bar by a mechanism which moves the magazine to a position in which the holder becomes engaged with a coupling which automatically positions it in respect to the needle bar for reciprocation therewith. A replacement needle holder is advantageously inserted with the needle in the top dead center position which is determined by movement of a locking lever into engagement with a notch on a locking wheel. The magazine itself includes a support and holding plate which has an edge with a plurality of notches of a number comparable to the number of needle holders which are to be engaged therein. The plate is movable with the needle holders after a selected needle holder is aligned with the needle bar. Coupling of the needle holder with the needle bar is effected by directing a pin-like extension of the needle bar into the hollow needle holder while engaging a locking sleeve associated with the needle bar so as to move it against a biasing force and cause a ball locking coupling to move to a position in which balls retained in radial recesses thereof engage in a locking groove formed on the pin of the needle bar.
With the exception of providing a circular groove at the end of the needle bar, the design and operation of magazines do not require any further adaptation or change in an embroidering or sewing machine. In consequence, the inventive mechanism is particularly suitable also for being mounted on a sewing machine subsequently, or sewing mechanism provided for other purposes may inexpensively be equipped with the inventive mechanism.
The needle holders are advantageously made hollow and include a receiving bore and a spring loaded locking bolt which is biased upwardly and compressed when coupling is effected. During uncouplng the bolt moves upwardly and causes balls which are positioned in a locking groove of the needle bar to move outwardly into a receiving groove defined in a locking sleeve which surrounds the hollow holder. The sleeve is urged by a compression spring upwardly against a retaining holder but may be moved downwardly by engagement of a obtaining ring of the sleeve in a groove of the holding plate of the needle holder magazine.
The arrangement secures a position of the balls upon uncoupling a needle holder, so that they cannot fall out of the cross bores. During the coupling of the needle holder, as soon as the locking bolt is pushed back, by butting against the needle bar end, the carrier and the locking sleeve are further retained by the pressure lever resiliently applying against the lower end of the carrier, in connection with the magazine recess receiving the locking sleeve, in the position holding the balls in the uncoupling position, so that the needle holder can be fully engaged on the needle bar end. Then, the spring biased locking sleeve is released by moving the magazine horizontally transversely from its transfer position into its rest position, and moves into the coupling or locking position in which the locking extension urges the balls into the circular groove of the needle bar. It is advantageous in this connection to provide the presser levers in a length ensuring that they leave the zone of the carrier only after the locking sleeve has reached its coupling or locking position.
Spring loaded clamping levers prevent the needle holders received in the magazine from falling out and clamp the thread extending from the needle of the respective needle holder to the thread supply, between the locking sleeve and the wall of the recess in the magazine. In this way, the threads which do not participate in the stitch formation are prevented from unthreading.
Catching levers hold the portions of the non-participating threads extending between the conventional thread tensioning device and the clamping locations, in a biased position so that the respective thread guide fingers of the take-up lever can move therealong without pushing them up or off. In this way, the threads not participating in the stitch formations are prevented from tangling individually or with each other.
A stop plate, movable along with the magazine in the longitudinal direction thereof is a particularly simple device for controlling the thread catching levers, requiring no drive.
The needle bar, which has been stopped by a needle positioning device known per se, in its upper dead center position within a tolerance zone of a few degrees of angle, can be moved into the dead center position exactly, so that the coupling and uncoupling of the needle holder can be effected safely and accurately. At the same time, the mechanism is secured against unintentional rotation of the arm shaft, whereby other casual damages to the thread changing mechanism and/or the needle bar are avoided.
Accordingly it is an object of the invention to provide an improved sewing machine which has a magazine for a plurality of needle holders with needles which are separately connected to a thread supply and wherein the magazine may be moved relative to a reciprocating needle bar and positioned to engage the needle bar for removing a previously engaged needle holder, and subsequently move after realignment to a position in which a new needle holder is positioned therein which advantageously also includes means for engaging the thread of the needle holders which are retained in the magazine so that they do not interfere with the operation of the one which is permitted to be drawn up by the take-up lever of the operating machine.
A further object of the invention is to provide a drive for a sewing machine which has a magazine for exchanging needle holders which cooperate with a reciprocating needle bar and which includes a long shaft which drives the needle bar and a rotary hook drive shaft which drives the rotary hook cooperating with the needle and wherein the rotary hook shaft is provided with a locking wheel having a notch and which is arranged adjacent a locking lever which is pivotally mounted on the machine and which can be automatically operated to engage in the notch to stop the machine in a top stop dead center position for exchange of the needle holders.
A further object of the invention is to provide a needle thread guide mechanism which includes a stop plate which is mounted on a slide adjacent the needle bars and has a plurality of alternately arranged needle support sectors and slots defined along the top face thereof arranged alongside a guide finger for a thread supply for each needle, and including a thread catching lever for each needle of each needle holder pivotally mounted on the arm of the sewing machine adjacent the stop plate and the guide finger. The catching levers are each engageable in an operative position on a respective one of the sectors and with the thread sets of each needle from each thread supply and being engageable in an nonoperative position in a respective slot portion in which it lies out of the path of movement of its associated needle thread.
A further object of the invention is to provide a coupling mechanism for effecting the quick coupling decoupling of a needle holder to a reciprocating needle bar.
A further object of the invention is to provide a sewing machine having improved thread changing elements which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevation of a sewing machine equipped with the thread changing mechanism;
FIG. 2 is a sectional view taken along the line II--II of FIG. 1;
FIG. 3 is a perspective view of the take-up lever and the thread catching lever;
FIG. 4 is a partly sectional view of a needle holder received in the magazine, and
FIG. 5 is a partial top plan view of the magazine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, in particular the invention embodied therein comprises a sewing machine generally designated 1 which comprises a reciprocating needle bar 7 shown in FIG. 4 which is arranged alongside a slide 58 which is mounted for backward and forward movement adjacent the needle bar. A magazine 84 for a plurality of needle holders 11 is carried by the slide and it is also connected to means for shifting it vertically 77 carried by the slide 58 connected to the magazine 84. The magazine 84 has a holding plate 85 as shown in FIG. 5 with a recess or opening 86 for each needle holder arranged in a row along one side of the plate 85 and extending the direction of movement of the slide. The slide is moved selectively by slide moving means 59 in the form of multiposition cylinders so as to position a selected needle holder 11 in alignment with the needle bar 7. A cross slide 80 is mounted on the slide 58 for movement toward and away from the needle bar 7 for the purpose of advancing a selected needle holder either into or out of engagement with the needle bar 7.
The sewing machine has a housing 1 comprising a base plate 2, a post 3, and an arm 4 terminating with a head 5. A hollow needle bar 7 mounted in head 5 is driven in a manner known per se (not shown) by an arm shaft 6 which is supported in arm 4. Also mounted in head 5 is a take-up lever 8 forming a component part of a known take-up mechanism.
According to FIG. 4 a flanged pin 9 provided with a wedge-shaped nose 9' and a circular groove 10 is secured in the hollow of needle bar 7. A needle holder 11 is engaged on pin 9, substantially comprising a carrier 12 and an axially displaceable locking sleeve 13 embracing the carrier. Carrier 12 is provided with a notch (not shown) cooperating with nose 9' to secure needle holder 11 against rotation, and with a guard ring 14 limiting the movement of locking sleeve 13. Carrier 12 has an axial bore 15 in which pin 9 is received, and a priority of radial bores 15' each displaceably accommodating the ball 16. In the lower portion of ball 15, a locking bolt 17 is received for displacement and loaded by a compression spring 18. A set screw 19 partly screwed into locking bolt 17 projects into a vertically extending slot 20 of carrier 12. Carrier 12 is designed with a stop shoulder 21.
Locking sleeve 13 has inside an inwardly projecting lock ring portion 22 which is limited on one side by a shoulder 23 and on the other side by a circular groove 24. Externally, locking sleeve 13 is provided with an outwardly projecting ring 25. A compression spring 26 received between carrier 12 and sleeve 13 and bearing against shoulder 23 and stop shoulder 21 urges locking sleeve 13 upwardly against guard ring 14. In this position, lock ring portion 22 pushes balls 16, which have a diameter exceeding the wall thickness of carrier 12 in this area, into circular groove 10 of pin 9, so that needle holder 11 is positively locked to needle bar 7.
Carrier 12 is designed with a mount 27 for a third guiding needle 28. Needle 28 cooperates with a rotary hook known per se (not shown) which is driven through a shaft 29 mounted below base plate 2. Shaft 29 is driven from arm shaft 6 through a gear belt 30.
On the right hand end of arm shaft 6, a pulse transmitter 31 known per se is provided which is effective in connection with a positioning motor (not shown) driving the sewing machine, to stop the sewing machine in the top dead center position of needle bar 7. A locking wheel 32 is secured to shaft 29, having a wedge-shaped notch 33. Wheel 32 is associated with a locking lever 35 which is pivotable by an air cylinder 34 and has an end portion conformable to notch 33.
Further mounted in head 5 is a presser bar 36 engaging a presser foot 37. Presser foot 37 is connected to an oscillating drive 38.
Arm 4 supports a bracket 39 which is secured thereto and carries five thread tighteners 40. Thread tighteners 40 comprise each a threaded bolt 41 which is secured to the bracket 39 and carries two tension discs 42. The tension discs are pressed against each other by a compression spring 43. Compression spring 43 bears against a pressure disc 44 which is spaced apart from tension discs 42 by a distance determining the force of the spring 43 and variable by an adjusting nut 45. On two extensions 46 of bracket 39, a shaft 47 is mounted to which one support 48 for each of thread tighteners 40 is secured. A finger 49 is hinged to each of supports 48, and the angular position of the finger relative to support 48 is adjustable by a set screw 50. The free end of each finger 49 is forked and engaged between pressure disc 44 and adjusting nut 45 of the associated thread tightener 40. Secured to shaft 47 are further two levers 51, 52 of which one 51 is associated with a short-stroke cylinder 53 (FIGS. 1, 2) and the other lever 52 is associated with a short-stroke cylinder 54 (FIG. 1). The two short-stroke cylinders 53, 54 secured to bracket 39 have unequal pistons, so that the basic tension adjusted by means of adjusting nut 45 can be augmented in two steps.
A supporting plate 55 mounted on arm 4 and head 5 carries two side plates 56 which are secured thereto and support two horizontally extending, mutually parallel guide rods 57. A slide 58 is mounted for displacement on guide rods 57. Slide 58 is driven by a so called multiposition cylinder 59 comprising an angle bracket 60 secured to arm 4, and three individual air cylinders 61,62,63 aligned in series. The housing 64 of air cylinder 61 is secured to angle bracket 60 and the piston rod 65 thereof is connected to the housing 66 of air cylinder 62. Housing 66 is shiftable on angle bracket 60. The piston 67 of air cylinder 62 is secured to the housing 68 of air cylinder 63. Housing 68 is also shiftable on angle bracket 60. The piston rod 69 of air cylinder 63 is secured to an extension 70 of slide 58.
Air cylinder 61,63 have a stroke of 20 mm, air cylinder 62 has a stroke of 40 mm. By supplying the air cylinders individually, in groups, or all at the same time, slide 58 can be brought into five different positions, with the spacing of these positions being stepped by 20 mm.
Slide 58 is apertured at 71 and has two extensions 72 and carries two mutually parallel vertically extending guide rods 73 on which a U-shaped carrier plate 74 extending through aperture 71 is mounted for displacement. Carrier plate 74 is provided with a recess 75 which is opened toward head 5. Connected to carrier 74 is the piston rod 76 of an air cylinder 77 which is secured to an extension 78 of slide 58. Carrier plate 74 comprises two mutually parallel horizontally extending guide rods 79 on which a cross slide 80 is mounted for displacement. Cross slide 80 is connected to the piston rod 81 of an air cylinder 82 which is mounted on a plate 83 secured to carrier plate 74.
At the other side of cross slide 80, a magazine 84 for five needle holders 11 is mounted. Magazine 84 comprises a holding plate 85 which is secuted to the cross slide 80 and is provided with five recesses 86 which are open toward needle bar 7 and are slightly wider than the diameter of locking sleeve 13. The center to center spacing of two adjacent recesses 86 is 20 mm. The side walls of recesses 86 are provided with a a groove 87 having the shape and size of retaining ring 25 of locking sleeve 13. On the top of holding plate 85, adjacent each of the recesses 86, a hook-shaped clamping lever 89 is pivoted by means of a flanged bolt 88. At the needle bar side, lever 89 has an oblique face 90. Each of clamping levers 89 is associated with a torsion spring 92 which is fixed to holding plate 85 by a flanged screw 91 and urges the respective arm of clamping lever 89 toward a stop pin 93 which is secured to plate 85.
On a lug 94 of holding plate 85, a presser lever 95 is mounted below each of recesses 86. Presser levers 95 threaded and provided with a recess 96, to form a fork 97. Recess 96 is slightly wider than the diameter of mount 27 of needle holder 11. At its end facing needle bar 7, fork 97 is beveled at 98 and thus wedge-shaped. Adjacent recess 96, fork 97 is provided with a shallow recess 99 having a width corresponding to the diameter of stop shoulder 21 of lever holder 11. Each of presser levers 95 is associated with a compression spring 100 effective to bias the fork 97 of presser lever 95 to pivot upwardly.
Secured to side plates 56 (FIG. 1) is a U-shaped frame 101 supporting two downwardly extended web plates 102. Web plates 102 support a bolt 103 carrying five thread catching levers 104 which are mounted thereon for free pivoting and are equidistantly spaced from each other. Each of the thread catching levers 104 comprises a long catching arm 106 terminating with a hook 105, and a short switching arm 107. Pivoted to bolt 103 is further a U-shaped switching bracket 108 associated with switching arm 107. An arm 109 is secured to switching bracket 108, which is connected to the piston rod 110 of an air cylinder 111. Air cylinder 111 is mounted on frame 101 through an angled support 112.
Thread catching levers 104 are associated with a stop plate 113 which is secured to slide 58 and thus movable along therewith. Stop plate 113 has five vertically extending slits 114 having a width slightly exceeding that of catching lever 106. Slits 114 subdivide stop plate 113 into six sectors 115 of such widths that, depending on the instantaneous position of slide 58, always four thread catching levers 104 repose against a respective sector 115 and occupy the upper pivotal position shown in FIGS. 2 and 3. While only the thread catching lever 104 associated with the needle holder 11 which is coupled to needle bar 7 being engaged in one of slits 114 into which it dropped under its weight, and occupying the lower pivotal position shown in FIGS. 2 and 3.
The free end of take-up lever 8 is formed with five juxtaposed thread guiding fingers 116. The spacing between the fingers is about twice the width of a catching arm 106 of thread catching levers 104. Each thread guiding finger 106 is provided with a bore 117. Below take-up lever 8 five thread holding hooks 118 are mounte on the head 5.
The mechanism operates as follows:
According to FIG. 1, needle holder 11 at the left hand side is shown coupled with needle bar 7. The other four needle holders 11 are received in the respective recesses 86 of magazine 84 with retaining rings 25 being engaged in grooves 86. Presser lever 95 resiliently apply against stop shoulders 21. Locking bolts 17 are in their upper positions and press balls 16 into groove 24, whereby locking sleeve 13 is held fast in its uncoupled position and balls 16 are prevented from falling out of radial bores 15'. Clamping levers 89 which resiliently apply against locking sleeves 13 retain needle holders 11 firmly in recesses 86 and, at the same time, clamp the needle thread portions extending from needles 28 to take-up lever 8 between retaining rings 25 and the walls of recesses 86.
Slide 58 is held by multiposition cylinder 59 in its right hand end position, so that the left hand (FIG. 1) recess of magazine 84 associated with the coupled needle holder 11 opposes needle bar 7. Air cylinder 77 holds carrier plate 74 with cross slide 80 and magazine 84 in its lifted position shown in FIG. 2, in which the needle holders 11 received in the magazine 84 are vertically spaced above the base plate 2 by the same distance as the needle holder 11 which is coupled to the needle bar 7, when occupying its upper dead center position. At the same time, air cylinder 82 holds cross slide 80 and magazine 84 in the position remote from the needle bar 7 as shown in FIG. 2. The needle holder 11 coupled to needle bar 7 is positively connected to needle bar 7, since locking sleeve 13, which is held in its upper position by compression spring 26, presses the balls 16 through ring portion 22 into circular grooves 10 of flanged pin 9.
Needle thread N1 which leads to a thread supply (not shown), extends between the tension discs 42 of the thread tightener 40 (FIG. 1) at the left hand side (FIG. 1) is deflected upwardly by the associated hook 188, and extends through bore 117 of the thread guiding pin 116 at the left (FIG. 3), and is threaded in the needle 28 of the needle holder 11 which is coupled to the needle bar 7. The left (FIG. 3) thread catching lever 103 is engaged in the associated left hand slit 114 of stop plate 113, so that hook 105 comes into a position below the path of motion of the thread guide finger 116 of take-up lever 8, and, consequently, does not produce any retaining effect on the needle thread portion N1 which is moved up and down by take-up lever 8 during the sewing operation.
Needle thread N2 which leads to a second thread supply, extends through the other thread tightener 40 (FIG. 3) to the associated hook 118 and thereupon through bore 117 of the other thread guiding finger 116 to the needle of the second needle holder 11 which is received in magazine 84. The needle thread N2 is clamped between needle holder 11 and magazine 84 in the way described above. The second to fifth thread catching lever 104 reposed on the other sectors 115 of stop plate 113 and occupy the upper pivotal position shown in FIG. 3. In this pivotal position, hooks 105 are in a position laterally adjacent the path of motion of the associated thread catching fingers 116, thus in the path of motion of the needle thread portions moved up and down by take-up lever 8. In this way, needle thread N2 (shown in FIG. 3 and representing also all the other needle threads which are not shown) is caught by the hook 105 of the second thread catching needle 104, whereupon the thread guiding finger 116 of take-up lever 8 moves alongside the portion of needle thread N2 which is stretched between the clamping location in magazine 84 and hook 105 without taking it up or pushing it away. Thread catching levers 104 thus engage the needle threads which lead to the needle holders 11 received in magazine 84 and prevent them from participating in the sewing operation and from being tangled by take-up lever 8 in themselves, or with the other ones.
To exchange a needle holder 11, the sewing machine is stopped in the upper dead center position of needle bar 7, through pulse generator 31. Then, through air cylinder 24, locking lever 35 is pivoted to notch 33 of locking wheel 32, to readjust the stop position of needle bar 7, if necessary in view of the tolerance field of pulse generator 31. By pivoting the locking lever 35 into the notch 33 of the wheel 32, the sewing machine is also secured against an unintentional turning of arm shaft 6.
As soon as needle bar 7 is stopped exactly in its upper dead center position, magazine 84 is moved by air cylinder 82 toward needle bar 7. At the end of this motion, the needle holder 11 coupled to needle bar 7 comes within recess 86. Then, magazine 84 is moved by air cylinder 72 downwardly, whereby locking sleeve 13 is pushed against the action of cooperation spring 26 from its coupled position into it uncoupling position. At the same time, ring portion 22 is moved away from ball 16 and instead, groove 24 is brought into the range of balls 16, whereupon the balls are pushed by the further working motion of magazine 84 from circular groove 10 into groove 24, and needle holder 11 is disengaged from flange pin 9 of needle bar 7. During the disengagement of needle holder 11 from needle bar 7, compression spring 18 pushes locking bore 17 upwardly, whereby balls 16 are arrested in groove 24 and locking sleeve 13 is firmly retained in its uncoupling position.
After needle holder 11 has been disengaged from needle bar 7, magazine 84 is moved by air cylinder 82 away from needle bar 7. Further, switching bracket 108 is pivoted by air cylinder 111 downwardly, whereby all the thread catching levers 104 are pivoted up and thus lifted from stop plate 113. Only then magazine 84 is positioned through multiposition cylinder 59, and the selected needle holder 11 is brought into its starting position for coupling the needle bar 7.
Magazine 84 is displaced again in the direction of needle bars 7 by air cylinder 82, then lifted by air cylinder 77, and needle holder 11 is engaged on flange pin 9. At the same time, locking bolt 17 is pushed back by flange pin 9. Presser lever 95 resiliently applying against carrier 12 holds the carrier 12 and locking sleeve 13 in the uncoupled position even during the pushing back of locking bolt 17, and prevents thereby compression spring 26 through ring portion 22 from pushing balls 16 between locking bolt 17 and flange pin 9 into bolt 15. After needle holder 11 has completely been engaged on flange pin 9 and circular groove comes opposite the balls 16, magazine 84 is retracted by air cylinder 82. During the retraction, locking sleeve 13 is released fast, and pushed by compression spring 26 upwardly into its coupling position in which ring portion 22 pushes balls 16 into circular groove 10.
Simultaneously with the retraction of magazine 84 by air cylinder 82, air cylinder 34 moves locking lever 35 away from locking wheel 32, and air cylinder 111 lifts switching bracket 108, so that thread catching levers 104 pivot downwardly under their own weight. The thread catching levers 104 associated with needle threads which do not participate in the sewing operation then apply against sectors 115 and remain in the upper pivotal position shown in FIG. 2. Only the thread catching lever 104 associated with the needle thread participating in the following sewing operation drops into the corresponding slits 114 of stop plate 113 and comes out of the range of motion of take-up lever 8. Since the needles 28 of all the needle holders 11 are permanently provided with a thread and the threads are not unthreaded during an exchange of needle holders 11, the next sewing operation can start immediately after coupling a needle holder 11 to needle bar 7.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A thread changing mechanism for sewing machines includes a magazine in which a plurality of needle holders is received, to be positively coupled to the sewing machine needle bar by a vertical motion of the magazine. Upon effecting a coupling, the magazine is retracted into a starting position remote from the needle bar, so that the needle bar with the needle holder can unobstructedly move during the sewing operation. The thread changing mechanism is mounted on a sewing machine as an attachment later, without particular adjustments. When the needle holders are held in the magazine the thread is engaged with each needle and held out of the way of the operating needle thread.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to earth boring bits and in particular to an insert type rock bit of the rolling cutter type having specially shaped cutting tips.
2. Description of the Prior Art
Rock bits using sintered tungsten carbide inserts or compacts with cutting tips having a generally wedge or chisel-shaped configuration are used for drilling soft and medium formations. Various configurations for wedge-shaped inserts are shown in U.S. Pat. No. 3,442,342 issued to Hughes Tool Company. Inserts of this type have a pair of symmetrical flanks that converge to a rounded crest. The inserts are interferringly secured in holes drilled normal to the cutter surface. Consequently as the cutter rotates, the crest initially contacts the formation at a time when the longitudinal axis of the insert is non-perpendicular with respect to the hole bottom. Bending stresses are thus generated in the inserts, tending to cause breakage.
SUMMARY OF THE INVENTION
In accordance with this invention, an insert is provided having asymmetrical flanks. In the preferred enbodiment, the leading face or flank is concave and the trailing flank is convex. The scoop-shaped leading flank aids in lifting cuttings, yet resists breakage because of the additional support provided by the convex trailing flank and improved stress distribution.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary view in longitudinal section of one of the three sections and assembled cutter of a three cone rock bit having inserts constructed in accordance with the principles of this invention.
FIG. 2 is a front elevational view of an insert of the invention.
FIG. 3 is a top view of the insert of FIG. 2.
FIG. 4 is a sectional view of the insert of FIG. 3, taken along the lines IV--IV.
FIG. 5 is a side elevational view of a cutter for use with the drill bit shown in FIG. 1 and containing inserts as shown in FIGS. 2 through 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The numeral 11 in FIG. 1 of the drawings designates a lubricated, rotatable cutter-type earth boring drill bit having a body 13 formed in three sections (and subsequently welded) that each support a rotatable cutter 15 having earth disintegrating teeth 17. The drill bit has an axial fluid passage 19 extending through the body and usually three nozzles 21 at the body's lower end for the discharge of drilling fluid against the borehole bottom. Passages 23 supply lubricant to the bearing means 25 between the cutter 15 and supporting shaft 26. A pressure compensator system 27 helps provide lubricant through passages 23 to the bearing means 25, and limits, preferably equalizing, the pressure differential across seal 29.
The inserts 17 are formed of sintered tungsten carbide in the desired shape in a pressing mold. Each insert 17 is pressed into drilled and reamed retaining holes 33 with an interference fit. The drill bit of FIG. 1 contains three cutters 15, the one shown in FIG. 1 and FIG. 5 normally being designated as the number one cutter. All three cutters normally contain a row of gage inserts 35 and a heel row of inserts 37 on the outer end of the cutter. In the illustrated bit, the number one and number two cutters (not shown) have one or more nose inserts 39 on the inner end. A pair of inner rows 41, 42 are located between the inner end and the heel row inserts 37 on each cutter. The nose row inserts 39 shown in FIG. 5 are of the prior art ovoid configuration. The heel row inserts 37 shown in FIG. 5 are also of a prior art configuration, shown more clearly in FIG. 7 through 10 of U.S. Pat. No. 3,442,342. That type of insert has short flanks that are symmetrical to each other but canted away from each other so that the crest is not of uniform width.
The inner row inserts 41, 42 are generally chisel-shaped and have a special configuration as shown in FIGS. 2 through 4. The inserts of inner rows 41, 42 have a cylindrical base 43 which is inserted in retaining hole 33 with its longitudinal axis 45 being normal to the surface 47 of cutter 15. A cutting tip 49 is formed integrally with a cylindrical base 43 and protrudes outwardly from cutter surface 47. The cutting tip has two faces or flanks comprising a leading flank 51 and trailing flank 53. Flanks 51, 53 commence at the joinder of the cutting tip 49 with the top 56 of base 43 and converge in a crest 55. Adjacent and connecting each flank, conical surfaces 57, 59 extend from the junction of the cutting tip 49 with the top 56 of base 43 to the crest 55. As shown in FIG. 2, these conical surfaces incline inward or toward each other approximately 15° from the vertical. "Vertical" is defined herein to be parallel with the longitudinal axis 45. The corners 61, 63 of the crest 55 at the junction with the conical surfaces 57, 59 are also rounded.
As is apparent from FIG. 4, the flanks 51, 53 are asymmetrical with respect to each other. A median plane 65 passing through longitudinal axis 45 divides the crest 55 in half along its length, defining two halves or portions that are asymmetrical. One portion contains a concave or depressed flank and the other a convex or rounded outward flank. "Concave" and "convex" are used generically herein to include surfaces not lying in a single plane, such as a flank with a combination of flat and curved surfaces, and not in the most limited sense to mean only portions of a sphere. Flank 51 is concave in a section that contains the longitudinal axis 45 and is normal to crest 55, which is the view shown in FIG. 4. Trailing flank 53 is convex as seen in that same sectional view.
In the preferred embodiment, the longitudinal axis 45 of the preferred insert is within the median plane 65 of crest 55. The cross section of crest 55 is also curvilinear, preferably arcuate, with the center point of its radius R 1 located on the longitudinal axis 45 as seen in FIG. 4. The center point of radius R 2 forming the concave flank 51 is preferably located on a line commencing from the center point of R 1 at a positive angle α of preferably 10° with respect to a line normal to the axis 45. This radius has a length to extend to the top 56 of cylindrical base 43 and tangent to the radius R 1 . For the convex flank 53, the center point of radius R 3 is located along a line commencing at the top 56 of the cylindrical base 43 at a negative angle β of preferably 10° to 15° with respect to a line normal to the axis 45 and is tangent to R 1 .
For an insert with a base 43 of 0.6278 inch diameter the total height of the insert is preferably 0.938 inch and the height of cylindrical base 43 is 0.488 inch. The radius of the crest 55 is preferably 0.094 inch. The radius R 2 of the concave flank 51 for a 10° reference angle α is 0.617 inch, and the radius R 3 of the convex flank 53 is 0.922 inch for a 15° reference angle β.
It should be apparent that an invention having significant advantages has been provided. The asymmetrical insert has a tilting effect that is believed to improve stress distribution. The scoop-shaped cutting tip meets the formation more squarely during drilling and tends to mechanically lift the cuttings. The rounded trailing flank adds strength to prevent breakage.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes and modifications without departing from the spirit thereof.
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A specially shaped insert of the type used for the cutter teeth of rock bits used in drilling soft and medium formations of the earth. The insert is generally chisel-shaped with flanks converging to a crest. The flanks are asymmetrical with respect to each other. The leading flank is scoop-shaped and the trailing flank is rounded outwardly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/734,852 filed Apr. 13, 2007, herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus and method for managing runoff water from a down spout of a gutter system. More particularly, the present invention relates to an apparatus and method for preventing streams of runoff water released over top of the surface of the landscaping surrounding a structure from eroding and destroying the landscaping by slowing, disrupting and diffusing the runoff water by passing the runoff water through a body with at least one baffle in fluid communication with the down spout before releasing over top the surrounding landscaping.
BACKGROUND OF THE INVENTION
[0003] Management of runoff water from a structure using a gutter system offers many benefits which are commonly known and appreciated. For instance, runoff water may be collected in the gutter system near the roof, carried from the roof to a distribution point below using a down spout and released over top of landscaping adjacent the structure and down spout.
[0004] In times past, tiling down runoff water into the sewer system adjacent the structure was acceptable practice. However, more and more regulations are being implemented which require runoff water to be released over top landscaping surrounding the structure. Runoff water released over top of a landscaped surface will continue to erode and destroy the landscaping unless managed by slowing, disrupting and/or diffusing the disruptive stream of runoff water before releasing over top the surface of the landscaping. Therefore, an apparatus and method for managing runoff water from a down spout to prevent uncontrolled streams of water released over top a landscaped surface from eroding and destroying the landscaping surrounding the structure is becoming increasingly important and needed.
[0005] Because, an increasing amount of time, money and resources are being invested into beautifying, upgrading and managing the landscaping surrounding a structure, an apparatus and method for preventing runoff water released over the top of the surface adjacent a structure from eroding the landscaping is desired and important.
BRIEF SUMMARY OF THE INVENTION
[0006] Therefore, it is a primary object, feature, or advantage of the present invention to improve over the state of the art.
[0007] It is a further object, feature, or advantage of the present invention to provide an apparatus and method for managing the destructive and eroding force of runoff water from a down spout of a gutter system.
[0008] Yet another object, feature, or advantage of the present invention is to provide an apparatus and method that users an enclosed body for passing the runoff water through to extract energy from the runoff water by slowing, disrupting and diffusing the runoff water before releasing over top the surrounding landscaping.
[0009] A further object, feature, or advantage of the present invention is to provide an apparatus and method that uses at least one baffle or a series of baffles in combination with the body to slow, disrupt and diffuse runoff water to prevent erosion and destruction of surrounding landscaping.
[0010] Yet another object, feature, or advantage of the present invention is to provide an apparatus and method that may be flipped up, out of the way, to rest flush against the down spout of the gutter system using the hinge as shown and disclosed in U.S. Pat. No. 5,735,085, the description of which is incorporated herein by reference in its entirety.
[0011] A still further object, feature, or advantage of the present invention is to provide an apparatus and method that uses a flexible baffle biased downward on the outlet toward the base to slow an evenly diffuse runoff water across the base of the apparatus.
[0012] One or more of these and/or other objects, features, or advantages of the present invention will become apparent from the specification and claims that follow.
[0013] According to one aspect of the present invention, an apparatus for connecting to a down spout of a gutter system to slow, diffuse and absorb energy from runoff water to thereby eliminate erosion and destruction of surrounding landscaping is disclosed. The apparatus has a body with an inlet and an outlet and a pair of sidewalls spaced apart and enclosed by a top wall and a bottom wall. A pair of upwardly extending baffles are spaced apart on the bottom wall between the pair of sidewalls. A pair of downwardly extending baffles are on the top wall. A plurality of ribs on the bottom wall are spaced apart and fanned outward to diffuse runoff water moving through the body and away from the outlet. The upwardly extending baffles and the downwardly extending baffles slow, diffuse and absorb energy from runoff water passing through the body to prevent erosion of surrounding landscaping. In the preferred form, one of the downwardly extending baffles is a rubber flap positioned at the outlet and biased against the bottom wall to slow and evenly diffuse runoff water exiting the body. The other downwardly extending baffle is a rigid planar member extending between the pair of sidewalls within the body to deflect some runoff water back upon itself to disrupt and discombobulate runoff water passing through the body. The pair of upwardly extending baffles are offset from each other so a gullet of one baffle is aligned with a tooth of the other baffle to disrupt runoff water flowing through the body.
[0014] According to another aspect of the present invention, an apparatus for connecting to a down spout of a gutter system to slow, diffuse and absorb energy from runoff water to thereby eliminate erosion and destruction of surrounding landscaping is disclosed. The apparatus has a tube having a pair of sidewalls spaced apart by a top wall and a bottom wall and an outlet and an inlet adapted to attach to the downspout. A pair of upwardly extending baffles are positioned within the tube on the bottom wall. The pair of upwardly extending baffles are for slowing, diffusing and absorbing energy from runoff water to eliminate erosion and destruction of surrounding landscaping. In the preferred form, a front edge of the top wall at the outlet is angled down toward the bottom wall to redirect some runoff water back upon itself to discombobulate and slow runoff water from the outlet. The pair of teeth on one baffle near the outlet are angled outward toward the pair of sidewalls to diffuse the runoff water flowing out of the outlet. The tube is a gutter elbow fitting for attaching to the down spout of the gutter system. The tube is a gutter extension fitting for attaching to the down spout of the gutter system.
[0015] A new method for preventing runoff water from a down spout of a gutter system from eroding surrounding landscaping is disclosed. The method includes providing an open-ended enclosure having at least one baffle within the open-ended enclosure for discombobulating runoff water flowing through the open-ended enclosure. The method also includes introducing runoff water into the enclosure from the down spout, absorbing energy from runoff water within the enclosure using the at least one baffle and slowing runoff water within and upon exiting the enclosure using the at least one baffle to prevent runoff water from eroding surrounding landscaping. In the preferred form, the method also includes the step of redirecting some runoff water back upon itself to discombobulate runoff water passing through the enclosure. The method also includes the step of deflecting some runoff water upward and downward using the at least one baffle and the step of diffusing runoff water using the at least one baffle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed that the present invention will be better understood from the following description taken into consideration with the accompanying drawings, which:
[0017] FIG. 1 is a partial isometric view of a structure with a gutter system, down spouts and various embodiments of the apparatus of the present invention.
[0018] FIG. 2A is an exploded view of the apparatus taken along line 2 A- 2 A in FIG. 1 .
[0019] FIG. 2B is a top view of the apparatus according to an exemplary embodiment of the present invention.
[0020] FIG. 2C is a top view of the bottom half of the apparatus according to an exemplary embodiment of the present invention.
[0021] FIG. 2D is an elevated perspective view of the inside of the top half of the of the apparatus according to an exemplary embodiment of the present invention.
[0022] FIG. 2E is a back view of the apparatus according to an exemplary embodiment of the present invention.
[0023] FIG. 2F is a cross-sectional view taken along line 2 F- 2 F in FIG. 2E showing runoff water passing through the apparatus.
[0024] FIG. 2G is an isometric view of a pair of adaptors according to an exemplary embodiment of the present invention.
[0025] FIG. 3A is an isometric view of another embodiment of the present invention.
[0026] FIG. 3B is a cross-sectional view taken along line 3 B- 3 B in FIG. 3A showing runoff water passing through the apparatus.
[0027] FIG. 4 is a cutaway view of another embodiment of the present invention.
[0028] FIG. 5 is an isometric view of the apparatus hinged to the downspout according to an exemplary embodiment of the present invention.
[0029] FIG. 6 is a side view of the apparatus flipped upward against the downspout according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] The present invention includes a number of aspects, all of which have broad and far reaching application. One aspect of the present invention relates to an apparatus and method for managing runoff water from a downspout to prevent erosion and the destruction of surrounding landscaping. Another aspect of the present invention relates to an apparatus and method wherein runoff water flowing through the apparatus is slowed, disrupted and diffused before passing over the surrounding landscaping. Although specific embodiments are described herein, the present invention is not limited to these specific embodiments. The present invention contemplates numerous other options in the design and use of the apparatus and method for managing runoff water from the down spout of a gutter system.
[0031] FIG. 1 is a partial isometric view of a structure with a gutter system, down spouts, and various embodiments of the apparatus according to an exemplary embodiment of the present invention. For example, FIG. 1 shows a gutter system 14 attached to a structure. The gutter system 14 has down spouts 12 for moving runoff water off the structure and onto the surrounding surface near the structure. In one embodiment, the apparatus 10 is an elbow fitting for attaching to the down spout 12 . In another embodiment, the apparatus 10 is an extension for attaching to the elbow of the down spout 12 . In an additional embodiment, the apparatus 10 is attached to the end of an extension from the down spout 12 . Any of the apparatus's 10 shown in FIG. 1 may be used to slow, disrupt and diffuse the flow of runoff water from the gutter system 14 before exiting the down spout 12 onto the surrounding landscaping.
[0032] The apparatus 10 as shown in FIG. 2A is an exploded view of the apparatus taken along line 2 A- 2 A in FIG. 1 . The apparatus 10 has a body 16 . The body 16 is fully enclosed with the exception of inlet 18 and the outlet 20 . The body 16 is formed by a top wall 24 that is spaced apart by sidewalls 22 . The body 16 is enclosed by a bottom wall 26 . The bottom wall 26 has a plurality of ribs 40 spaced apart and extending in an outwardly direction from the inlet 18 toward the outlet 20 . A downwardly extending baffle 30 is positioned at the outlet 20 on the top wall 24 of the body 16 . The downwardly extending baffle is preferably constructed of a flexible-type material, such as rubber, plastic or any like material. The downwardly extending baffle 30 is biased toward the bottom wall 26 . The body 16 of the apparatus 10 is preferably constructed of a material suitable for handling and passing runoff water, withstanding interrogation by elements external to the body 16 and wears from use. For example, the body 16 may be constructed of a plastic or metal material like the gutter system 14 to resist rust, wear, fatigue and damage due to wear and being unintentionally impacted. The body 16 may be a single molded piece or fabricated from several pieces.
[0033] The inlet 18 of the body 16 , as best shown in FIG. 2E , is capable of accommodating one of the adapters 52 shown in FIG. 2G . The adapters 52 mate the down spout 12 to the inlet 18 of the body 16 . For example, if the down spout 12 is constructed of B-style gutter or alternatively A-style gutter, the appropriate adapter 52 may be used to ensure that the down spout 12 mates properly with the inlet 18 of the body 16 . The top wall 24 of the body 16 tapers downward from the inlet side 18 toward the outlet side 20 . Generally speaking, from the inlet 18 to the outlet 20 , the body 16 tapers in height and expands in width. Thus, the outlet 20 is longer in width and shorter in height than the inlet 18 . However, though the outlet 20 is wider than the inlet 18 , the bottom wall 26 preferably tapers to the width of the inlet 18 to the extent the bottom wall 26 extends outward away from the outlet 20 of the body 16 . It is understood and appreciated that the bottom wall 26 could be shaped so that the front edge of the bottom wall 26 farthest away from the outlet 20 is wider than the inlet 18 of the body 16 .
[0034] As best shown in FIG. 2B , the bottom wall 26 may be fitted with apertures 44 . Apertures 44 may be used to stake the body 16 of the apparatus 10 to a surface to prevent the body 16 from becoming unattached from the down spout 12 , from being moved by the force of runoff water passing through the body 16 or by some unintentional contact with the body 16 .
[0035] FIG. 2C shows positioned on the bottom wall 26 of the body 16 a pair of upwardly extending baffles 28 , specifically a first baffle 32 and a second baffle 34 . The baffle 32 , 34 have a gullet 36 spaced between teeth 38 . Each tooth 38 ends at its top in a planar surface 60 . The gullet 36 between each tooth 38 is preferably shaped in the form of a “V,” may be shaped liked a “V” or other shapes best suited for controlling the flow of runoff water. The height of the teeth 38 on the second baffle 34 are less than the height of the teeth 38 on the first baffle 32 . It is preferred that each tooth 38 on the second baffle 34 be aligned with a gullet 36 on the first baffle 32 , as best illustrated in FIG. 2E and described later in the application. The second baffle 34 is positioned on the bottom wall 26 downstream of the first baffle 32 . Also positioned on the bottom wall 26 of the body 16 is a plurality of ribs 40 . The ribs 40 are spaced apart and extend outwardly away from each other from the inlet 18 toward the outlet 20 . Additional ribs 40 also extend along the edges of the bottom wall 26 near the inlet 18 and extending from the inlet 18 along the outer periphery of the bottom wall 26 toward the outlet 20 to control the flow of runoff water.
[0036] FIG. 2D shows a top portion of the body 16 . The top portion of the body 16 is formed by sidewalls 22 spaced apart between the top wall 24 . Positioned on the top wall 24 is first baffle 64 of the downwardly extending baffles 30 . The downwardly extending baffle 30 preferably extends between the pair of sidewalls 22 . The first baffle 64 is preferably a planar element constructed of a rigid or semi-rigid material. For example, the first baffle 64 may be constructed of a plastic or some other lightweight inexpensive material capable of withstanding the force of the runoff water passing through the body 16 and the effects of weather and continued exposure to water and moisture. The first baffle 64 is preferably a solid member that is adapted to attach to the top wall 24 . The first baffle 54 may be attached to the top wall 24 using various types of fasteners such as a rivet, screw or weld. Alternatively, the first baffle 64 and the top wall 24 may be constructed as a single piece. The first baffle 64 is preferably angled downstream having an obtuse angle with respect to the top wall 24 upstream from the first baffle 64 . However, it is further understood that the first baffle 64 may be angled at an acute angle with respect to the top wall 24 depending on the desired deflective behavior. Positioned downstream from the first baffle 64 is a second baffle 66 of the downwardly extending baffles 30 . The second baffle 66 is positioned on the outlet side 20 along the top wall 24 of the body 16 . The second baffle 66 preferably extends between the sidewalls 22 and away from the outlet side 20 . Similar to the first baffle 64 , the second baffle 66 may also be attached to the top wall 24 using various types of fasteners, such as a weld, rivet or screw. Alternatively, the top wall 24 and the second baffle 66 may be molded as a single piece.
[0037] FIG. 2E shows the inlet 18 of the apparatus 10 . The inlet 18 is adapted to receive either one of the adapters 52 shown in FIG. 2G . The adapter 52 is positioned within the inlet 18 so that the down spout 12 , whether an extension or elbow piece, may mate properly with the inlet side 18 to close off the inlet 18 to thereby discourage any runoff water from escaping back out of the body 16 through the inlet 18 .
[0038] FIG. 2F shows the apparatus 10 with the upwardly extending baffles 28 and downwardly extending baffles 30 for slowing, disrupting and diffusing runoff water 46 entering the body 16 through the inlet side 18 and exiting the outlet side 20 . In operation, runoff water 46 enters the body 16 through the inlet side 18 from the down spout 12 . As the runoff water 46 exits the down spout 12 it approaches the first baffle 32 of the upwardly extending baffles 28 . Some of the runoff water 46 comes into contact with teeth 38 on the first baffle 32 and some portion of the runoff water 46 is allowed to pass through a gullet 36 on the first baffle 32 as shown by the flow arrow 48 running parallel to the bottom wall 26 . The portion of the runoff water 46 that comes into contact with teeth 38 on the first baffle 32 is deflected in an upwardly direction toward the top wall 24 . A portion of this deflected runoff water 46 is thrown back upon runoff water 46 running at, near or along the bottom wall 26 which causes the runoff water 46 to be discombobulated, slowed, and disrupted in its progression through the body 16 . Other portions of this deflected runoff water 46 pass over top of the planar top edge 60 of each tooth 38 and is deflected in a downwardly direction back into the runoff water 46 passing along or near the bottom wall 26 as shown by flow arrow 48 . As best illustrated by FIG. 2E , the portion of the runoff water 46 that passes through a gullet 36 on the first baffle 32 comes into contact with a tooth 38 on the second baffle 34 . This is what was meant when stated earlier that a gullet 36 on the first baffle 32 is preferably aligned with each tooth 38 on the second baffle 34 . As shown in FIG. 2F , the discombobulated runoff water 46 continues from the inlet 18 to the outlet 20 and comes into contact with a second baffle 34 of the upwardly extending baffles 28 . A portion of the runoff water 46 is allowed to pass through gullets 36 in the second baffle 34 . Some of the runoff water 46 is again deflected in an upwardly direction by teeth 38 on the second baffle 34 . A portion of the runoff water 46 deflected in an upwardly direction is again deflected in a downwardly direction toward the runoff water 46 passing at, near, or along the bottom wall 26 . For example, some of the runoff water 46 is deflected backwards upon the runoff water 46 traveling at, near, or along the bottom wall 26 using the top wall 24 of the body 16 . Other portions of the runoff water 46 may be deflected forward using the top wall 24 . The forward deflected portion of the runoff water 46 is directed back into the runoff water 46 passing at, near or along the bottom wall 26 to cause the runoff water to be discombobulated, slowed and interrupted in its progression. As the runoff water 46 passes by the second baffle 28 , it continues forward toward the outlet 20 . Positioned on the outlet 20 is second baffle 66 of the downwardly extending baffles 30 . The second baffle 66 is biased toward the bottom wall 26 . The second baffle 66 causes the runoff water 46 to be spread across the bottom wall 26 before exiting the outlet 20 . Moreover, because the second baffle 66 is biased toward the bottom wall 26 , it further slows the runoff water 46 before exiting the body 16 .
[0039] In addition to the discombobulation, absorption of energy, slowing and disruption of runoff water 46 caused by the upwardly extending baffles 28 and the downwardly extending baffles 30 , the runoff water is diffused as it travels from the inlet 18 toward the outlet 20 . Diffusion is caused by the tapering height and expanding width of the body 16 from the inlet 18 to the outlet 20 . In addition, ribs 40 encourage runoff water 46 to spread outwardly within the body 16 further diffusing the runoff water 46 . Thus, the runoff water 46 enters the body 16 near the inlet 18 having a runoff cross-section akin to the cross-section of the down spout 12 . The cross-section of the runoff water 46 passing from the down spout 12 is diffused by spreading the runoff water 46 across a greater area while passing from the inlet 18 to the outlet 20 .
[0040] Thus, the apparatus 10 has the ultimate effect of slowing, disrupting, absorbing energy from, and diffusing runoff water 46 having a potentially significant amount of energy and eroding capability before passing the runoff water 46 over the surrounding landscaping. In addition, the tapering height of the top wall 24 of the body 16 from the inlet 18 to the outlet 20 allows the apparatus 10 to rest flush against the down spout 12 when rotated upward using the hinge 50 as shown in FIGS. 5 and 6 . Further, the apparatus 10 may be rotated upward out of the way, when necessary, to manicure or care for surrounding landscaping.
[0041] FIGS. 3A and 3B show another embodiment of the apparatus 10 . FIG. 3A shows that the apparatus 10 has a body 16 of a gutter elbow. The inlet side 18 attaches to the down spout 12 . The body 16 is defined by a top wall 24 connected to sidewalls 22 and enclosed by bottom wall 26 . Positioned on the bottom wall 26 is a first baffle 32 and second baffle 34 of the upwardly extending baffles 28 . The first baffle 32 is formed by teeth 32 spaced apart by gullet 36 . The top planar edge 60 of each tooth 38 of the first baffle 32 is parallel with the bottom planar surface 42 of each gullet 36 . Similar to the first baffle 32 , the second baffle 34 has teeth 38 spaced apart by gullets 36 . The second baffle 34 has angled teeth 62 positioned on the outermost portions of the second baffle 34 . The angled teeth 62 are angled in an outwardly direction toward the sidewalls 22 of the body 16 . A downwardly extending baffle 30 is positioned on the outlet 20 on the top wall 24 of the body 16 . The downwardly extending baffle 30 is formed preferably by bending down the top wall 24 of the body 16 toward the bottom wall 26 . The angle of bend for the angled teeth 62 on the second baffle 34 and downwardly extending baffle 30 may be altered to control the flow dynamics of runoff water 46 passing through the body 16 .
[0042] In use, runoff water 46 passes from the inlet 18 through the body 16 of the apparatus 10 out the outlet 20 as shown in FIG. 3B . As runoff water 46 comes into contact with the first baffle 32 , a portion of the runoff water 46 is allowed to pass through each gullet 36 and some of the runoff water 46 is deflected in an upwardly direction against the top wall 24 as shown by flow arrow 48 . The runoff water 46 deflected upward by teeth 38 is thrown back down upon the runoff water 46 passing at, near or along the bottom wall 26 to thereby discombobulate, disrupt and slow the progression of the runoff water 46 from the inlet 18 toward the outlet 20 . Downstream from the first baffle 32 , the runoff water 46 comes into contact with the second baffle 34 before exiting the body 16 . A portion of the runoff water 46 passes through each gullet 36 and some of the runoff water 46 is deflected upwardly toward the top wall 24 . A portion of the runoff water 46 deflected upwardly is deflected backwards upon runoff water 46 passing at, near or along the bottom wall 26 . Other portions of the runoff water 46 deflected upwardly is deflected in a downwardly direction by the downwardly extending baffle 30 into runoff water 46 traveling at, near or along the bottom wall 26 to further discombobulate, slow and disrupt the flow of runoff water 46 from the outlet side 20 . Some of the runoff water traveling by or near the sidewalls 22 is diffused in an outwardly direction away from the sidewalls at the outlet 20 by the angled teeth 62 . Thus, the runoff water 46 is slowed in its progression and diffused and deprived of its destructive, eroding power before passing over top of the surrounding landscaping.
[0043] FIG. 4 shows another embodiment of the apparatus 10 . The body 16 is a gutter extension tube having a first baffle 32 and a second baffle 34 with a downwardly extending baffle 30 . The operation of the first baffle 32 and second baffle 34 in addition to the downwardly extending baffle 30 is similar to the operation of the embodiment as discussed and shown in FIGS. 3A and 3B . For example, as shown in FIG. 4 , some of the runoff water 46 is permitted to flow through each gullet 36 following the flow arrows 48 . Other portions of the runoff water 46 are deflected upward and forced to flow over top of each tooth 38 on the first baffle 32 and second baffle 34 . In addition, the downwardly extending baffle 30 forces runoff water back down upon itself to discombobulate and slow the progression of runoff water 46 from the outlet 20 across the surrounding landscaping. Again, like apparatus 10 in FIGS. 3A and 3B , the angled teeth 62 help to diffuse runoff water 46 before passing from the outlet 20 onto the surrounding landscaping.
[0044] The preferred embodiment of this invention has been set forth in the drawings and specification and those specific terms are employed, these are used in the generically descriptive sense only and are not used for the purposes of limitation. Changes in the formed portion and parts as well as in the substitution of equivalents are contemplated as circumstances expressed are rendered expedient without department from the spirit and scope of the invention as further defined in the following claims.
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An apparatus and method for connecting to the down spout of a gutter system to slow, disrupt, diffuse and absorb energy from runoff water to thereby eliminate erosion and destruction of surrounding landscaping is beneficial and desirable. The apparatus has an enclosure for passing runoff water therethrough. At least one upwardly extending baffle is used to slow and disrupt water from the down spout and at least one downwardly extending baffle is also used to slow, disrupt and diffuse runoff water from the down spout. The upwardly extending baffle and the downwardly extending baffle are for managing runoff water from the down spout to prevent erosion and destruction of surrounding landscaping.
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Cross-Reference to Related Application
This application is a continuation of copending application Ser. No. 715,974 filed Mar. 26, 1968, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a process for oxidizing halo-olefins without the use of an added catalyst, initiator or other external means of initiation.
The oxidation of halo-olefins to obtain epoxides, acyl halides haloketones or haloaldehydes by employing initiators or catalysts such as, for example, gamma radiation, peroxides, and ultraviolet light, especially when the reaction is promoted by adding molecular chlorine, is known. Heretofore it has been thought that the oxidation of such material must be carried out in the presence of one or more of these initiators. (U.S. Pat. No. 2,472,946).
SUMMARY OF THE INVENTION
It has now been found that surprisingly high yields and conversion rates are obtained by simply contacting a liquid halo-olefin with oxygen at a temperature of from 25° to 350°C., and at an oxygen pressure of from 100 to 1200 psi and higher. The oxygen may be employed undiluted, or it may be diluted with other inert gases such as, for example, argon, if desired. Air may also be employed but it should be dry. Generally, pure oxygen is preferred, but diluted oxygen may be used to advantage with highly active haloolefins such as, for example, 1,1-dichloroethylene.
The reaction is characterized by having an induction period, after which the conversion to useful oxygenated products proceeds smoothly. The induction period can be minimized by using halo-olefins which do not contain inhibitory impurities or by adding a more reactive halo-olefin. The induction period is essentially eliminated by filling the reactor with the reaction mixture of a prior oxidation run, then introducing oxygen and the desired halo-olefin.
It has further been found that it is possible to control the start-up of the oxidation of the more reactive halo-olefins such as, for example, 1,1-dichloroethylene, which hitherto have been extremely difficult to oxidize because of the tendency of the reaction to run out of control in the early stages, by feeding the halo-olefin, alone or in admixture with inert or less reactive halo-olefins, into a reaction chamber that contains an inert material or a partially oxidized less reactive halo-olefin and has been brought to the operating conditions before the addition of the undiluted reactive halo-olefin begins. Alternatively, the latter may be fed into a reaction chamber that already contains the reaction products of the controlled oxidation. When oxidizing 1,1-dichloroethylene it is preferred that the operating conditions be such that the conversion of 1,1-dichloroethylene is better than 90%. In this manner the start-up of the reaction proceeds smoothly without an excessive exothermic reaction and the process continues substantially as with other haloolefins.
It has also been found, and it forms a further embodiment of this invention, that halo-olefins that are relatively more inert may be more readily oxidized to higher conversions by co-oxidizing them with a more readily oxidizable halo-olefin. For example, greater conversions of tetrachloroethylene to trichloroacetyl chloride are obtained when the tetrachloroethylene is co-oxidized in admixture with 1,1-dichloroethylene.
Halo-olefins that may be oxidized in accordance with this invention include those containing from 2 to 7 carbon atoms wherein the halogen may be chlorine, fluorine, bromine or iodine. The preferred haloolefins are the 2 to 3 carbon halo-olefins containing a plurality of halogens. Most advantageously the halogen is fluorine or chlorine.
The preferred operating conditions are generally from about 70° to 300°C., and from 300 to 1000 psig of oxygen. These conditions will vary with the properties of the material being oxidized and are interdependent, i.e. at higher temperatures greater pressures may be desirable and vice versa. The temperature and pressure conditions are such that the halo-olefin remains in the liquid state. The conditions will also vary with the properties of the desired end product, for example, lower operating temperatures are preferred if it is desired to isolate the oxides. In starting up the reaction it is best to employ temperatures near the lower end of the above described ranges in order to obtain better conversions of the halo-olefins to the desired oxygenated products.
The process may be run batchwise, continuously or semi-continuously, and in one or more stages, as desired. An excess of oxygen is desired if the operation is continuous, as the excess would be vented with the reaction products. In batch operations, mole ratios of 1:1 of oxygen to halo-olefin are generally preferred, although variations in pressure will give a wide variation in the amount of oxygen in solution. In order to get best results the oxygen should be finely dispersed. This is advantageously accomplished by introducing the oxygen into the reactant in a finely divided state, e.g. through a frit unless other means of agitation are used, such as, for example, fast cycling of the reaction mixture through a pump and back into the reactor. In continuous reactors it has been found that length-to-diameter ratios of from about 4 to 34 are advantageously employed, with the preferred length-to-diameter ratio being about 10 to 20.
In the oxidation of tetrachloroethylene, improved conversions are obtained in a preferred twostage mode of operation that employs two reactors in sequence, preferably with the first reactor having about twice the volume of the second. In this preferred method, the temperature in the first reactor is kept in the range of from 80° to 110°C. and the pressure is from about 500 to 1000 p.s.i.g. In the second reactor the temperature is preferably kept at about 225°-275°C. and the pressure at about 500 to 1000 p.s.i.g. In this preferred process, conversions of over 90 percent are readily obtained. At temperatures above 275°C. in the second reactor the yield of trichloroacetyl chloride is reduced. At temperatures below 225°C. in the second reactor the conversion falls off.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will be further understood by reference to the following examples wherein all percentages are mole percents unless otherwise noted.
EXAMPLE I
A one-liter stainless steel reaction vessel was charged with 800 ml. of stabilized dry cleaning grade (DOWPER) tetrachloroethylene. An oxygen cylinder was attached to an inlet such that when oxygen was pressured into the reaction vessel it entered the vessel below the surface of the tetrachloroethylene through a stainless steel frit. The vessel was vented at the top for a few seconds to purge out the air above the tetrachloroethylene, then the vent line was blocked and the vessel pressured with oxygen (and simultaneously heated to a temperature of 100°C.) to a pressure of 800 p.s.i.g. The oxygen cylinder was left attached to the reaction vessel with a pressure regulator and check valve between them so that more oxygen would be supplied as the pressure in the reaction vessel dropped below 800 p.s.i.g. No more heat was applied to the reaction vessel during this run. The temperature of the reaction mixture was recorded at intervals and samples for analysis were taken at intervals from an outlet near the bottom of the vessel.
__________________________________________________________________________ Composition of Conversion Products, % CCl.sub.2 --CCl.sub.2 OTime Reaction % ∠ ∥(Min.)Temp. °C. Conv. CCl.sub.3 --COCl O Cl--C--Cl C.sub.2 Cl.sub.6__________________________________________________________________________5 105 -- -- -- -- --10 124 3.2 15.6 78.1 6.3 0.120 155 16.0 33.7 57.2 8.6 0.630 225 23.4 56.4 32.2 11.5 0.140 212 34.5 76.4 14.9 8.6 0.150 193 46.4 87.1 5.1 7.8 0.160 173 52.7 86.8 5.9 7.1 0.290 130 53.3 89.8 2.3 7.6 0.2__________________________________________________________________________
EXAMPLE 2
Using the same reaction vessel and equipment hook-up as in Example 1 above, oxygen was pressured into stabilized tetrachloroethylene to a pressure of 500 p.s.i.g. at ambient temperature (˜30°C.). The reaction exothermed to about 125°C. after about 18 hours of contact time and thereafter dropped slowly to ambient temperature. A sample was taken after 24 hours and conversion of the C 2 Cl 4 was found to be 42.8%. The yield was 81% of trichloroacetyl chloride.
This run was repeated using fresh unstabilized tetrachloroethylene and 600 p.s.i.g. oxygen pressure. An exotherm of 147°C. was observed in 5 hours. Trichloroacetyl chloride was produced in good yield.
EXAMPLE 3
The experiment of Example 2 was repeated using stabilized tetrachloroethylene except that a pressure of 600 p.s.i.g. was employed. The following table described the reaction.
__________________________________________________________________________ Composition of Conversion Products, %Reaction CCl.sub.2 --CCl.sub.2 OTime Reaction % ∠ ∥(Hrs.)Temp.°C. Conv. CCl.sub.3 --COCl O Cl--C--C--Cl C.sub.2 6__________________________________________________________________________0 ˜32 -- -- -- -- --8.25 36 3.0 30.5 50.8 18.7 09.0 37 3.2 23.5 64.7 11.8 09.5 39 4.4 39.1 36.8 24.1 09.75 42 6.7 42.4 30.6 27.2 010.1752 8.5 49.4 24.2 26.5 010.5 134 25.7 54.5 17.5 27.3 0.811.0 130 32.0 62.4 12.7 24.0 1.012.0 110 41.5 68.1 10.0 21.9 0.813.0 90 42.6 84.0 1.2 14.0 0.714.0 74 45.0 81.2 1.9 16.2 0.715.0 64 47.4 79.2 2.1 18.1 0.7__________________________________________________________________________
EXAMPLE 4
Stabilized tetrachloroethylene was oxidized continuously, without catalyst addition, in a series of runs, to determine the effect of reaction temperature. Oxidations were conducted in a 1000 ml. stainless steel reactor equipped with an inlet and outlet, means of temperature measurement and control, means of pressure control, means of oxygen dispersion, facilities for sampling reaction products and suitable safety devices. In all runs, tetrachloroethylene was continuously metered into the reactor inlet at a rate of 8.33 ml./min.; giving an average contact time of 2 hours. Oxygen was continuously metered into the reactor inlet through a frit at a ratio of 1 mole of oxygen per mole of tetrachloroethylene. Excess oxygen was vented from the reactor outlet along with the reactor effluent. Reactor pressure was controlled at 800 p.s.i.g. for all runs. Samples of the reactor effluent were collected, in a cold-trap, from the reactor outlet on an hourly basis during each run. Samples were analyzed by gasliquid chromatography to determine the progress of the reaction. Each run was continued for several hours after reaction equilibrium had been reached. Representative samples were then analyzed by mass spectrometry. The following table shows the results of five runs, under equilibrium conditions, will all reaction conditions being constant except that of temperature, which was as designated.
______________________________________ O OReaction ∥ ∠Temperature Cl.sub.2 C=CCl.sub.2 Cl.sub.3 C--CCl Cl.sub.2 C--CCl.sub.2 COCl.sub.2(°C.) Conv. (%) Yield (%) Yield (%) Yield (%)______________________________________60 2.3 46.1 35.9 18.080 18.9 48.8 38.2 13.1100 23.3 74.1 15.9 9.9120 13.0 89.5 0 10.6130 2.0 86.3 0 13.7______________________________________
EXAMPLE 5
Stabilized tetrachloroethylene was oxidized continuously, without catalyst addition, in a series of runs and in the manner of Example 4, except that the single reactor was replaced with two equal volume, stainless steel reactors connected in series. The two reactors (the first reactor designated R-I and the second, R-II) were equipped with independent temperature controls. The effect of R-I temperature was determined at two R-II temperatures in a series of 8 runs conducted under otherwise the same conditions of Example 4. Results are tabulated below.
______________________________________Effect of R-I Temperature (R-II=120°C.) O OR-I ∥ ∠Temperature % Cl.sub.3 C--CCl Cl.sub.2 C--CCl.sub.2 COCl.sub.2(°C.) Conv. Yield (%) Yield (%) Yield (%)______________________________________60 1.4 75.8 5.8 18.380 24.7 86.0 4.5 9.6100 26.3 88.8 1.2 9.9120 13.0 89.5 0 10.6______________________________________
______________________________________Effect of R-I Temperature (R-II=170°C.) O OR-I ∥ ∠Temperature % Cl.sub.3 C--CCl Cl.sub.2 C--CCl.sub.2 COCl.sub.2(°C.) Conv. Yield (%) Yield (%) Yield (%)______________________________________60 36.7 90.4 0 9.680 39.1 90.8 0 9.7100 36.9 88.6 0 11.4120 4.4 84.8 0 15.2______________________________________
EXAMPLE 6
Stabilized tetrachloroethylene was oxidized continuously, without catalyst addition, in a series of runs and in the manner of Examples 4 and 5 except that the volumes of the two reactors, R-I and R-II, were varied with the total volume being constant.
Constant reaction conditions employed were:
R-I Temperature 100°C.R-II Temperature 150°C.Reactor pressure 1000 psigTotal Reactor contact time 6.2 hrs.
The results of 3 runs are tabulated below.
______________________________________Effect of R-I/R-II Volume Ratio O OR-I/R-II ∥ ∠Volume Cl.sub.2 C=CCl.sub.2 Cl.sub.3 C--CCl Cl.sub.2 C--CCl.sub.2 COCl.sub.2Ratio Conv. (%) Yield (%) Yield (%) Yield (%)______________________________________0.33 27.0 87.4 0 12.61.0 40.8 92.0 0 8.02.0 53.5 91.7 0 8.3______________________________________
EXAMPLE 7
Stabilized tetrachloroethylene was oxidized continuously, without catalyst addition, in a series of runs conducted in the manner of Examples 4 and 5 to determine the effect of R-II temperature. Constant reaction conditions employed were:
R-I temperature 100°C.Total reactor contact time 5.9 hrs.Reactor pressure 1000 psigVolume ratio, R-I/R-II 2/1
The results of 10 runs in which R-II temperature was varied are shown in the following table.
______________________________________Effect of R-II Temperature O OR-II ∥ ∥Temperature Cl.sub.2 C=CCl.sub.2 Cl.sub.3 C--CCl CCl.sub.2 Cl.sub.3 C--CCl.sub.3(°C.) Conv. (%) Yield (%) Yield (%) Yield (%)______________________________________100 42.7 92.1 7.5 0.4125 48.0 92.0 7.7 0.3150 53.5 91.7 8.0 0.3175 65.3 92.7 7.1 0.2200 79.0 92.7 6.8 0.5225 80.9 90.7 8.9 0.4250 85.1 94.0 5.4 0.6275 86.1 90.1 7.1 2.8300 85.0 86.6 8.3 5.1325 81.5 79.4 9.0 11.6______________________________________
EXAMPLE 8
Stabilized tetrachloroethylene was oxidized continuously, without catalyst addition, in a series of runs conducted in the manner of Examples 4 and 5, to determine the effect of reactor contact time. Constant reaction conditions employed were:
R-I Temperature 100°C.R-II Temperature 275°C.Reactor pressure 1000 psigVolume ratio, R-I/R-II 2/1
The results of 5 runs, in which the total reactor contact time was varied are shown below.
______________________________________Effect of Reactor Contact Time O OTotal Reactor ∥ ∠Contact Time Cl.sub.3 C--CCl Cl.sub.2 C--CCl.sub.2 COCl.sub.2(Hrs.) Conv. (%) Yield (%) Yield (%) Yield (%)______________________________________4 73.8 85.3 0.4 11.35.7 80.9 89.1 0.2 7.57.4 85.8 94.5 0.2 4.910.7 87.0 87.5 0.1 9.018.5 90.2 89.4 0 7.3______________________________________
EXAMPLE 9
Stabilized tetrachloroethylene was oxidized continuously, without catalyst addition, in a series of runs conducted in the manner of Examples 4 and 5 except that the reactor oxygen pressure was varied. Constant reaction conditions employed for the first 3 runs were:
R-I Temperature 100°C.R-II Temperature 275°C.Total Reactor Contact Time 6 hrs.Volume ratio, R-I/R-II 2/1
Reaction conditions employed for the last run are as indicated in the footnote. Results of the 4 runs are shown below.
______________________________________Effect of Reactor Pressure O OReactor ∥ ∠Pressure Cl.sub.2 C=CCl.sub.2 Cl.sub.3 C--CCl Cl.sub.2 C--CCl.sub.2 COCl.sub.2(p.s.i.g.) Conv. (%) Yield (%) Yield (%) Yield (%)______________________________________1000 86.1 90.1 0 7.1700 64.8 90.3 1.8 7.9400 41.6 86.7 5.1 8.2 400* 21.2 71.5 18.4 8.3______________________________________ *R-I temp. = R-II temp. = 100°C., contact time = 4 hrs.
EXAMPLE 10
Trichloroethylene was oxidized, without catalyst addition, in a batch reaction system which consisted of a 300 ml. nickel reactor equipped with means of temperature measurement and control, means of agitation, facilities for the continuous introduction of oxygen during reaction and suitable safety devices. Oxygen was fed to the reactor from a calibrated supply cylinder. The reactor was charged with trichloroethylene, purged free of air with oxygen, pressured and checked for a period of 30 min. to assure no oxygen consumption or leakage in the system. The reactor was then depressured and the temperature and pressure brought up to operating conditions simultaneously to avoid overpressuring. Pressure readings on the oxygen supply cylinder were recorded frequently during the reaction and the rate of oxygen consumption (hence, the oxidation rate) determined. The system was such that as little as 0.1 gm of oxygen consumption could be detected.
At the end of the reaction the reactor was chilled, opened and its contents transferred to a sample bottle. Samples were then analyzed by gas-liquid chromatography, mass spectrometry and infra-red spectroscopy.
According to the above procedure, 200 gms of trichloroethylene was charged to the reactor and oxidized under conditions of 100°C. and 100 p.s.i.g. Data showing the progress of the reaction are shown in the following table.
______________________________________Oxidation of Trichloroethyleneat 100°C. and 100 p.s.i.g.Reaction Oxygen ConsumedTime (Min.) By Reaction (grams)______________________________________0 010 015 0.1430 1.0845 2.4460 4.0775 4.8890 5.15105 5.28150 5.42______________________________________
Analysis of the reaction products showed that 25.9% of the trichloroethylene was converted to yield 33.2% trichloroethylene oxide, 42.2% dichloroacetyl chloride, 19.1% trichloroacetaldehyde and 5.5% phosgene.
EXAMPLE 11
Trichloroethylene was oxidized continuously, without catalyst addition, using the equipment and procedure described in Example 4. Approximately 30 runs were made for the purpose of studying the reaction variables. One such run was conducted under conditions of 200°C., 400 p.s.i.g. and a 5 hr. contact time. Product analysis by mass spectrometry gave the following results.
______________________________________Unreacted trichloroethylene 2.5Trichloroacetaldehyde 8.5Dichloroacetyl chloride 28.5Dichloromaleic anhydride 0.22(1,2,2,2-tetrachloroethoxy)chloroacetyl chloride 8.7Chloroform 0.8Various oxygen-free products 50.8______________________________________
The conversion of trichloroethylene was found to increase with increased reactor pressure and/or increased reactor contact time. Dichloroacetyl chloride and trichloroacetaldehyde were found to form at the expense of trichloroethylene oxide at higher temperatures.
EXAMPLE 12
1,1-Dichloroethylene was oxidized continuously, without catalyst addition, in the equipment and manner as described in Example 4. Reaction conditions employed were: 105°C. reaction temperature, 500 p.s.i.g. reactor pressure and 2.2 hr. reactor contact time. The reactor initially contained perchloroethylene and its oxidation products from a preceding run. The reactor was brought up to operating conditions and 1,1-dichloroethylene feed and oxygen feed were started to the reactor. The reaction was continued until all tetrachloroethylene and its oxidation products were swept from the reactor and then continued until the reaction reached equilibrium conditions. Samples were then collected from the reactor outlet and analyzed by mass spectrometry. Analytical results showed that 99.8% of the 1,1-dichloroethylene fed was converted to yield 89.7% monochloroacetyl chloride and 2.7% phosgene.
EXAMPLE 13
1,1-Dichloroethylene was oxidized continuously, without catalyst addition, in the manner of Example 12, except that the reactor was lined with Teflon and the oxygen tube and frit were of Teflon, thus excluding all metals from the reaction zone. The temperature employed was 100°C., the pressure was 150 p.s.i.g. and the contact time as 1.6 hours. The conversion was 98.3% with a 96.5% yield of chloroacetyl chloride and 2.9% phosgene.
EXAMPLE 14
1,1-Dichloroethylene was oxidized under the same conditions as Example 12 except at a reaction temperature of 90°C. and with the products of Example 12 in the reactor initially. The reaction was continued for 12 hrs. Analysis of samples showed that 99.5% of the 1,1-dichloroethylene fed to the reactor was converted to yield 89.3% monochloroacetyl chloride and 3.4% phosgene.
Great difficulty was encountered in trying to start-up initially with only 1,1-dichloroethylene and oxygen due to the explosive nature of the mixture. By first filling the reactor with any of a variety of other suitable materials, one can then begin feeding 1,1-dichloroethylene and oxygen to the reactor without difficulty.
EXAMPLE 15
Cis- and trans- 1,2-dichloroethylenes were oxidized without catalyst addition, using the same equipment and in the same manner as described in Example 10. The reactor was charged with 200 grams of 1,2-dichloroethylene which was comprised of 60% of the cis- isomer and 40% of the trans- isomer. Reaction conditions employed were 100°C. and 100 p.s.i.g. The reaction was continued for 2.5 hrs. Reaction products were identified and analyses made by gas-liquid chromatography, infra-red spectroscopy and mass spectrometry. Analytical results showed that 6.0% of the 1,2-dichloroethylene charged was converted to yield 68.5% trans-1,2-dichloroethylene oxide, 14.1% cis-1,2-dichloroethylene oxide and 15.8% dichloroacetaldehyde. The 1,2-dichloroethylene oxides were isolated by gas-liquid chromatography and their I.R. spectra obtained.
EXAMPLE 16
2,3-Dichloropropene was oxidized, without catalyst addition, using the equipment and in the manner of Example 10. The reactor was charged with 50 grams of 2,3-dichloropropene. Reaction conditions employed were 80°C. and 150 p.s.i.g. the progress of the reaction is shown in the following table.
______________________________________Reaction Time Oxygen Consumed by the(minutes) Reaction (grams)______________________________________21 023 0.3035 0.6050 1.0660 1.3690 1.96108 2.27145 2.57160 2.72______________________________________
Oxygen consumed corresponded to 37.7% conversion of 2,3-dichloropropene based on 1/2 mole oxygen/mole of 2,3-dichloropropene.
Sample analysis showed 1,3-dichloropropanone as the only major reaction product.
EXAMPLE 17
Cis- and trans-1,2,3-trichloropropenes were oxidized, without catalyst addition, using the equipment and in the manner described in Example 10. The reactor was charged with 100 grams of 1,2,3-trichloropropene which was comprised of 47.5% of the trans- isomer and 52.0% of the cis- isomer. Reaction conditions employed were 100°C. and 150 p.s.i.g. The progress of the reaction is shown in the following table.
______________________________________Reaction Time Oxygen Consumed by the(minutes) Reaction (grams)______________________________________9 012 0.2915 0.5720 0.8625 1.0035 1.14240 1.48______________________________________
Gas-liquid-chromatographic (G.L.C.) analysis of the reaction product showed 15.7% conversion of the 1,2,3-trichloropropene to three major products. Analysis also showed that the trans- isomer was oxidized to a greater extent than the cis- isomer.
Identification of these products by the combined use of G.L.C., mass spectrometry and infra-red spectroscopy showed the following products in decreasing order of concentration: 2,2,3-trichloropropanol; 1,1,3-trichloropropanone; chloroacetyl chloride; dichloroacetyl chloride; and chloroform.
EXAMPLE 18
1,1,2,3-Tetrachloropropene was oxidized without catalyst addition, using the equipment and in the manner described in Example 10. The reactor was charged with 50 grams of tetrachloropropene. Reaction conditions employed were 150°C. and 150 p.s.i.g. The run was ended after 1 hr. 35 min. reaction time. G.L.C. analysis of the reaction products showed 16.6% conversion of the tetrachloropropene to three major products. Further analysis indicated the following products in decreasing order of concentration: 1,1,1,3-tetrachloropropanone; chloroacetyl chloride; 1,1,2-trichloropropionyl chloride; dichloroacetyl chloride; chloroform and phosgene.
EXAMPLE 19
Trans-1,4-dichloro-2-butene was oxidized, without catalyst addition, using the equipment and in the manner described in Example 10. The reactor was charged with 35 grams of trans-1,4-dichloro-2-butene. Reaction conditions employed were 100°C. and 150 p.s.i.g. The progress of the reaction is shown in the following table.
______________________________________Reaction Time Oxygen Consumed by(minutes) Reaction (grams) Remarks______________________________________ Run started3 0.50 reaction exothermed to 115°C.5 1.10 reaction exothermed to 165°C.7 1.64 reaction tempera- ture 140°C.9 1.78 reaction tempera- ture 125°C.10 1.92 reaction tempera- ture 115°C.15 2.06 reaction tempera- ture 100°C.18 2.19 Run ended.______________________________________
Oxygen consumption indicated 48.8% conversion of trans-1,4-dichloro-2-butene, based on 1/2 mole oxygen/mole trans-1,4-dichloro-2-butene.
Analysis of reaction products indicated the following products in decreasing order of concentration: chlorohydroxybutanol; 1,3,4-trichloro-2-butanone; chlorobutanol; chloroacetaldehyde and dichlorobutanone.
EXAMPLE 20
Tetrachloroethylene was oxidized continuously, without catalyst addition, in the manner of Example 4 under conditions of 100°C., 400 p.s.i.g. and using a 4-hr. reactor contact time. The run was continued for about 18 hrs. Under reaction equilibrium, sample analysis by G.L.C. showed the following results:
O O ∥ ∠Cl.sub.2 C=CCl.sub.2 Cl.sub.3 C--CCl Cl.sub.2 C--CCl.sub.2 COCl.sub.2Conv. % Yield (%) Yield (%) Yield (%)______________________________________21.2 71.5 18.4 8.3______________________________________
The above run was continued except that the reactor feed was switched to a mixture comprised of 23.2% 1,1-dichloroethylene and 76.8% tetrachloroethylene. After only 1 hr. continued run time the tetrachloroethylene conversion increased to 58.2%. The run was continued for about 8 hrs. Under reaction equilibrium conditions the following results were obtained:
O O ∥ ∠Cl.sub.2 C=CCl.sub.2 Cl.sub.3 C--CCl Cl.sub.2 C--CCl.sub.2 COCl.sub.2Conv. (%) Yield (%) Yield (%) Yield (%)______________________________________80.8 90.1 0 9.9______________________________________
About 99% of the 1,1-dichloroethylene was converted to yield about 90% chloroacetyl chloride.
EXAMPLE 21
1,2-Dichloroethylene was oxidized continuously, without catalyst addition, in the manner of Example 5 and under conditions of 100°C. R-I temperature, 150°C. R-II temperature, 300 p.s.i.g. and using an 8 hr. reactor contact time. The run was continued for about 24 hrs. Under reaction equilibrium conditions only about 2% of the 1,2-dichloroethylene was converted to yield primarily 1,2-dichloroethylene oxide and dichloroacetaldehyde.
The above run was repeated under the same conditions except using a feed mixture comprised of 50% 1,2-dichloroethylene and 50% tetrachloroethylene. The run was continued for about 22 hours. Under reaction equilibrium conditions 34.2% of the 1,2-dichloroethylene was converted to yield primarily 1,2-dichloroethylene oxide and dichloroacetaldehyde. At the same time, about 30% of the tetrachloroethylene was converted to yield 93.3% trichloroacetyl chloride.
EXAMPLE 22
Using the equipment in the manner described in Example 10, an attempt was made to oxidize 3-chloropropene under conditions of 80°C. and 150 p.s.i.g. The run was allowed to continue for about 18 hrs., during which time no appreciable oxygen consumption was observed.
The reaction exhibited strong inhibition due to impurities in the 3-chloropropene. Sample analysis showed less than 1% conversion of the 3-chloropropene.
The above run was repeated except that 0.1% 1,1-dichloroethylene was added to the 3-chloropropene reactor charge. After an induction time of about 1 hr. oxygen consumption began. The reaction was allowed to continue for about 18 hrs. after which time the oxygen consumed indicated 39.6% conversion of the 3-chloropropene based on 0.5 mole oxygen per mole of 3-chloropropene.
EXAMPLE 23
Stabilized tetrachloroethylene was oxidized, without catalyst addition, using the equipment and in the manner described in Example 10, under conditions of 100°C. and 150 p.s.i.g. The reactor was fitted with means of remote sampling and means of purging oxygen through the reaction medium and venting from the reactor. Small samples were removed from the reactor periodically and analyzed. The reaction was allowed to continue for a period of 18 hrs. at which time analyses indicated that tetrachloroethylene conversion was remaining constant at about 25% with 83.4% yield to trichloroacetyl chloride, 7.4% yield to tetrachloroethylene oxide and 9.2% yield to phosgene. At this time oxygen was gently purged through the reactor for about 5 minutes to remove the major portion of accumulated phosgene and the reaction then continued. Sample analysis showed tetrachloroethylene conversion to immediately increase and after about two hours to again remain constant at about 32% conversion of tetrachloroetylene with similar product yields. The reaction was continued for an additional 16 hours during which time oxygen was continuously purged through the reactor at a low rate. Conversion steadily increased during this time and analysis of the final products indicated about 98% conversion of the tetrachloroethylene and about 97% yield to trichloroacetyl chloride.
EXAMPLE 24
Tetrachloroethylene is continuously oxidized in a three stage reactor system at a pressure of about 800 p.s.i.g. wherein the temperature of the first reactor is about 100°C., the temperature of the second reactor is 250°C. and the temperature of the third reactor is 150°C. A vapor space is maintained in the top of each reactor, product is removed from the bottom of each reactor and a continuous purge of oxygen is maintained through each reactor, with the excess oxygen and phosgene vented from the top of each reactor. In this system conversion of about 98% can be obtained in six hours.
EXAMPLE 25
Tribromoethylene was oxidized, without catalyst addition, using the equipment and in the manner described in Example 10. The reactor was charged with 90 grams (0.3399 mole) of tribromoethylene. The reaction was started at 27°C. and at a pressure of 150 p.s.i.g. No heat was applied. The progress of the reaction is shown in the following table.
______________________________________Reaction Time Oxygen Consumed by(Minutes) Reaction (grams) Remarks______________________________________2 0.30 reaction temp. began increasing3 0.74 reaction temp. at 50°C.4 1.485 2.07 reaction temp. at 55°C.8 2.52 reaction temp. at 60°C.12 2.66 run ended temp. at 60°C.______________________________________
Based on oxygen consumption, 48.9% conversion of tribromoethylene was obtained (assuming 0.5 mole oxygen per mole of tribromoethylene charged). Sample analysis by G.L.C. indicated about 50% conversion of tribromoethylene.
The product was analyzed by the combined use of G.L.C., mass spectroscopy and infra-red techniques and the oxidation products were identified as:
dibromoacetyl bromide
tribromoacetaldehyde, and
methyl dibromoacetate.
In accordance with this invention, other halo-olefins such as fluoro-olefins, fluoro-chloro-olefins, chloro-bromo-olefins and fluoro-bromo-olefins were also converted to useful oxygenated products. For example, hexafluoropropene is oxidized to hexafluoropropanone and pentafluoropropionyl fluoride, chlorodifluoroacetyl chloride is obtained by the oxidation of 1,1-dichloro-2,2-difluoroethylene and fluorodichloroacetyl fluoride is obtained by the oxidation of 1,2-dichloro-1,2-difluoroethylene.
Various modifications may be made in the present invention without departing from the spirit or scope thereof and it is understood that I limit myself only as defined in the appended claims.
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Process for the non-catalytic liquid phase oxidation of halo-olefins, having 2 to 7 carbon atoms, by O 2 at elevated temperatures and pressures to produce oxygenated organic products having the same number of carbon atoms as the starting material.
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FIELD OF THE ART
[0001] The present invention refers to the technology of equipment, applied to operating machines provided with hydraulic or electric plant, and in particular to the buckets of the loading and digging machines. The international classification of reference is E 01 C.
STATE OF THE ART
[0002] Machines to crush stones or different kinds of debris are known. The problem to be solved is that of equipping operating machines of small dimensions with buckets provided with rotating crushing devices activated by engines hydraulic or electric gear motors fed by the hydraulic or electric circuit resting inside operating machines or outside the bucket.
DESCRIPTION
[0003] The invention is now disclosed with reference to the figures of the attached drawings, as unrestrictive example.
[0004] FIG. 1 shows schematically in a transversal section a bucket (B) inside which there is at least one rotor (R) provided with a crushing blade (L) that interacts with the fixed plates (F) applied inside the bucket. It can be noticed the presence of the upper feed opening (A) and of the lower emptying out mouth (S).
[0005] FIG. 2 shows schematically in a transversal section a bucket (B) inside which there is a rotor (R) provided with two crushing blades (L′) that interact with the fixed blades (F′).
[0006] FIG. 3 shows schematically in a transversal section a bucket with the rotor provided with three crushing blades (L″) that interact with fixed blades (F″) that are especially shaped.
[0007] FIG. 4 shows schematically in transversal section a bucket with the rotor provided with four crushing blades (L′″) that interact with the matching fixed plates (F′″).
[0008] FIG. 5 shows a bucket (B) during the crushing operation of the various material and the emptying out of the resulting debris.
[0009] FIG. 6 shows schematically in section a bucket (B) provided with an upper lid (K) closing the feeding opening and a lid (H) closing the emptying out mouth.
[0010] FIG. 7 shows an operating machine (T) equipped with a bucket (B) in loading position.
[0011] FIG. 8 shows an operating machines (T) provided with a bucket (B) in the position of crushing the previously loaded material.
[0012] FIG. 9 shows an operating machine (T′) with the bucket (B), working towards the operating machines, in operating position of crushing the previously loaded material.
[0013] FIG. 10 shows an operating machine (T′) equipped with the bucket (B) that works in the opposite direction.
[0014] FIGS. 11 a, 11 b, 11 c, 11 d and 11 e show some examples of different type of crushing blades located on the rotor in a different number and different fashion.
[0015] FIG. 12 shows schematically in plant the bucket (B) equipped with a rotor (R) provided with crushing blades (L) interacting with their respective fixed plates (F). It can be noticed that the rotor (R) is actuated by two engines or by two hydraulic or electric rotors (M, M′), both inside the body of the bucket (B).
[0016] FIG. 13 shows schematically the application of two motors or rotors (M, M′) outside the body of the bucket (B).
[0017] FIG. 14 shows schematically the application of a single engine or rotor (M) inside the bucket (B).
[0018] FIG. 15 shows schematically the application of a single engine or rotor (M) outside the bucket (B).
[0019] FIG. 16 shows schematically a bucket equipped internally with two rotors (R, R′).
[0020] FIG. 17 a , 17 b , 17 c , 17 d show schematically a bucket whose fixed plates are respectively replaced by a flat surface, or by a shaped surface, or by a cylindrical surface, or by different shapes, either fixed, moving or rotating.
[0021] The clearness of the figures highlights the executive and operative simplicity of the present invention, which wholly solves all the technical problems ensuring a security and total functioning reliability, coupled with a extreme affordability in the practical realization.
[0022] Now that the original inventive features of the present invention have been disclosed, any average technician skilled in this specific technological field will be able to realize, with simple logical deductions and without any inventive effort, buckets that are interchangeably applicable to operating machines provided with hydraulic or electric plant, that rests either inside of the machine or nonetheless outside the bucket, that will present the very original features of the present invention as so far described, illustrated and hereinafter claimed.
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A bucket (B) that is applicable interchangeably to operating machines provided with hydraulic or electric plant, equipped with one or more rotors (R) actuated by one or more hydraulic or electric (M) engines or gear motors fed by the hydraulic or electric circuit resting inside operating machines or outside the bucket.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to scuba diving apparatus, and more particularly pertains to an in-line air pressure regulator interposed between a tank of high pressure air and a second stage demand regulator.
2. Description of the Prior Art
The average recreational scuba diver must carry a tank filled with life sustaining air on his back while underwater. In order for this air to be breathable, it must be reduced from the very high pressure that is found in the tank to a much lower pressure that enables the breathing apparatus or second stage regulator to operate properly. With today's present technology, a large bulky and somewhat cumbersome regulator is attached to the scuba diver's tank in order to reduce this high pressure air from the tank to a much lower pressure at which the second stage or demand regulator can operate properly. The existing type of first stage regulator in common use today also has several optional ports providing both high and low air pressure for optional equipment used in diving. The addition of these optional ports increases the overall size of the first stage. It is a highly recommended practice when diving that the diver be equipped with a spare or alternate second stage air pressure regulator due to the dangers of equipment failure while underwater. It is common practice for most divers to be equipped with such a spare second stage regulator, but the spare regulator relies on the same first stage regulator to reduce the high pressure air to a lower pressure at which the second stage regulator can work as the diver's primary second stage regulator.
Therefore, if the diver's first stage regulator should fail, then both his primary and spare second stage regulators will be inoperative. There is available for purchase today a Y-type of tank valve that with the purchase of an additional first stage regulator gives the diver the option of having two air supplies completely independent of each other. But due to the large expense and the fact that the Y-valve is threaded into the diver's tank permanently, this is not a viable solution for a diver who travels and uses rented tanks. More specifically, this Y-valve connection cannot be easily removed from a diver's personal tank to be carried with him to another location where he must rent commercially available tanks.
As such, it can be appreciated that there exists a continuing need for new and improved auxiliary first stage air pressure regulators which can be utilized to backup an existing first stage air pressure regulator. In this regard, the present invention substantially fulfills this need by providing a first stage regulator that utilizes present technology but gives the diver two completely independent of each other air supplies with the use of a standard tank supply valve. The diver is also given the convenience of using rented tanks which then have two independent air supplies.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of first stage air pressure regulators now present in the prior art, the present invention provides an improved first stage air pressure regulator construction wherein the same can be used as an auxiliary first stage air pressure regulator by being attached to a high pressure air port forming a part of an existing first stage air pressure regulator. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved auxiliary first stage air pressure regulator which has all the advantages of the prior art first stage air pressure regulators and none of the disadvantages
To attain this, the present invention essentially comprises a first stage air pressure regulator that is small and compact enough so that it can be attached at one end to a high pressure line that comes from a high pressure port found on all standard first stage air pressure air regulators, with the other end being attached to an air supply conduit that leads to the diver's spare second stage demand regulator. As such, the diver is given the convenience of two completely independent of each other air supplies to use in case of a primary regulator failure. Since the valve comprising the present invention is attached at one end to an air supply conduit that goes to a high pressure port on the primary first stage regulator with its other end being attached to a conduit that goes to a diver's spare second stage regulator, the present invention can be used on any tank with a standard air valve.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved auxiliary first stage air pressure regulator which has all the advantages of the prior art auxiliary first stage air pressure regulators and none of the disadvantages.
It is another object of the present invention to provide a new and improved auxiliary first stage air pressure regulator which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved auxiliary first stage air pressure regulator which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved auxiliary first stage air pressure regulator which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such auxiliary first stage air pressure regulators economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved auxiliary first stage air pressure regulator which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved auxiliary first stage air pressure regulator which can be attached in-line to an existing auxiliary second stage or demand air pressure regulator, thereby to provide two independent air supplies to a diver from a high pressure air supply tank.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an end elevation view of the housing forming a part of the present invention.
FIG. 2 is a cross-sectional view of the housing taken along the line 2--2 in FIG. 1.
FIG. 3 is a left end elevation view of a piston forming a part of the present invention.
FIG. 4 is a cross-sectional view of the piston as taken along the line 4--4 in FIG. 3.
FIG. 5 is a right end elevation view of the piston.
FIG. 6 is an end elevation view of a low pressure end cap forming a part of the present invention.
FIG. 7 is a side elevation view of the low pressure end cap.
FIG. 8 is an end elevation view of a high pressure end cap forming a part of the present invention.
FIG. 9 is a side elevation view of the high pressure end cap.
FIG. 10 is a cross-sectional view of the high pressure end cap as taken long the line 10--10 in FIG. 8.
FIG. 11 is an end elevation view of the assembled auxiliary first stage air pressure regulator forming the present invention.
FIG. 12 is a cross-sectional view of the auxiliary first stage air pressure regulator as taken along the line 12--12 in FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1-12 thereof, a new and improved auxiliary first stage air pressure regulator embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More particularly, the in-line first stage air pressure regulator 10 includes a housing 12 which is of a cylindrical construction and which is provided with a through-extending bore 14. The housing 12 is appropriately threaded at opposed ends 16, 18, and is provided with a pair of aligned internal cylindrical chambers 20, 22 interconnected by an axially-aligned bore 24. A pair of pressure balancing 26, 28 are orthogonally directed through the sidewalls of the housing 12 so as to provide fluid communication between the ambient atmosphere and the first cylindrical chamber 20. The axial alignment of the first chamber 20, the second chamber 22, and the interconnection bore 24 provide for a fluid communication between the opposed threaded ends 16, 18 of the housing 12.
FIGS. 3, 4, 5 and 12 illustrate a piston 30 which is positionable within the housing 12 for a purpose yet to be described. The piston 30 includes an enlarged cylindrically shaped piston head 32 having a circumferentially extending groove 34 for receiving a sealing o-ring 36. An internal face 38 of the piston head 32 includes a circular groove 40 designed to capture and retain the end of a compression spring 42 as best illustrated in FIG. 12.
The piston 30 further includes an integral elongated shaft 44 attached to the piston head 32 having a beveled end 46 and a further circumferentially extending groove 48 for holding a sealing o-ring 50. The piston 30 also includes an axially aligned, through-extending metering orifice 52. The metering orifice 52 is shown on an enlarged scale in FIG. 4; however, it is envisioned that the orifice will be of such a size as to substantially restrict air flow therethrough.
As shown in FIGS. 6, 7 and 12, one end of the housing 12 is threadably or otherwise closed by a removable low pressure end cap 54. The low pressure end cap 54 includes a through-extending orifice 56 which allows fluid communication with the first air chamber 20, thereby to provide for a continuous air flow path through the air regulator 10.
FIGS. 8, 9 10 and 12 illustrate a high pressure end cap 58 which is used to seal the opposed end of the housing 12, with this cap having a through-extending, L-shaped orifice 60 so as to provide fluid communication with the second air chamber 22. Additionally, a bleed orifice 62 is provided in the high pressure end cap 58, wherein this bleed orifice can be used to selectively provide air supplies to other devices commonly used in scuba diving. Normally however, the orifice 62 would be closed with a plug 63.
With particular reference to FIGS. 10 and 12 of the drawings, it will be noted that one end of the high pressure end cap 58 is also provided with a beveled section 64 with this beveled end functioning as a valve seat and being engageable with the beveled end 46 of the piston 30.
In operation, a user need only to attach a conduit from the existing first stage air pressure regulator on a scuba tank to the orifice 60 associated with the high pressure end cap 58. A flexible conduit to a second auxiliary second stage air pressure regulator is then threadably attached to the orifice 56 associated with the low pressure end cap 54. High pressure air delivered through the orifice 60 travels to the secondary air chamber 22 and around the beveled end 46 of the piston 30. The air travels down the metering orifice 52 outwardly through the orifice 56 to the second stage regulator. This high pressure air additionally forces the piston 30 to move against the compression of the spring 42 whereby the beveled section 46 of the piston comes into engagement with the beveled section 64 formed in the high pressure cap 58. This movement of the piston 30 effectively causes a slight fluctuating on-and-off supplying of air through the metering orifice 52 in as much as the meeting of the beveled surfaces 46, 64 operates as a valve seat to control air flow. The face 33 of the piston 30, as best illustrated in FIG. 4, can be provided with a concavity or other hollowed out section to greatly increase the area against which the air pressure operates thereby to cause a more effective movement of the piston 30. While the piston face 33 is shown as flat in FIG. 4, it is to be understood that it can be beveled out partially or to any degree desired to increase the air contact surface. As shown, the air pressure regulator 10 comprising the present invention may be positioned in line between the existing first stage air pressure regulator, thereby to provide a desired safety backup function or alternatively, it can be utilized as a primary stage regulator in and of itself.
As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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An in-line air pressure regulator for scuba diving is designed to augment an independent air supply system in the event of a failure of the primary pressure regulator. The in-line air pressure regulator comprises a small, encapsulated, spring-biased valve which is designed to reduce tank pressure to a level which is compatible with the spare, or backup, second stage regulator. In effect, it is a simplified auxiliary primary air pressure regulator.
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FIELD OF THE INVENTION
This invention relates to high density integrated circuit non-volatile memory, and specifically to a method of making a ferroelectric device wherein etching of a bottom electrode is accomplished without damaging the underlying substrate.
BACKGROUND OF THE INVENTION
One of the most difficult steps in metal/ferro metal oxide semiconductor (MFMOS) ferroelectric memory transistor fabrication is that of etching the bottom electrode. In known NFMOS ferroelectric memory transistor fabrication, the bottom electrode must be selectively etched, without etching through the thin oxide located beneath the bottom electrode, and thereby penetrating the silicon substrate. The oxide located below the bottom electrode may be silicon dioxide, or any other suitable high-k insulator. If the silicon substrate is inadvertently etched, it will be impossible to form source/drain junctions which have adequate connections to the conductive channel of the transistor.
SUMMARY OF THE INVENTION
A method of making a ferroelectric memory transistor includes preparing a silicon substrate including forming plural active areas thereon; depositing a layer of gate insulator on the substrate, and depositing a layer of polysilicon over the gate insulator layer; forming a source region, a drain region and a gate electrode; depositing a layer of bottom electrode material and finishing the bottom electrode without damaging the underlying gate insulator and silicon substrate; depositing a layer of ferroelectric material on the bottom electrode, depositing a layer of top electrode material on the ferroelectric material; and finishing the transistor, including passivation oxide deposition, contact hole etching and metalization.
An object of the invention is to provide a production method for single transistor ferroelectric memory device fabrication.
Another object of the invention is to provide a method of forming a bottom electrode in a ferroelectric stack without penetrating the underlying silicon substrate.
This summary and objectives of the invention are provided to enable quick comprehension of the nature of the invention. A more thorough understanding of the invention may be obtained by reference to the following detailed description of the preferred embodiment of the invention in connection with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-10 depict successive steps in a first embodiment of the method of the invention.
FIGS. 11-12 depict successive steps in a second embodiment of the method of the invention.
FIGS. 13-16 depict successive steps in an alternate embodiment of the method of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The fabrication process for a ferroelectric memory transistor constructed according to the method of the invention does not require highly selective etching for the electrode etching process. Referring initially to FIG. 1, a silicon substrate 20 is a p-type silicon wafer. Boron is implanted into what will become the p-well regions of the wafer. The implanted wafer is heated to diffuse the implanted ions to form a p-well. A thin layer of gate insulator 22 , such as a layer of gate oxide, is grown and a layer of undoped polysilicon 24 is deposited. Alternately, the gate oxide may be replaced with a layer of high-k gate dielectric. A layer of photoresist 26 is applied prior to a trench isolation process, as shown in FIG. 1 . The figures depict the construction of two transistors wherein the left side of the drawing figure depicts one transistor and the right side of the drawing figure depicts a second transistor, turned 90° from the view of the left side of the drawing figure.
Turning to FIG. 2, shallow trenches 28 , 30 , 32 are etched through the polysilicon, the gate insulator and through about 500 nm of silicon substrate. The photoresist is then removed. Any plasma etching damage is removed, the wafer is cleaned, and a layer of oxide 34 is deposited onto the wafer. The thickness of the oxide is at least 1.5 times, and may be more than 2 times thicker than the depth of the shallow trenches. CMP is used, stopping at the level of polysilicon, to planarize the wafer. All of the polysilicon, except that on the active areas, is removed, as shown in FIG. 2 .
Photoresist is applied and the polysilicon selectively etched to form a source area 36 and a drain area 38 , and to form a gate electrode 40 . The source and drain of the device is implanted with arsenic or phosphorus ions, as shown in FIG. 3 . Exemplar implantation specification are by implantation of arsenic ions, at a dose of about 1·10 15 cm −2 to 5·10 15 cm −2 , and at an energy level of 30 keV to 60 keV, or implantation of phosphorus ions, at a dose of about 1·10 15 cm −2 to 5·10 15 cm − 2, and at an energy level of 10 keV to 30 keV, to form N+, heavily doped polysilicon. A thin layer of oxide 44 is deposited onto the wafer and the wafer is CMP plainarized, as shown in FIG. 4 .
Bottom electrodes 46 are deposited onto the wafer, and are finished by etching or CMP, without damaging underlying gate insulator layer 22 or silicon substrate 20 . If the bottom electrode cannot be removed by a CNIP process, such as when pure iridium is used as the bottom electrode, photoresist is applied prior to etching of the bottom electrode. With respect to conventional etching techniques, the bottom electrode has very similar characteristics to the remaining polysilicon gate, which assists in stopping the downward penetration of the etching process. In this embodiment of the method of the invention, bottom electrode 46 and polysilicon 40 are not perfectly aligned, as shown in FIGS. 5 to 12 . A thin layer of oxide 50 is deposited and is plainarized by CMP, resulting in the structure shown in FIG. 6 .
If the bottom electrode is formed of a material which may be polished, such as Pt, TiN, Ta, TaN, TiTaN, IrTa alloy and IrPt alloy, the steps of the preceding paragraph are replaced by selective etching of portions of N+ polysilicon, deposition of bottom electrode material, and CMP of the bottom electrode. In this case, the bottom electrode and the n+ polysilicon are self-aligned. The underlying oxide layer 22 and silicon substrate 20 are protected from penetration during polishing of the bottom electrode.
The wafer is now ready for deposition of the ferroelectric material. After a layer of ferroelectric thin film material 52 is deposited, the top electrode material 54 is deposited, as shown in FIG. 7 .
Photoresist is applied to mask the top electrode prior to etching. Top electrode 54 functions as a control gate, therefore, it extends beyond the horizontal boundaries of the active area. The ferroelectric thin film may also be etched during this step, with the resulting structure depicted in FIG. 8 . However, because etching a ferroelectric thin film usually degrades the ferroelectric property of the thin film, etching the ferroelectric thin film may be done in a separate step, using techniques less likely to degrade the ferroelectric properties of the thin film.
A thin layer of dielectric 56 , such as titanium oxide or aluminum oxide, is deposited to protect the ferroelectric thin film from hydrogen damage, as shown in FIG. 9 .
The remaining steps of passivation oxide deposition 58 , contact hole etching and metallization 60 , 62 , 64 and 66 , may be accomplished using any state-of-the-art process, resulting in the finished structure depicted in FIG. 10 .
Optionally, the structure of FIG. 9 may be masked an a plasma etch process used to remove the horizontally disposed portions of the dielectric thin film, except on the sidewall of the top electrode and ferroelectric stack, as is shown in FIG. 11 . The finished structure for this embodiment of the method of the invention is depicted in FIG. 12 .
Several alternative steps may be performed during fabrication of a ferroelectric memory transistor according to the method of the invention. One alternative step take place after those steps described in connection with FIG. 6, wherein a thin layer oxide 70 , having a thickness of between about 100 nm to 400 nm, is deposited as is shown in FIG. 13, over the already-deposited oxide and the bottom electrode. Photoresist 72 is applied, and the oxide is etched to open holes 74 , 76 where ferroelectric memory material is to be deposited for the memory transistor, as shown in FIG. 14 . The resist is then removed .
A thin layer of barrier dielectric 78 , such as titanium oxide or aluminum oxide, is deposited and is plasma etched to form a protective layer at the sidewall of the holes previously opened, as is shown in FIG. 15 .
Ferroelectric material 52 is then deposited onto the wafer. Although both MOCVD and spin-on coating may be applied, the spin-on coating is preferred. A low viscosity precursor spin-on coating will fill the holes more economically. The ferroelectric material on the top surface is etched. This may be achieved with or without an etch mask, or by a CMP process. If the etching is done without a mask, the etching also etches a portion of the ferroelectric material at the transistor area, that is, in the hole area.
The remaining ferroelectric material thickness is the required ferroelectric material thickness for the memory transistor. Top electrode 54 is deposited and etched to form the control gate of the memory transistor, as shown in FIG. 16 . The remaining process steps of CVD of oxide, application of photoresist prior to opening contact holes, and final metallization may be accomplished by any of the state-of-the-art techniques.
Thus, a method of making a ferroelectric memory transistor has been disclosed. It will be appreciated that further variations and modifications thereof may be made within the scope of the invention as defined in the appended claims.
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A method of making a ferroelectric memory transistor includes preparing a silicon substrate including forming plural active areas thereon; depositing a layer of gate insulator on the substrate, and depositing a layer of polysilicon over the gate insulator layer; forming a source region, a drain region and a gate electrode; depositing a layer of bottom electrode material and finishing the bottom electrode without damaging the underlying gate insulator and silicon substrate; depositing a layer of ferroelectric material on the bottom electrode; depositing a layer of top electrode material on the ferroelectric material; and finishing the transistor, including passivation oxide deposition, contact hole etching and metalization.
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BACKGROUND OF THE INVENTION
The present invention relates to a bath and method for the desizing and bleaching of fabrics in a single operation in a bath based on hydrogen peroxide.
Such a bath and method are the subject of French patent application No. 80 27866, equivalent to U.S. Pat. No. 4,457,760.
French patent application No. 80 27866 discloses using a bath comprising hydrogen peroxide, sodium hydroxide, a sequestering agent, an amylase, a surfactant, and, optionally, a stabilizing agent such as sodium silicate.
The commercial implementation of this procedure has encountered certain difficulties. On the one hand, the results obtained depend on the pH fixed at the start. In fact, at a very alkaline pH the bleaching is excellent, but the desizing generally is inadequate. Conversely, at a low alkaline pH the desizing is good but the bleaching is inadequate.
On the other hand, the level of results is closely linked to the nature of the fabric subjected to the desizing/bleaching treatment, with the enzymatic degradation of the starches used as sizing generating acidic products which cause the pH to fluctuate during the course of the reaction.
Depending on the quantity and the nature of the starches used for the sizing of the fabric, the pH of the desizing/bleaching bath is more or less modified during the course of the treatment, leading to important differences between the level of bleaching results and the level of desizing results.
These observations have led the applicant to search for a buffer capable of fixing the pH of the desizing/bleaching bath in order to have at one's disposal a simultaneous desizing/bleaching procedure, making it possible to obtain both optimum desizing and bleaching, while at the same time not adversely affecting the degree of polymerization of the particular fiber.
SUMMARY OF THE INVENTION
The present invention overcomes the problems discussed above and furnishes an improved bath and method for the simultaneous desizing/bleaching of fabrics.
Briefly stated, the bath comprises hydrogen peroxide, a sequestering agent, an amylase, a surfactant, and sodium tetraborate decahydrate. Optionally, sodium silicate can be added as a stabilizing agent.
The invention also comprises the method of simultaneously desizing and bleaching fabrics comprising saturating a sized fabric with the above-noted bath, maintaining said saturated fabric for a time and at a temperature sufficient to desize and bleach to the degree desired, and then washing said fabric to remove the unreacted bath and byproducts.
DETAILED DESCRIPTION
During the course of investigation numerous buffers were tested and it was surprisingly found that only with sodium tetraborate decahydrate were a good desizing and a good bleaching obtained at the same time.
A desizing/bleaching bath utilizable according to the instant invention comprises an aqueous bath containing:
______________________________________35% H.sub.2 O.sub.2 40-60 ml/lSodium silicate about 20 g/l(stabilizing agent)Sequestering agent 2-6 g/lAmylase 8-12 g/lSurfactant 1-2 ml/l,______________________________________
and a buffer consisting of sodium tetraborate decahydrate in a quantity determined so as to fix the pH of the bath at 9.8. This is generally about 10 g of sodium tetraborate decahydrate for each liter of a bath as set forth above.
The adoption of the simultaneous desizing/bleaching method of the present invention makes it possible to achieve important savings in water, steam, labor, and capital investment and leads to desizing/bleaching results which are superior to those obtained without buffer or by utilizing another buffer which is capable of fixing the pH of the bath at an equivalent value.
Moreover, the use of sodium tetraborate decahydrate as the buffer avoids working in a strongly alkaline medium and thus protects the fabric being treated against the formation of "cracks" during the course of deposition thereof in folds.
The sizes used as starchy materials; amylaceous in nature, against which the amylase enzymes are effective.
The invention also comprises the method of desizing/bleaching that is described in greater detail in the examples that follows.
In the examples the desizing/bleaching tests described were carried out according to the following method:
(1) Saturating the sized and natural-colored (unbleached) fabric in the desizing/bleaching bath; squeezing the fabric in order to leave in the fabric only the quantity of bath necessary for the reaction; this quantity was fixed at 100% of the weight of the dry fabric;
(2) Steaming the fabric in order to raise the temperature thereof to the desired reaction temperature of about 90°-95° C.;
(3) Maintaining the temperature at about 90°-95° C. for approximately one hour while the fabric is either in folds or in a roll; and
(4) Washing in aqueous baths, first, at 90°-95° C., then at 60° C., and finally in a cold bath of water to remove whatever remains of the bath and byproducts.
The basic aqueous desizing/bleaching bath used in the examples that follow contained for each liter:
______________________________________Ethylene Diamine Tetraacetic 2 g/lAcid (TRILON C by B.A.S.F.)Sodium silicate 20 g/l35% Hydrogen peroxide 40 ml/lHigh temperature Amylase 10 g/l(Enzylase C by DIAMALT)Non-ionic wetting agent 1.5 ml/l(UKANIL 1036 by PCUK)______________________________________
The following examples are set forth for purposes of illustration of the invention only and not by way of limitation.
EXAMPLES 1 TO 5
Examples 1 to 5 were carried out with a 100% cotton cloth of 160 g/m 2 containing as sizing 9.20% of starch compounds (amylaceous materials) and having a ZEISS ELREPHO reflectance of 56° and a polymerization index of 1940.
The following buffers were tested by being added to the bath noted above (the quantities indicated are expressed in g for 1/l of bath):
______________________________________Example 1 Sodium formate 15 g/l pH obtained: 10.4Example 2 Sodium bicarbonate 22 g/l Potassium carbonate 8.4 g/l pH obtained: 9.5Example 3 Sodium metaborate 14 g/l pH obtained: 9.8Example 4 Glycine 20 g/l pH obtained: 10.4Example 5 Sodium tetraborate deca- 10 g/l hydrate pH obtained: 9.8______________________________________
Examples 1 to 4 are comparative examples and Example 5 illustrates a procedure according to the present invention. The results obtained are set forth in Table I below.
TABLE I______________________________________ Hydrophilic Residual starch affinity White in %/weight of (absorbency)Example (in °ELREPHO) fabric s______________________________________1 81.5 0.60 0.42 78.2 1.95 0.23 83.5 0.61 1.04 78.9 0.34 0.45 82.5 0.22 0.1 DP* = 1620______________________________________ *Degree of polymerization
Only the use of sodium metaborate (Example 3) yields a degree of white superior to the one obtained with sodium tetraborate decahydrate (Example 5 according to the invention), but the ratio of residual starch obtained in Example 3 is too high (the ratio of residual starch of Example 3 amounts to 0.61, while it is only 0.22 in Example 5).
Moreover, the hydrophilic affinity of Example 5 is 10 times lower than that of Example 3. Also, the degree of polymerization (DP=1620) obtained in Example 5 according to the invention shows that the fiber is not degraded during the course of the desizing/bleaching operation.
EXAMPLES 6 TO 10
Examples 6 to 10 were carried out with a 100% cotton cretonne of 190 g/m 2 containing as sizing 11.57% of starch compounds (amylaceous materials) and having a ZEISS ELROPHO reflectance of 55° and a polymerization index of 2700.
The buffers tested were identical to the ones tested in Examples 1-5. The buffer of Example 6 is identical to the one used in Example 1; Example 7 corresponds to Example 2; Example 8 corresponds to Example 3; Example 9 corresponds to Example 4, and Example 10 corresponds to Example 5.
Examples 6 to 9 are comparative examples, while Example 10 illustrates a method according to the present invention.
The results are set forth in Table II below.
TABLE II______________________________________ Hydrophilic Residual starch affinity White in %/weight of (absorbency)Example (in °ELREPHO) fabric s______________________________________6 76.2 0.85 17 73.3 2.92 18 77.9 0.79 1.69 75.6 0.42 110 76.8 0.21 1.2 DP = 1930______________________________________
EXAMPLES 11 TO 15
Examples 11 to 15 were carried out with a 100% cotton poplin of 140 g/m 2 containing as sizing 7.6% of starch compounds (amylaceous materials) and having a ZEISS ELREPHO reflectance of 52.2°, and a polymerization index of 2700.
The buffers tested are as follows: The buffer of Example 11 is identical to the one used in Example 1; Example 12 corresponds to Example 2; Example 13 corresponds to Example 3; Example 14 corresponds to Example 4; and Example 15 corresponds to Example 5.
Examples 11 to 14 are comparative examples, and Example 15 illustrates a desizing/bleaching procedure according to the present invention.
The results are set forth in Table III below.
TABLE III______________________________________ Hydrophilic Residual starch affinity White in %/weight of (absorbency)Example (in °ELREPHO) fabric s______________________________________11 80.9 1.82 1.412 75.9 7.7 0.913 83 3.31 114 79.6 2.5 1.215 82.6 0.79 1 DP = 1830______________________________________
The above examples show that only the use of sodium tetraborate decahydrate according to the present invention makes it possible to simultaneously obtain a good bleaching and a satisfactory desizing (starch removal).
EXAMPLES 16 TO 18
The bath described above, to which 10 g/l of sodium tetraborate decahydrate were added, was used in order to carry out the simultaneous desizing/bleaching of three different 67/33 polyester/cotton fabrics whose ratios of starchy compounds (amylaceous materials), respectively, were:
______________________________________ Example 16 12.2% Example 17 9.5% Example 18 8.9%______________________________________
The results are set forth in Table IV below.
TABLE IV______________________________________ Hydrophilic Residual starch affinity White in %/weight of (absorbency)Example (in °ELREPHO) fabric s______________________________________16 85.6 0 0.417 81.4 0 0.818 85.1 0 0.8______________________________________
The fabrics contained no starch and the white content obtained was remarkable.
It will be understood that the reaction time can be varied dependent upon the degree of bleaching (whiteness) and starch removal desired.
While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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A bath for the simultaneous desizing and bleaching of fabrics comprising hydrogen peroxide, a sequestering agent, an amylase, a surfactant, and a buffer consisting essentially of sodium tetraborate decahydrate. Also, the method for the simultaneous desizing and bleaching a fabric comprising saturating a fabric with the above destarching and bleaching bath, maintaining the saturated fabric for a time and at a temperature sufficient to desize and bleach to the desired degree, and washing the fabric.
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TECHNICAL FIELD
[0001] The invention concerns vaccines against Neisseria meningitidis
BACKGROUND ART
[0002] Neisseria meningitidis is the cause of epidemic bacterial meningitis. Capsular polysaccharide is a major virulence determinant of N. meningitidis . Among the 13 meningococcal serogroups classified based on capsular polysaccharide structure, serogroups A, B, C, Y, and W135 are associated with the majority of cases of meningococcal disease. In the African meningitis belt most large epidemics have been caused by serogroup A meningococci, whereas sporadic disease and outbreaks in developed countries are usually caused by serogroup B and C meningococci. Serogroup Y meningococci emerged as an important cause of sporadic disease and outbreaks in the United States in the late 1990s, and in 2000 serogroup W135 meningococci caused worldwide disease in association with the Hajj pilgrimage and large outbreaks in sub-Saharan Africa.
[0003] Serogroup X Neisseria meningitidis (MenX), previously a rare cause of sporadic cases of meningitis, has recently been associated with increased incidence of meningococcal disease and has emerged as a cause of large outbreaks in the “Meningitis Belt” of Africa. Outbreaks have been documented in Niger, Burkina Faso, Togo and Ghana and have varied in size. In the meningitis season of 2010 over 6500 meningitis cases were reported in Burkina Faso, and it is reasonable to assume that at least 1000 of these cases were due to MenX with a locally reported incidence of 120 cases per 100,000. Earlier, several patients were confirmed with MenX disease in an outbreak of at least 82 cases of bacterial meningitis on the border of Kenya and Uganda in 2007.
[0004] The capsular polysaccharides of serogroup B, C, Y, and W135 meningococci are composed of sialic acid derivatives. Serogroup B and C meningococci express (α2-8)- and (α2-9)-linked polysialic acid, respectively, while alternating sequences of D-glucose or D-galactose and sialic acid are expressed by serogroup Y and W135 N. meningitidis . In contrast, the capsule of serogroup A meningococci is composed of (α1-6)-linked N-acetylmannosamine 6-phosphate, while N. meningitidis serogroup X synthesizes capsular polymers of (α1-4)-linked N-acetylglucosamine 1-phosphate.
[0005] The increase in incidence of MenX disease in African Meningitis Belt in the last 5 years warrants development and introduction of a MenX vaccine in selected areas of the region to prevent and control future epidemics. The conjugation of meningococcal capsular polysaccharides to a carrier protein has led to the development of monovalent (A or C) polysaccharide conjugate vaccines with high effectiveness, and immunogenicity data from clinical trials indicate that wide use of tetravalent conjugate vaccines covering serogroups A, C, Y and W-135 may be similarly effective. A similar approach may also be fruitful for MenX. Refer Ouli Xiea et al “Characterization of size, structure and purity of serogroup X Neisseria meningitidis polysaccharide, and development of an assay for quantification of human antibodies”, Vaccine 30, 2012.
[0006] Gunnstein Norheim discusses that at present vaccine against serogroup X is not available and that next generation affordable vaccines should target most prevalent serogroups: A, W-135, X. Refer “Preventing the emerging serogroup X meningococcal disease in the African. Meningitis Belt” Oxford Vaccine Group, 2011.
[0007] The lack of a vaccine against group X meningococci is a cause for concern given the outbreaks caused by meningococci of this serogroup in the past few years. Refer “Meningococcal vaccines: WHO position paper”, November 2011.
[0008] In order to facilitate Men X polysaccharide based conjugate vaccine development, it is necessary to obtain structurally intact Men X polysaccharides with higher yields.
[0009] Several synthetic media were discovered for large-scale production of meningococcal polysaccharide (Frantz, I. D. Jr. Growth Requirements of the Meningococcus. J. Bact., 43: 757-761, 1942; Catlin, B. W. Nutritional profiles of Neisseria lactamica, gonorrhoeae and meningitidis , in chemically defined media. J. Inf. Dis., 128(2): 178-194, 1973; Watson-Scherp Medium: Watson R G, et al. The specific hapten of group C (group IIa) meningococcus, II. Chemical nature. J Immunol 1958; 81:337-44; Marcelo Fossa da Paz; Júulia Baruque-Ramos; Haroldo Hiss; Márcio Alberto Vicentin; Maria Betania Batista Leal; Isaías Raw. Polysaccharide production in batch process of Neisseria meningitidis serogroup C comparing Frantz, modified Frantz and Catlin 6 cultivation media, Braz. J. Microbiol. vol. 34., no. 1. Sao Paulo January/April 2003).
[0010] U.S. Pat. No. 5,494,808 reports a large-scale, high-cell density (5 g/L dry cell weight, and an optical density of between about 10-13 at 600 nm) fermentation process for the cultivation of N. meningitidis (serogroup B 11). This patent disclose the following medium (called “MC.6”) for culturing Neisseria meningitidis for isolation of OMPC (“Outer Membrane Protein Complex”)
[0011] U.S. Pat. No. 7,399,615 discloses a fermentation composition wherein the composition omits NH 4 Cl, and an improved method′ of fermenting Neisseria (serogroups A, C, Y & W135) in a fermentation composition replaces ammonium chloride(nitrogen source) with a soy peptone(HSP-A; Nutricepts, Inc; Minneapolis, Minn.). The said fed batch fermentation(2 L), wherein the fermentation medium as well as feed solution contains HSP-A results in Men A polysaccharide yield of about 1300-1400 mg/l at an average max OD between 14-20.
[0012] U.S. Pat. No. 7,491,517 discloses a Neisseria meningitidis fastidious culture medium (NMFM) for producing capsular polysaccharides from Neisseria meningitidis (serogroups A, C, Y & W135) comprising: DI (deionizer) water, NaCl, K 2 SO 4 , KCl, trisodium citrate.2H 2 O, MgSO 4 .7H 2 O, MnSO 4 .H 2 O, MnCl 2 .6H 2 O, vitamin. B12, NAD (Nicotinamide Adenine Dinucleotide) thiamine HCl, soy peptone, D-glucose, L-glutamic acid, L-arginine, L-serine, L-cysteine, glycine, morpholinepropanesulphonic acid [MOPS], CaCO 3 to maintain pH at 6.5 to 7.0 and Fe 2 (SO 4 ) 3 for serogroup A and NH 4 Cl for serogroup W-135. The said fermentation results in polysaccharide yield of about 30-40 mg/L at an average max OD of 10.
[0013] David Bundle et al discusses preparation and isolation of Men X polysaccharide from N. meningitidis strain 247 X(Laboratory Center for Disease Control) wherein said strain was grown on a chemically defined medium (NCDM) for 18 hours. The said fermentation results in Men X polysaccharide yield of about 20 mg/L. Refer “Studies on the Group-specific Polysaccharide of Neisseria meningitidis Serogroup X and an improved Procedure for its isolation” JBC, 1974.
[0014] Ouli Xiea et al discloses preparation of MenX PS from strains BF7/07 and BF12/03. Briefly, the MenX strains were grown on Brain Heart Infusion agarplates with Levinthals' supplement, and following a pre-culturestep in 0.2 L Franz medium, the strain was cultivated in four separate 2.8 L baffled shaking flasks containing 1.0 or 1.5 L modified Franz liquid medium each. Liquid cultures were inactivated after 16 h of growth by adding formaldehyde to a final concentration of 1% (v/v). MenX PS yield per liter of growth medium appeared to be slightly higher for isolate BF 7/07 (4.5 mg/L) than for isolate BF12/03 (3.8 mg/L). Refer “Characterization of size, structure and purity of serogroup X Neisseria meningitidis polysaccharide, and development of an assay for quantification of human antibodies”, Vaccine 30, 2012.
[0015] Prior art discusses structural and yield improvement studies with respect to polysaccharides from serogroups Men A, C, Y & W135. However none of the prior art addresses the long felt need for preparation of Men X polysaccharide with higher yield which is a prerequisite for development of Men X plain polysaccharide and Men X polysaccharide protein conjugate vaccines.
[0016] Present inventors have found that prior art feeding strategies based on pH stat, spiking and constant rate which are suitable for Men A C Y W135 fermentation, however suffer from following setbacks for Men X: i) satisfactory growth but less polysaccharide yield ii) growth limiting, less polysaccharide yield and iii) satisfactory growth but early decline phase. Further prior art methods employ soya peptone & yeast extract as feed medium components that result in lower polysaccharide yield associated with increased load of protein contaminants.
[0017] It is an object of the present invention to provide improved culture, fermentation and purification conditions for preparing Neisseria meningitidis X polysaccharides with high yield and minimum impurities With said improvements, Men X polysaccharide protein conjugate vaccine manufacturing can be economical and subsequently vaccine can be made available to children of developing countries at an affordable rate.
SUMMARY OF THE INVENTION
[0018] Present invention arises from the surprising finding that it is possible to prepare Men X polysaccharide with high yields and high purity by utilizing a) a fermentation medium containing casamino acid along with other components, b) novel continuous exponential feeding strategy and feed medium composition that can result in delaying the decline phase, c) optimal fermenter conditions and d) improved purification process devoid of chromatographic methods.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 : Growth profile of “ N. meningitidis X 8210” in medium containing casamino acid in comparison with medium containing soya peptone.
[0020] FIG. 2 : 13 C NMR Spectrum of Men X
[0021] FIG. 4 : 31 P NMR Spectrum of Men X
[0022] FIG. 5 : 1 H NMR Spectrum of Men X
DETAILED DESCRIPTION OF INVENTION
[0023] Accordingly in a first embodiment, present invention preferably utilizes fermentation medium containing casamino acid as nitrogen source instead of soya peptone or yeast extract thereby providing following advantages i) significant increase in polysaccharide yield due to delay in decline phase as a result of utilization of a novel continuous exponential feeding strategy ii) 50% decrease in concentration of protein and nucleic acid contaminants at fermenter harvest 100 KDa stage itself, thereby ensuring that subsequent purification process can easily remove remaining impurities iii) scale up of fermentation medium containing casamino acid can be simple and economical.
[0024] A second embodiment of the instant invention is that said Neisseria meningitidis fermentation medium for producing capsular polysaccharides from Neisseria meningitidis X can comprise of dextrose between 9 and 10 g/l, sodium chloride between 5.5 and 6 g/l, potassium sulphate between 0.8 and 1 g/l, potassium phosphate dibasic between 3.5 and 4 g/l, ammonium chloride between 0.14 and 0.19 g/l, glutamic acid between 4.5 and 5.5 g/l, L-arginine between 0.2 and 0.4 g/l, L-serine between 0.4 and 0.6 g/l, L-cysteine between 0.24 and 0.26 g/l, magnesium chloride between 0.18 and 0.20, calcium chloride 0.02 g/l, ferrous sulphate 0.002 g/l & casamino acid between 5 and 20 g/l.
[0025] A preferred embodiment of the instant invention is that said Neisseria meningitidis fermentation medium for producing capsular polysaccharides from Neisseria meningitidis X can comprise of dextrose 10 g/l, sodium chloride between 5.8 and 6 g/l, potassium sulphate between 0.9 and 1 g/l, potassium phosphate dibasic between 3.8 and 4 g/l, ammonium chloride between 0.14 and 0.17 g/1, glutamic acid between 4.8 and 5 WI, L-arginine between 0.2 and 0.3 g/l, L-serine between 0.4 and 0.5 g/l, L-cysteine between 0.24 and 0.25 g/l, magnesium chloride between 0.18 and 0.19, calcium chloride 0.02 g/l, ferrous sulphate 0.002 g/l & casamino acid between 5 and 10 g/l.
[0026] An important aspect of the instant invention is that present inventors have surprisingly found an advantageous continuous exponential feeding strategy that can maintain cells in stationary phase for a longer duration, thereby increasing N. meningitidis X polysaccharide yield, such that the initial feed addition can be started when OD at 590 nm is between 3 to 4 at a rate of 10 ml/hr/1.5 L which gradually increases to 30 ml/hr/1.5 L till the culture OD is highest and then maintained at 60 ml/hr/1.5 L till culture OD reaches 50% of highest OD and then culture can be harvested.
[0027] Further inventors of present application have found that during fermentation to avoid pH drop resulting from accumulation of released cellular metabolites, NaoH at a concentration between 0.25N and 0.5N and orthophosphoric acid at a concentration between 5 and 10% can be continuously provided by the dosing pumps in cascade with the pH kept at set point, wherein ratio of sodium carbonate (20%) to NaoH (0.5N) is maintained at 1:3.
[0028] One important aspect of the instant invention is that said N. meningitidis X strain 8210 was found to have a log phase between 5 th and 9 th hr, stationary phase between 9 th and 12 th hr and decline phase between 12 th and 19 th hr.
[0029] The fermentation in the present invention may be carried out in batch or fed batch manner, preferably in a continuous fed batch mode.
[0030] In yet another aspect of the instant invention, said feed solution can comprise of dextrose between 72 and 76 g/l, sodium glutamate between 38 and 42 g/l, L-arginine between 2.8 and 3.2 g/l, L-serine between 2.8 and 3.2 g/l, L-cysteine between 1.9 and 2.1 g/l, magnesium chloride between 1.9 and 2.1, calcium chloride between 0.13 and 0.15 g/l and ferrous sulphate 0.02 g/l.
[0031] In a third embodiment, present invention provides a Men X capsular polysaccharide having yield between 600 mg/l to 800 mg/l at 100 KDa fermenter harvest stage wherein optical density measured at 590 nm can be between 8 and 15, preferably between 8 and 11.
[0032] A third embodiment of the present invention is that fermentation of Neisseria meningitidis X can be performed at set point values of i) pH from 7 to about 7.2, ii) temperature between 36 and 37° C. and at cascading values for i) dissolved oxygen from 15 to 25%, ii) agitation from 350-500 rpm, iii) Gas flow from 1 to 1.5, iv) Air from 0 to 100% and v) Oxygen from 0 to 100%.
[0033] A fourth embodiment of the instant invention is that the 100 KDa diafiltration harvest can be further subjected to purification steps comprising of:
(a) removal of protein and endotoxin impurities by utilizing deoxycholate at a concentration of 1% in combination with ethylenediaminetetraacetic acid at a concentration of 2 mM & ethanol at a concentration of 40%; (b) addition of 4 to 6% sodium acetate for removal of nucleic acids; (c) addition of cetyltrimethylammonium bromide at a concentration from 3 to 4% for binding polysaccharide and impurities; (d) precipitation of polysaccharide from cetyltrimethylammonium, bromide-polysaccharide complex by utilizing sodium chloride at a concentration of 0.05 M in presence of 96% absolute ethanol; (e) removal of protein and nucleic acid impurities by washing pellet with ethanol at a concentration of 45% in presence of sodium chloride at a concentration of 0.4 M; (f) selective precipitation of polysaccharide by utilizing 96% absolute ethanol; (g) dissolving polysaccharide in WFI and subjecting to tangential flow filtration; and wherein said purification process does not utilize any chromatography and said purified polysaccharide has yield from 300 to 500 mg/L, average molecular weight from 400 to 550 KDa, contains less than 0.5% proteins/peptides, less than 0.5% nucleic acids Jess than 5 EU/μg endotoxins with purification step recovery from 60% to 65%.
[0042] Another aspect of the fourth embodiment is that said N. meningitidis X polysaccharide purification process is robust and cost-efficient as it provides about 60 to 70% polysaccharide recovery and does not require any additional chromatographic steps.
[0043] A fifth aspect of the present invention is that said process can be applicable to N. meningitidis serotype X, A, B, C D, Y, Z, 29E and W-135, preferably to N. meningitidis serotype X strains selected from M9601, M9592, M9591, 247X, M9554, M8210 and M2526, 5967 strain (ST 750), most preferably to“M8210”.
[0044] A sixth embodiment of the instant invention is that said N. meningitidis X polysaccharide of the instant invention can be utilized to prepare polysaccharide protein conjugate composition by methods disclosed in WO 201314268 wherein, i) polysaccharide X can be sized mechanically to obtain fragments having size between 150 and 200 KDa, ii) sized saccharide can be conjugated to carrier protein via a linker with a cyanylation conjugation chemistry iii) saccharide to protein ratio in final conjugate can be between 0.2-0.6.
[0045] In an aspect of sixth embodiment said N. meningitidis X polysaccharide of the instant invention can also be utilized to prepare a multivalent meningococcal polysaccharide protein conjugate composition comprising capsular saccharide from serogroups X and at least one additional capsular polysaccharide from A, C, W135 and Y by methods disclosed previously in WO 201314268.
[0046] Seventh embodiment of present invention is that said carrier protein can be selected from a group of but not limited to CRM 197, diphtheria toxoid, tetanus toxoid, pertussis toxoid, E. coli LT, E. coli ST, and exotoxin A from Pseudomonas aeruginosa , outer membrane complex c (OMPC), porins, transferrin binding proteins, pneumolysin, pneumococcal surface protein A (PspA), pneumococcal adhesin protein (PsaA), pneumococcal surface proteins BVH-3 and BVH-11, protective antigen (PA) of Bacillus anthracis and detoxified edema factor (EF) and lethal factor (LF) of Bacillus anthracis , ovalbumin, keyhole limpet hemocyanin (KLH), human serum albumin, bovine serum albumin (BSA) and purified protein derivative of tuberculin (PPD). Preferably, carrier proteins can be selected from tetanus toxoid, diphtheria toxoid and CRM197.
[0047] Monovalent or multivalent immunogenic compositions containing N. meningitidis X polysaccharide can be in a buffered liquid form or in a lyophilized form. Preferably, said polysaccharide protein conjugate can be lyophilized as disclosed previously in US2013/0209503, wherein the formulation can have at least 6 month stability at 40° C. and free polysaccharide content can be less than 11% w/w.
[0048] The lyophilized vaccine composition of the present invention can be reconstituted with a delivery vehicle having pH from about 6 to 7.5, particularly with saline or PBS.
[0049] Compositions can comprise of aluminium salt adjuvant added at an amount of 25-125 μg of Al +++ per 0.5 ml.
[0050] Also said composition can comprise of a preservative selected from thiomersal and 2-phenoxyethanol.
[0051] The lyophilized vaccine composition of the instant invention can be given as 1, 5 or 10 dose formulation.
[0052] The polysaccharide or a conjugate thereof is preferably administered parenterally, e.g. by injection or infusion by intravenous, intraperitoneal, intramuscular, intraarterial or intralesional route.
EXAMPLES
I) Fermentation Procedure
[0053] Seed vial containing 3 ml of “ N. meningitidis X M8210” (CBER) culture having OD 1/ml was freezed at −70° C. Then vial was thawed and seeded into 30 ml of seed medium which was incubated at 37° C. and agitated at 150 to 180 rpm. The volume was doubled to 60 ml when OD was above 0.7 and then to 120 ml, 210 ml respectively.
[0054] Culture having OD 10±0.2 with volume 70±10 ml was seeded into the reactor, wherein the medium volume in the reactor was 1500 ml. After inoculation of reactor 0 hr OD was maintained at 0.04 to 0.05.
[0055] The entire fermentation process was carried out in NBS bio flow Celligen 115 (2.2 L) glass bioreactor, wherein fermentation cycle was run in a continuous fed batch mode and total duration of fermentation cycle was 19 hrs.
II) Fermentation Medium Composition
[0056]
[0000]
TABLE 1
Composition of novel medium containing casamino acid for
N. meningitidis serogroup X(NMXM-CA-I)
Component
Concentration (gm/l)
Dextrose
10
Sodium chloride
5.8
Potassium sulphate
1
Potassium phosphate dibasic
4
Ammonium chloride
0.15
Glutamic acid
5
Arginine
0.3
Serine
0.5
Cysteine
0.25
Magnesium chloride
0.19
Calcium chloride
0.02
Ferrous sulphate
0.002
Casamino acid
10
[0000]
TABLE 2
Composition of novel medium containing casamino acid for
N. meningitidis serogroup X(NMXM-CA-II)
Component
Concentration (gm/l)
Dextrose
10
Sodium chloride
5.8
Potassium sulphate
1
Potassium phosphate dibasic
4
Ammonium chloride
0.15
Glutamic acid
5
Arginine
0.3
Serine
0.5
Cysteine
0.25
Magnesium chloride
0.19
Calcium chloride
0.02
Ferrous sulphate
0.002
Casamino acid
8
[0000]
TABLE 3
Composition of novel medium containing casamino acid for
N. meningitidis Serogroup X(NMXM-CA-III)
Component
Concentration (gm/l)
Dextrose
10
Sodium chloride
5.8
Potassium sulphate
1
Potassium phosphate dibasic
4
Ammonium chloride
0.15
Glutamic acid
5
Arginine
0.3
Serine
0.5
Cysteine
0.25
Magnesium chloride
0.19
Calcium chloride
0.02
Ferrous sulphate
0.002
Casamino acid
7
[0000]
TABLE 4
Composition of a medium containing soya peptone for
N. meningitidis serogroup X(NMXM-SP)
Component
Concentration (gm/l)
Dextrose
10
Sodium chloride
5.8
Potassium sulphate
1
Potassium phosphate dibasic
4
Ammonium chloride
0.15
Glutamic acid
5
Arginine
0.3
Serine
0.5
Cysteine
0.25
Magnesium chloride
0.19
Calcium chloride
0.02
Ferrous sulphate
0.002
Soya peptone
9
[0000]
TABLE 5
Composition of a medium containing soya peptone for N. meningitidis
serogroup X(NMXM-SP-II)
Component
Concentration (gm/l)
Dextrose
10
Sodium chloride
5.8
Potassium sulphate
1
Potassium phosphate dibasic
4
Ammonium chloride
0.15
Glutamic acid
5
Arginine
0.3
Serine
0.5
Cysteine
0.25
Magnesium chloride
0.19
Calcium chloride
0.02
Ferrous sulphate
0.002
Soya peptone
8
III) Growth Kinetics, Novel Feeding Strategy & Feed Solutions
[0057]
[0000]
TABLE 6
Growth profile of N. meningitidis X strain 8210
OD (590 nm) in medium
OD (590 nm) in medium
containing soya
Age
containing casamino acid
peptone
0
0.07
0.08
1
0.19
0.23
2
0.40
0.55
3
0.80
1.27
4
1.73
2.55
5
3.89
5.49
6
6.93
8.17
7
12.45
10.08
8
16.40
12.49
9
14.40
11.03
10
13.49
10.33
11
11.48
9.28
12
10.74
8.84
13
10.09
7.89
14
10.29
7.92
15
10.32
7.97
16
11.32
7.94
17
11.67
5.21
18
11.54
5.77
[0058] The log phase was identified between 5 th and 9 th hr, stationary phase between 9 th and 12 th hr and decline phase between 12 th and 19 th hr.
Novel Feeding Strategy:
[0059] The feeding strategy was designed such that the initial feed addition can be started when OD at 590 nm is between 3 to 4 at a rate of 10 ml/hr/1.5 L which gradually increases to 30 ml/hr/1.5 L till the culture OD is highest and then maintained at 60 ml/hr/1.5 L till culture OD reaches 50% of highest OD and then culture can be harvested.
Feed Solutions:
[0060]
[0000]
TABLE 7
Composition of novel “Feed Solution 1”(FS-1) for N. meningitidis
serogroup X
Concentration
Component
(gm/l)
Dextrose
75
Sod glutamate
40
Arginine
3
Serine
3
Cysteine
2
Magnesium chloride
2
Calcium chloride
0.15
Ferrous sulphate
0.02
[0000]
TABLE 8
Composition of novel “Feed Solution 2”(FS-2) for N. meningitidis
serogroup X
Component
Concentration (gm/l)
Dextrose
75
Sod glutamate
40
Results:
[0061] Continuous exponential feeding strategy resulted in maintaining cells in stationary phase for a longer duration, thereby increasing yield of N. meningitidis X polysaccharide. Use of Casamino acid as a nitrogen source was found to provide high yield & high molecular weight Men X polysaccharide with minimal impurities at 100 Kda stage as compared to soya peptone as nitrogen source.
[0062] When only dextrose and sodium glutamate were used as feed solution (FS-2), cell morphology was affected ultimately resulting in unfavorable polysaccharide characteristics. Whereas when FS-1 (containing amino acids, salts in addition to dextrose and sodium glutamate) was used morphology of cells was found to be improved, thereby increasing polysaccharide yield and providing polysaccharide with favorable characteristics.
[0063] Study of growth profile of N. meningitidis X 8210 reveals that during fermentation a pH drop resulting from accumulation of released cellular metabolites was observed that was adversely affecting rate of capsular polysaccharide production. To avoid such pH drop, NaoH at a concentration between 0.25N and 0.5N and orthophosphoric acid at a concentration between 5 and 10% was continuously provided by the dosing pumps in cascade with the pH kept at set point, wherein ratio of sodium carbonate (20%) to NaoH (0.5N) is maintained at 1:3.
IV) Fermenter Conditions
[0064]
[0000]
TABLE 9
Fermenter variables
Fermentation aspect
Concentration
Temperature
36° C.
OD
16 OD
pH
7.2
DO (%)
25%
Agitation (rpm)
400
Gas flow
1.0
Air (%)
0-100%
Oxygen (%)
0-100%
[0000]
TABLE 10
Polysaccharide Concentration & purity profile at 100 KDa
Polysaccharide
Relative concentrations
concentration
of Endotoxin,
Nitrogen sources utilized
(mg/l)
Protein & Nucleic acid
Men X Ps at 100 KDa
650
Protein: 50-75%
fermentation harvest stage for
Nucleic acid: 15-30%
NMXM-CA-I
Men X Ps at 100 KDa
625
Protein: 42-70%
fermentation harvest stage for
Nucleic acid: 15-30%
NMXM-CA-II
Men X Ps at 100 KDa
610
Protein: 35-65%
fermentation harvest stage for
Nucleic acid: 15-30%
NMXM-CA-III
Men X Ps at 100 KDa
500
Protein: 65-95%
fermentation harvest stage for
Nucleic acid: 15-40%
NMXM-SP-I
Men X Ps at 100 KDa
475
Protein: 65-90%
fermentation harvest stage for
Nucleic acid: 15-40%
NMXM-SP-II
Results:
[0065] For NMXM-CA medium containing casamino acids, at 100 KDa stage, polysaccharide yield was between 500 and 650 mg/1 with minimal load of wherein harvesting was carried at when OD reached 50% of highest culture OD. Whereas for NMXM-SP medium containing soya peptone, at 100 KDa stage, polysaccharide yield was comparatively low i.e. between 450 and 500 mg/1 with greater load of impurities.
V) Harvesting & Inactivation
[0066] The fermentation was terminated once drop in optical density was observed followed by inactivation using 1% formaldehyde for 2 hrs at 37° C. Further the temperature was reduced at 10° C. and incubated for 30 minutes. The harvest was unloaded and centrifuged at 14,500 g for 45 minutes.
[0067] Then supernatant was subjected to 0.2μ filtration followed by 100 KD diafiltration (10-15 times) and was further concentrated with WFI. Later sterile filtration with 0.2μ filter was carried.
VI) Purification of Men X Polysaccharide
Protocol 1:
[0068] Addition of 0.5% deoxycholate, 6% sodium acetate, 2 mM EDTA & 40% ethanol to the 100 KD diafiltered harvest. Then the mixture was kept at 2-8° C. for 3-4 hrs with stirring. Later mixture was subjected to centrifugation at 10000 rpm for 20 min and supernatant was diafiltered against 25 mM Tris with 100 KD cassette membrane. Further 10% w/v CTAB precipitation was carried overnight at 2-8° C. with stirring and pellet was collected. Said pellet was dissolved in 96% ethanol with 0.05M NaCl at 2-8° C. for 2 hrs on stirring. Then polysaccharide precipitation was carried for 30 minutes and pellet was collected. Said pellet was dissolved in 45% ethanol with 0.4M NaCl for 1 hr. The supernatant was collected & filtered through CUNO R32SP carbon filter. Then polysaccharide was precipitated in 96% ethanol for 1-2 his and pellet was collected. Then pellet was dissolved in WFI followed by TFF. Final purified N. meningitidis X polysaccharide was stored at −20° C.
Protocol 2:
[0069] Addition of 1.5% deoxycholate, 6% sodium acetate, 2 mM EDTA & 40% ethanol to the 100 KD diafiltered harvest. Then the mixture was kept at 2-8° C. for 3-4 hrs with stirring. Later mixture was subjected to centrifugation at 10000 rpm for 20 min and supernatant was diafiltered against 25 mM Tris with 100 KD cassette membrane. Further 6% w/v CTAB precipitation was carried overnight at 2-8° C. with stirring and pellet was collected. Said pellet was dissolved in 96% ethanol with 0.05M NaCl at 2-8° C. for 2 hrs on stirring. Then polysaccharide precipitation was carried for 30 minutes and pellet was collected. Said pellet was dissolved in 45% ethanol with 0.4M NaCl for 1 hr. The supernatant was collected & filtered through CUNO R32SP carbon filter. Then polysaccharide was precipitated in 96% ethanol for 1-2 hrs and pellet was collected. Then pellet was dissolved in WFI followed by TFF. Final purified N. meningitidis X polysaccharide was stored at −20° C.
Protocol 3:
[0070] Addition of 1% deoxycholate, 6% sodium acetate, 2 mM EDTA & 40% ethanol to the 100 KD diafiltered harvest. Then the mixture was kept at 2-8° C. for 3-4 hrs with stirring. Later mixture was subjected to centrifugation at 10000 rpm for 20 min and supernatant was diafiltered against 25 mM Tris with 100 KD cassette membrane. Further 3% w/v CTAB precipitation was carried overnight at 2-8° C. with stirring and pellet was collected. Said pellet was dissolved in 96% ethanol with 0.05M NaCl at 2-8° C. for 2 hrs on stirring. Then polysaccharide precipitation was carried for 30 minutes and pellet was collected. Said pellet was dissolved in 45% ethanol with 0.4M NaCl for 1 hr. The supernatant was collected & filtered through CUNO R32SP carbon filter. Then polysaccharide was precipitated in 96% ethanol for 1-2 hrs and pellet was collected. Then pellet was dissolved in WFI followed by TFF. Final purified N. meningitidis X polysaccharide was stored at −20° C.
[0071] Protocol 1 having low DOC resulted caused inefficient removal of contaminants (protein/nucleic acids) whereas & high CTAB concentrations resulted in a complex of CTAB-polysaccharide that was not readily separable.
[0072] Protocol 2 having higher DOC resulted in more viscous polysaccharide solutions thus making it difficult for TFF processing. Also intermediate CTAB concentration resulted in a complex of CTAB-polysaccharide that was not readily separable.
[0073] Protocol 3 having intermediate DOC and less CTAB concentration was found to be more efficient than Protocol 1/2 and hence was finalized for purification of N. meningitidis X polysaccharide.
[0074] The purified N. meningitidis X polysaccharide prepared by Protocol 3 was tested for impurities like Protein, Nucleic acid, Endotoxin and Molecular size. Although WHO specification/guidelines for Men X polysaccharide were not available, purified N. meningitidis X polysaccharide was found to meet WHO specifications already set for a similar phosphodiester containing polysaccharide i.e. N. meningitidis A.
[0075] Further, comparison of 1 H, 13 C, 31 P NMR assignments of SIIL's Men X polysaccharide with recently published X-related NMR data (Vaccine 30, 2012, 5812-5823 & Vaccine 30, 2012, 6409-6415) confirm structural identity of SIIL's Men X polysaccharide.
[0000]
TABLE 11
Characteristics of Purified Men X polysaccharide
Nitrogen sources
Ps Conc
Nucleic acid
Endotoxin
Protein
Mw
utilized
(mg/l)
(%)
(Eu/ug)
(%)
(KDa)
Men X Ps for
440
0.062
1.51
0.18
410
NMXM-CA-I
Men X Ps for
420
0.047
1.33
0.14
520
NMXM-CA-II
Men X Ps for
380
0.052
1.25
0.13
549
NMXM-CA-III
Men X Ps for
300
0.081
1.90
0.19
380
NMXM-SP-I
Men X Ps for
250
0.062
1.25
0.15
463
NMXM-SP-II
Results:
[0076] Both, NMXM-CA NMXM-SP based batches of Men. X polysaccharide were found to meet WHO specifications set for N. meningitidis A polysaccharide.
[0077] For NMXM-CA medium containing casamino acids, at final purified stage, purification step recovery was between 60 and 65%, polysaccharide yield was between 350 and 500 mg/l with minimal load of impurities when harvesting was carried when culture OD reaches 50% of highest culture OD. Whereas for NMXM-SP medium containing soya peptone, at final purified stage, purification step recovery for polysaccharide as well as polysaccharide yield was comparatively low along with greater load of impurities.
[0078] Above high Men X polysaccharide yield was achieved without utilizing any additional chromatographic methods, thereby demonstrating that above purification protocol is robust & cost-efficient.
VII) Preparation of Lyophilized, Immunogenic MenX Polysaccharide-Protein Conjugates
[0079] Monovalent or multivalent immunogenic compositions containing N. meningitidis X polysaccharide-tetanus toxoid can be in a buffered liquid form or in a lyophilized form.
[0080] Preferably, said polysaccharide protein conjugate can be lyophilized as disclosed previously in US 2013/0209503, wherein the formulation can have at least 6 month stability at 40° C. and free polysaccharide content can be less than 11% w/w.
[0081] Men X polysaccharide of the instant invention can be utilized to prepare immunogenic, multivalent meningococcal polysaccharide protein conjugate compositions comprising capsular saccharide from serogroups X and at least one capsular saccharide from A, C, W135 and Y as discussed previously in WO 201314268.
[0082] In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims, We therefore claim as our invention all that comes within the scope and spirit of these claims.
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The instant invention provides improved culture, fermentation and purification conditions for preparing Neisseria meningitidis polysaccharides. The invention in particular relates to a novel fermentation medium, optimal feed solution addition strategies and an improved purification process devoid of any chromatographic methods for obtaining high yield of Neisseria meningitidis X polysaccharide.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ultra fine groove chip (or tip) having less susceptibility of the working surface to thermal damage during the working in shear (ductile) mode and having high efficiency in disposing of swarf, and to an ultra fine groove tool provided with the ultra fine groove chips.
2. Description of the Related Art
With such difficult-to-cut brittle hard materials such as metal, crystals, glass or the like, it is vitally important to maintain the sharpness of tips by maintaining working resistance at a low level and by controlling heat, thereby maintaining the quality of work surface constant.
Brittle hard materials are particularly susceptible to surface cracking during working, which often is a cause of brittle fracture. The susceptibility to cracking of the brittle hard material is more pronounced when a larger-edged tool is used in any grinding, cutting or lapping process. Further, the fracture of a material occurs more often in a "brittle mode", which shall be considered to mean, throughout this specification, a state, wherein the surface of the brittle hard material is covered with cracks, as is often seen in a case when glass is rubbed with rough sandpaper, white powder is generated, and the glass turns opaque due to cracks produced on its surface.
Generally, when grinding a brittle hard material, swarf generated by brittle-mode grinding tends to be rough, and those by shear-mode tend to be fine and uniformly shaped. Here, the "shear mode" (or ductile mode) shall be understood to mean, throughout this specification, the following state. For example, the glass, as described above, if rubbed with a rough sandpaper, generates white powder and turns opaque due to cracks on its surface. On the other hand, if rubbed with a fine sandpaper under a very slight pressure, no white powder is generated and no cracking is caused. Such a crack-free state of the glass surface is called the shear mode where the initial transparency of the glass is mostly maintained after the glass is ground with very fine sandpaper under very slight pressure.
As an example of a tool employed for such working processes for workpieces as grinding, lapping, polishing or cutting, diamond grinding wheels are known for their excellent characteristics in performance, durability, precise finishing and so on.
1) Grinding
The following types (1)-(3) of the diamond grinding wheels are known:
(1) An electroplated grinding wheel, wherein diamond abrasives are affixed by nickel-plating (type-1 diamond grinding wheel);
(2) A grinding wheel, wherein diamond abrasives initially bonded onto a base surface by nickel-plating are subsequently reversed to obtain evenly leveled abrasive tops (type-2 diamond grinding wheel); and
(3) A grinding wheel formed by sintering a mixture of fine diamond abrasives and a bonding material made of elastic resinoid or metal, which is particularly suitable for grinding brittle hard materials in the shear mode (type-3 diamond grinding wheel).
The above diamond grinding wheels of the related arts, however, have the following problems, respectively.
That is, the type-1 diamond grinding wheel has problems such as: (1) it has a limit in reducing surface roughness since sizes of diamond abrasives are irregular, and (2) it has a limit in reducing surface roughness since amount of abrasion and crushing state among the diamond abrasives are different each other due to irregularity of crystal orientations of the respective abrasive.
The type-2 diamond grinding wheel has problems such as: (1) a manufacturing process to evenly put the diamond abrasive tops in order by reversing is complicated, (2) amount of abrasion and crushing state among the diamond abrasives are different each other since crystal orientations of the respective abrasive are irregular, and (3) it is difficult to control the density of the diamond abrasive.
Lastly, the type-3 diamond grinding wheel has the following problems: (1) the volume of material removed per unit time is small and grinding efficiency is low because the diamond abrasives are very fine, (2) scratch is created on the workpiece surface due to loose abrasives, (3) the grinding force is reduced by loading and glazing of the grinding wheel during the grinding process, and the grinding burn occurs on the workpiece surface due to the grinding heat which is generated during the grinding process, and (4) it is liable to variations in grinding performance, trueing and finishing efficiency due to a sintered product.
2) Cutting
Conventionally, a wide variety of materials and shapes have been adopted for cutting tools, and this is evident from manufacturing history. However, the necessity of using large-sized tips in cutting a hard-cutting material, whether it is metal or brittle hard material, is accompanied by heat generation. As a result, deterioration in shape precision caused by unavoidable wear has not been preventable.
3) Lapping
Lapping differs from the grinding in that it is a constant-pressure processing, whereas the latter is a constant-feed processing. The manufacturing method of a lapping tool, therefore, has conventionally been identical with that for the grinding.
SUMMARY OF THE INVENTION
An object of the present invention, therefore, is to provide an ultra fine groove chip (or tip), wherein the coolant (or working fluid) retained in grooves serves to reduce thermal damage by stopping heat generation during the working. The advantage is particularly remarkable in a shear mode (or ductile mode) working of brittle hard materials.
Another object of the present invention is to provide an ultra fine groove chip, wherein swarf removed from the workpiece is confined within grooves on the surface and are kept from interfering with the workpiece, thus realizing high working efficiency.
Still another object of the present invention is to provide an ultra fine groove chip, wherein the working resistance is small and constant, thus realizing high efficiency and high working precision.
The inventor has found that a tip made of hard material can serve this purpose, wherein the hard material may be selected from the group consisting of diamond, cubic boron nitride, tungsten carbide, cemented carbide, high-speed steel, ceramics and others, and the tip has its face engraved with a number of fine grooves to form working surfaces, and whereby each working surface separated by grooves constitute an ultra fine edge. The present invention is based on the above finding. Further, the tool according to the present invention does not need the load to the workpiece for the grinding. Although the conventional grinding method is operated as the load-constrained grinding, the method according to the present invention is operated as the depth of cut-constrained grinding.
According to one aspect of the present invention, there is provided an ultra fine groove chip (or tip), wherein a chip made of hard material selected from the group consisting of diamond, cubic boron nitride, tungsten carbide, cemented carbide, high-speed steel, ceramics, and others has its face engraved with a number of fine grooves to form working surfaces, and whereby each working surface separated by said grooves constitute an ultra fine edge.
According to another aspect of the present invention, there is provided an ultra fine groove tool which is provided with a rotatable base board and at least one ultra fine groove chip, wherein said board holds as a holder the ultra fine groove chip and a chip made of hard material selected from the group consisting of diamond, cubic boron nitride, tungsten carbide, cemented carbide, high-speed steel, ceramics, and others, has its face engraved with a plurality of fine grooves to form working surfaces, and whereby a working surface thus separated by grooves constitutes an ultra fine edge.
The nature, principle and utility of the invention will become more apparent from the following detailed description when read in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a schematic perspective view of a boat-shaped ultra fine groove chip (or tip);
FIG. 2 is an enlarged schematic view of S 1 part on a facade of ultra fine edges shown in FIG. 1;
FIG. 3 is a sectional view taken along the line X--X of FIG. 2;
FIG. 4 is a schematic perspective view of an ultra fine groove chip as illustrated in FIG. 1, wherein the bow bottom face has a flat plane with an edge line thereof being straight;
FIG. 5 is an enlarged schematic view of S 2 part on a facade of ultra fine edges of the ultra fine groove chip illustrated in FIG. 4;
FIGS. 6A and 6B illustrate a comparative test using two mono-crystal diamond tips of exactly the same shape, but one having ultra fine groove chips and the other without them, wherein FIG. 6A is a side view and FIG. 6B is a plane view;
FIGS. 7A and 7B illustrate a shape of the ultra fine groove chip, wherein FIG. 7A is a side view and FIG. 7B is a plan view;
FIGS. 8A and 8B illustrate an ultra fine groove lapping tool, wherein FIG. 8A is a rear plan view and FIG. 8B is a front view;
FIG. 9 is a schematic view illustrating a configuration of another ultra fine groove lapping tool;
FIG. 10 is a sectional view illustrating still another ultra fine groove tool;
FIG. 11 is a rear plan view of the ultra fine groove tool of FIG. 10;
FIG. 12 is a graph showing the change in working resistance of a silicon wafer over accumulated cutting times;
FIG. 13 is a graph showing the change in surface roughness of a silicon wafer over accumulated cutting times;
FIG. 14 is a rear plan view of a further ultra fine groove tool; and
FIG. 15 is a rear plan view of yet another ultra fine groove tool.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An ultra fine groove chip (or tip) according to the present invention has its working surface grooved, thereby an edge of the groove constituting a negative cutting edge. The grooves on the working surface form a plurality of cutting edges, thus increasing the number of edges per surface area and decreasing the work load of each edge.
Thermal damage during the working is minimized, as the working fluid guided by and retained in the grooves stops heat generation. Interference of swarf with the workpiece is minimized, as removed swarf is confined within grooves of the working surface.
A small and constant working resistance makes a shear mode process possible, thus realizing high precision of the worked surface. Preferably the groove on the working surface shall have a depth of 0.001 μm or more so as the working force of an ultra fine edge can be maintained at the same level, irrespective of the resistance (grinding resistance, cutting resistance, lapping resistance). Also, it is important that the depth shall be at least 0.01 μm so as to permit smooth flow of the coolant (grinding fluid, cutting fluid, polishing fluid) and smooth disposal of swarf.
The ultra fine area of each edge constituted on the working surface enables production of swarf small enough to satisfy conditions for obtaining a shear mode surface. Further, the size of the area accounts for the sustainability of a constant working force and the over-heating by friction with the workpiece. If the area of an edge is 0.000001 μm 2 or less, the working force of the ultra fine edge drops sharply and proper working force is no longer sustainable. On the other hand, if the area is 100,000 μm 2 or more, a degradation of the ultra fine edge is induced in a short time and an over-working on the work surface (work layer) occurs, thus resulting in insufficient surface precision. The proper area of each edge, therefore, is in a range from 0.000001 to 100,000 μm 2 .
Referring now to the drawings, the ultra fine groove chip according to the present invention and embodiments thereof will be described.
Embodiment 1
First, description will be made of the first embodiment illustrated in FIGS. 1-3.
FIG. 1 is a schematic perspective view of a boat-shaped ultra fine groove chip according to the present invention, FIG. 2 is an enlarged schematic view of an S 1 part on a facade of the ultra fine groove chip shown in FIG. 1, and FIG. 3 is a sectional view taken along a line X--X of FIG. 1.
In these drawings, an ultra fine groove chip 1 comprises a tip 10, wherein its face has a plurality of fine grooves 11 regularly engraved by applying a laser or electric energy or by a method of chemical vapor deposition or machining to form working surfaces 12, and whereby each working surface separated by grooves constitutes an ultra fine edge 13. By using the ultra fine edge 13, materials can be worked under a small resistance, and this small and constant resistance as well as the guaranteed shear mode working results in an excellent precision of the worked surface.
Thermal damage during the working is minimized, as the working fluid guided by and retained in the fine grooves 11 stops heat generation. Interference of swarf with the workpiece is maximally avoided, as removed swarf is confined within the fine grooves 11 of the working surfaces 12. Preferably, the fine grooves 11 on the working surface 12 shall have depth of 0.001 μm or more so that the working force of the ultra fine edge 13 can be kept at the same level irrespective of the resistance (grinding resistance, cutting resistance, lapping resistance). It is also important that the depth "d" of the groove 11 be at least 0.01 μm in order to secure smooth flows of the coolant (grinding fluid, cutting fluid, polishing fluid) and smooth disposals of swarf.
Areas S 1 , S 2 , S 3 , S 4 , . . . of each ultra fine edge 13 constituted on the working surface 12 accounts for the sustainability of a constant working force and the over-heating generated by the friction with the workpiece. If the area of an ultra fine edge 13 is 0.000001 μm 2 or less, its working force drops sharply and the proper level is no longer sustainable. On the other hand, if the area of the ultra fine edge 13 is 100,000 μm 2 or more, a degradation of the ultra fine edge 13 is induced in a short time, resulting in insufficient working precision. The proper area of each edge, therefore, is in the range from 0.000001 to 100,000 μm 2 .
The ultra fine groove chip 1 illustrated in FIG. 1 has the working surfaces 12 consisting of side faces 12 1 and 12 2 , bottom face 12 3 , and bow bottom face 12 4 , each being shaped in flat or curved planes. The working surfaces 12 may also consist of curved planes only.
In FIG. 3, the fine grooves 11 are formed to have a pitch "p" in the range of from 0.001 μm to 1 mm and a width "w" of 0.01 μm or more.
As mentioned above, although a wide variety of materials and shapes have been adopted for cutting tools, the necessity of using large-sized tips in cutting a hard-cutting material, whether it is metal or brittle hard material, is accompanied by heat generation. As a result, deterioration in shape precision caused by unavoidable wear has not been preventable. For solving the above problems, the ultra fine groove chip according to the present invention is extremely effective.
Embodiment 2
A second embodiment is described with reference to FIG. 4, FIG. 5, FIGS. 6(A)and 6(B), FIGS. 7(A) and 7(B). FIG. 4 is a schematic perspective view of an ultra fine groove chip as illustrated in FIG. 1, wherein a bow bottom face 12 4 has a flat plane with an edge line thereof being straight. The ultra fine groove chip as illustrated in FIG. 1 and FIG. 4 may be used as an edge for face cutting, cylindrical cutting, and planing on a fly cutter, a turning machine and so on. The ultra fine groove chip may also be used as a grinding edge not only for cup wheels as illustrated in FIGS. 10, 11, 14 and 15 (which shall be referred to later) but also for other wheels such as plane cup wheels.
FIG. 5 is an enlarged schematic view of an S 2 part on a facade of an ultra fine edge of the ultra fine groove chip illustrated in FIG. 4. Whereas the arrangement of the ultra fine groove chips illustrated in FIG. 2 is regular, that of FIG. 5 is irregular. Depending on materials and working conditions, the irregular arrangements sometimes bring about excellent effects in cooling and disposal of swarf.
Turning now to a comparative test (with reference to FIGS. 6(A) and 6(B)) using two mono-crystal diamond tips of exactly the same shape, but one having ultra fine groove chips and the other without these, results of the test are presented below. The workpiece is BK7 glass and the feed speed is set at 25 mm/min.
Beginning with the one with ultra fine groove chips, the workpiece surface is in full brittle mode at a working speed of 1500 rpm. At 3000 rpm, the shear mode is somewhat notable.
As the revolution speed gradually increased from 4500 rpm through 6000 rpm, the shear mode area also increased to reach maximum at 7500 rpm. This is results in the amount of material removed per the ultra fine edge becoming minimized. The cooling effect secured by coolant being fed within grooves also contributes to sustained normal working conditions even at higher revolution speeds.
In the other test, under the same working conditions, using the same shaped tips but without ultra fine groove chips, the entire surface of the same material continued to show the brittle mode despite increases in revolution speed. The result of the above test also demonstrates the remarkable advantages of the ultra fine groove chip.
As stated above, the manufacturing method of a lapping tool is identical with that for grinding and therefore drawbacks and problems to be solved are also the same. Accordingly, by using an ultra fine groove tool provided with ultra fine groove chips, the following advantages are achieved: (1) an improved distribution of abrasive density or an equivalent thereof is effectively obtained, (2) it is possible to uniformly put the crystal orientation of the ultra fine groove cutting chip in order to a friction-optimized direction, and (3) it is possible to uniformly put size and height of the ultra fine groove chips in order and this is equal to the uniformity of the size and protrusion of abrasives.
In accordance with the design as described above, a lapping tool can be manufactured by such methods as laser, electric energy, chemical vapor deposition and machining or the like. The tool brings about such advantages as an improved lapping efficiency, an improved surface roughness, and a reduction of work affected layer.
Embodiment 3
FIG. 8(A) is a rear plan view of an ultra fine groove lapping tool and FIG. 8(B) is an elevational view of an ultra fine groove lapping tool. The ultra fine groove chips are arranged on a disk with ultra fine edges S 3 formed onto undersides of the pellets. An enlarged view of the ultra fine edges S 3 is the same as those illustrated in FIGS. 2 and 5. While the shape of pellets illustrated in FIGS. 8(A) and 8(B) are cylindrical, other columnar shapes such as quadrilaterals, ellipses and polygons may be employed with ultra fine edges formed onto the undersides thereof. The pellets may also be arranged to have bows of boat-shaped ultra fine groove chips as illustrated in FIGS. 1 and 4 traveling in the direction of rotation.
FIG. 9 is a schematic view illustrating the configuration of another ultra fine groove lapping tool. This embodiment shows an application wherein a couple of ultra fine groove lapping tools are simultaneously processing each surface of a workpiece. Specifications of the ultra fine edges and the ultra fine groove chips as described in grinding.
Embodiment 4
FIG. 10 is a sectional view illustrating yet another ultra fine groove tool, and FIG. 11 is a rear plan view of the ultra fine groove tool of FIG. 10. This embodiment shows an application of the ultra fine groove tool, wherein the ultra fine groove chips made of diamond are arranged along concentric circles. A result of a comparison test with a conventional diamond tool revealed differences between the two as presented below.
The test was made on a mono-crystal silicon wafer as the test-piece by the same method as described in FIGS. 6(A) and 6(B). However, the feed speed was set at 100 mm per minute. The tool was rotated at 2000 rpm and the cutting depth was set at 2 μm.
FIG. 12 is a graph showing the change in working resistance of a silicon wafer over accumulated cutting times. Namely, the graph shows the change of working resistance during the processing. The conventional tool showed a gradual increase in working resistance caused by the degradation of diamond abrasives due to heat generation and by loading of swarf. The ultra fine groove tool, however, showed a constant working resistance without any such problems.
FIG. 12 is a graph showing the change in surface roughness of a silicon wafer over accumulated cutting times. Namely, the graph shows the roughness corresponding to the accumulated volume of materials removed. In the case of a conventional tool, non-uniform orientations of diamond abrasives caused the uneven abrasion, which further caused the non-level protrusion of abrasives. Accordingly, the roughness increased as the accumulated volume of materials removed increased. In the ultra fine groove tool, all the ultra fine edges have the same orientation and the same initial protrusion. Therefore, no change in roughness occurs. As such, the difference between the two is clear.
Embodiment 5
FIGS. 14 and 15 are rear plan views of further ultra fine groove tools. These drawings show applications of the ultra fine groove tools, wherein the ultra fine groove chips are arranged with each of the ultra fine edge formed in rectangular and triangular shape. While these are almost the same as those illustrated in FIGS. 10 and 11, there are differences in the shapes of the ultra fine groove chips and their plural concentric arrangements. Further, the ultra fine edges may be formed in a circular or elliptical shape.
The present invention is comprised as described above and has the following effects regarding material to be processed and working conditions:
An optimum density distribution of cutting edges can be designed, and an optimum size of cutting edge and a distribution mode thereof can be designed. An ultra fine groove chip or tool with all cutting edges thereof having uniform orientation can be designed by choosing a crystal orientation less susceptible to wear and Initial protrusions of cutting edges can be leveled. As the heat generated when working can be stopped by the working fluid retained in the grooves, the degradation of cutting edges is suppressed. Further, grooves facilitate easy disposal of swarf, and the evenness of abrasion volume among the cutting edges owing to uniform crystal orientation brings about an excellent roughness value of the worked surface. The sustained cutting capacity of edges facilitates maintaining the depth of the work affected layer at a low level despite the increase in worked volume. Still further, the stabilized grinding permits maintaining working precision at a high level, and as the crystal orientation in the ultra fine edges can be made uniform at high density, a shear-mode processing is possible on those otherwise impossible materials.
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The present invention relates to an ultra fine groove chip (or tip) and an ultra fine groove tool, wherein thermal damage is reduced as coolant retained in grooves stops heat generation when working in shear (ductile) mode and whereby good quality of worked surface is obtained. The present invention comprises an ultra fine groove chip, wherein a chip made of hard material selected from the group consisting of diamond, cubic boron nitride, tungsten carbide, cemented carbide, high-speed steel, ceramics and others has its face engraved with a number of fine grooves to form working surfaces, and whereby each working surface sectioned by grooves constitutes an ultra fine edge. The invention also comprises an ultra fine groove tool which is provided with a rotatable base board and at least one ultra fine groove chip, wherein the board constituting a holder is holding the ultra fine groove chip.
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RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 61/393,327, filed Oct. 14, 2010, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to the use of novel derivatives of dipyrazolopyridine as modulators of GABA A α5 for the intended use of therapy for enhancing cognition.
2. Description of the Related Art
The inhibitory neurotransmitter γ-aminobutyric acid (GABA), serves as a ligand for two distinct classes of receptors, GABA A and GABA B . The GABA A class is a ligand-gated ion channel while GABA B is a canonical seven transmembrane G-protein coupled receptor. The GABA A receptor is comprised of a number of subunits, including α, β, γ, and δ. Cloning of the individual subunits of the GABA A receptor has confirmed the existence, so far, of six α subunits, three β subunits, three γ subunits, and one δ subunit. The overall structure of the receptor is a pentamer with a minimum subunit requirement of at least one α subunit, one β subunit, and one γ subunit.
Due to afore mentioned diversity of subunits, there are more than 10,000 possible combinations of the subunits that comprise the GABA A receptor, though not all appear in nature. Specific combinations that have been identified to have biological relevance (and their relative abundance in rat brains, include α1β2γ2 (43%), α2β2/3γ2 (18%), α3βγ2/3 (17%), α2βγ1 (8%), α5β3γ2/3 (4%), α6βγ2 (2%), α6βδ (2%), and α4βδ (3%) (Barnard, E. A., et al. (1998) Pharmacol. Rev. 50: 291-313 incorporated herein in its entirety).
There are a number of distinct, small molecule binding sites on the GABA A receptor that modulate the activity of the receptor including sites for benzodiazepines, steroids, barbiturates, ethanol, and convulsants (e.g. picrotoxin). The GABA binding site is located at the α/β interface. A tremendous amount of pharmaceutical research has been invested in identifying compounds that bind to the benzodiazepine binding site (BZ-site), which is located at the α/γ interface. Binding of GABA is greatly modulated by binding of drugs to the BZ-site, which can cause a number of different pharmacological responses. Drugs such as diazepam and zolpidem, agonists of GABA A function, have shown historic success as anxiolytic agents (Muller, W. E. (1988) Drugs of Today 24: 649-663 incorporated herein in its entirety). More recent work has suggested that the sedative and hypnotic effects of these drugs are primarily due to interaction with the α1-containing receptors, therefore much effort has been focused on finding drugs that have preferential activity towards α2β2γ2 and α3βγ2 over α1βγ2 in order to maintain the anxiolytic activity but reduce the sedative side effects (Rudolph, U. F., et al. (1999) Nature 401: 796-800 incorporated herein in its entirety; Löw, K. F., et al. (2000) Science 290: 131-134 incorporated herein in its entirety; McKernan, R. M., et al. (2000) Nat. Neurosci. 3: 587-592 incorporated herein in its entirety).
The α5-subunit is predominantly found in the hippocampus, a part of the brain that plays a part in memory and spatial navigation. As a result, much research has been focused on identifying links between α5-containing GABA receptor function and cognition. Results from a number of laboratories have indicated that selective inverse agonism of the α5βγ2/3 GABA A receptor can show marked improvement of memory function in a number of animal models. There have been a growing number of examples of inverse agonists in both the patent and scientific literature (Yokoyama, N., et al. (1982) J. Med. Chem. 25: 337-339 incorporated herein in its entirety; Takada, S., et al. (1988) J. Med. Chem. 31: 1738-1745 incorporated herein in its entirety; Atack, J. R., et al. (2006) European Journal of Pharmacology 548: 77-82 incorporated herein in its entirety). A preferable profile for a cognitive enhancer is one that shows negative modulation at α5, but with less modulation of α1, α2, or α3 to minimize side effects such as convulsion or sedation. As yet, no α5 selective GABA A negative modulator has been brought to market, and only a limited number have been investigated in human clinical trials.
SUMMARY OF THE INVENTION
Herein described is the composition and use of a new chemical series that is shown to bind to the benzodiazepine site of the GABA A receptor and negatively modulates the α5 subtype of GABA A . The general structure of formula I is shown below:
The compounds of Formula I encompass all possible tautomers of the chemical structures and mixtures thereof.
Embodiments, Aspects and Variations of the Invention
It is recognized in the following structures, when a formula is depicted as a mixture of two or more tautomeric structures, that the definitions of “R 3 ” can be different in each form.
For example, in a compound of formula (I), in the structure on the left the definition of “R 3 ” can be hydrogen and in the other two structures “R 3 ” can be absent. Compounds represented by the tautomeric structures can exist in all possible tautomeric forms and mixtures thereof. Additionally, compounds need not exist in all three forms. A compound that can be represented by either drawn structure, whether in equilibrium or not in equilibrium, falls within the present disclosure.
It is recognized, that two tautomeric forms are drawn for some formulas. For simplicity, in some places (including the claims), only the tautomeric form on the right is drawn for an indicated formula, this is not to exclude the other tautomeric form. In places where only one tautomeric form is drawn for a formula the other tautomeric form is also contemplated.
One embodiment of the invention provides a compound of formula (I):
wherein:
Z 1 , Z 2 and Z 3 are each independently N (nitrogen), NR 7 or CR 8 , wherein at least one of Z 1 , Z 2 or Z 3 is NR 7 ;
R 7 is —C(═Y)NR 1 R 2 ;
R 8 is hydrogen, halo, (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro, or (C 1 -C 6 )alkoxy optionally substituted with up to 5 fluoro;
Y is O (oxygen) or S (sulfur);
R 1 and R 2 are each independently selected from the group consisting of hydrogen, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkylOR a , (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro, (C 1 -C 6 )alkyl optionally substituted with up to 5 chloro, (C 1 -C 6 )alkoxy optionally substituted with up to 5 fluoro, (C 1 -C 6 )alkylNR a R b , and aryl, or R 1 and R 2 are taken together with the nitrogen to which they are attached to form a heterocycle group optionally substituted with one or more R c ; wherein the heterocycle group optionally include one or more groups selected from O (oxygen), S(O) x , and NR d ;
x is 0, 1 or 2;
Ar is aryl, or heteroaryl, each optionally substituted with one or more M;
R 3 is hydrogen, or oxide;
R 4 is selected from the group consisting of hydrogen, hydroxy, halo, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro, and (C 1 -C 6 )alkoxy optionally substituted with up to 5 fluoro;
each R a and R b is independently hydrogen, (C 1 -C 6 )alkyl, aryl, heteroaryl, heterocycle, (C 1 -C 6 )alkylaryl, —S(O) x (C 1 -C 6 )alkyl, —S(O) x aryl, —C(O)(C 1 -C 6 )alkyl;
each R c is independently hydrogen, aryl, heteroaryl, heterocycle or (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro;
each R d is independently hydrogen, halo, oxo, hydroxy, —C(O)NR e R f , cyano, nitro, hydroxy(C 1 -C 6 )alkyl, aryl, aryl(C 1 -C 6 )alkyl, (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro, (C 1 -C 6 )alkoxy optionally substituted with up to 5 fluoro, or (C 1 -C 6 )alkyl substituted with one or more R dd ;
R dd is hydroxyl, alkoxy, alkylamino or halo;
each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, trifluoromethoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle; and
each R e and R f is independently (C 1 -C 6 )alkyl.
In some embodiments, Ar can be:
wherein W is CM or N (nitrogen); and each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle.
In one embodiment, the compound of formula (I) has the formula Ia:
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen), and each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle. In one embodiment, Y can be S (sulfur). In another embodiment, Y can be O (oxygen).
In another embodiment, the compound of formula (I) has the formula Ib:
tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen), and each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle. In one embodiment, Y can be S (sulfur). In another embodiment, Y can be O (oxygen).
In another embodiment, the compound of formula (I) has the formula (Ic)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen), and each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle. In one embodiment, Y can be S (sulfur). In another embodiment, Y can be O (oxygen).
In another embodiment, the compound of formula (I) has the formula (Id)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen), and each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle. In one embodiment, Y can be S (sulfur). In another embodiment, Y can be O (oxygen).
In another embodiment, the compound of formula (I) has the formula (Ie)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen), and each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle. In one embodiment, Y can be S (sulfur). In another embodiment, Y can be O (oxygen).
In another embodiment, the compound of formula (I) has the formula (If)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen), and each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle. In one embodiment, Y can be S (sulfur). In another embodiment, Y can be O (oxygen).
In another embodiment, the compound of formula (I) has the formula (IIa)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen); each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle; R 7 is
and R 5 is alkyl, chloroalkyl, alkylaminoalkyl, alkoxyalkyl or trifluoromethylalkyl.
In another embodiment, the compound of formula (I) has the formula (IIb)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N, (nitrogen); each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle, R 7 is
and n is 0, 1 or 2.
In another embodiment, the compound of formula (I) has the formula (IIc)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N; (nitrogen), each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle; R 7 is
and R dd is (C 1 -C 6 )alkyl optionally substituted with hydroxyl, alkoxy, alkylamino or halo.
In another embodiment, the compound of formula (I) has the formula (IIa)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen); each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle, R 7 is
and R 5 is alkyl, chloroalkyl, alkylaminoalkyl, alkoxyalkyl or trifluoromethylalkyl.
In another embodiment, the compound of formula (I) has the formula (IVa)
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein W is CM or N (nitrogen); each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle; R 7 is
and R 5 or R 6 are independently alkyl, chloroalkyl, alkylaminoalkyl, alkoxyalkyl or trifluoromethylalkyl.
In another embodiment the compound is selected from the group consisting of:
or tautomer thereof, or their pharmaceutically acceptable salts.
The present embodiments provide for a method of modulating one or more GABA A subtypes in an animal comprising administering to the animal an effective amount of a compound of formula (I):
or tautomer thereof, or their pharmaceutically acceptable salts,
wherein:
Z 1 , Z 2 and Z 3 are each independently N (nitrogen), NR 7 or CR 8 , wherein at least one of Z 1 , Z 2 or Z 3 is NR 7 ;
R 7 is —C(═Y)NR 1 R 2 ;
R 8 is hydrogen, halo, (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro, or (C 1 -C 6 )alkoxy optionally substituted with up to 5 fluoro;
Y is O (oxygen) or S (sulfur);
R 1 and R 2 are each independently selected from the group consisting of hydrogen, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkylOR a , (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro, (C 1 -C 6 )alkyl optionally substituted with up to 5 chloro, (C 1 -C 6 )alkoxy optionally substituted with up to 5 fluoro, (C 1 -C 6 )alkylNR a R b ; and aryl, or R 1 and R 2 are taken together with the nitrogen to which they are attached to form a heterocycle group optionally substituted with one or more R c ; wherein the heterocycle group optionally include one or more groups selected from O (oxygen), S(O) x , and NR d ;
x is 0, 1 or 2;
Ar is aryl, or heteroaryl, each optionally substituted with one or more M;
R 3 is hydrogen, or oxide;
R 4 is selected from the group consisting of hydrogen, hydroxy, halo, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro, and (C 1 -C 6 )alkoxy optionally substituted with up to 5 fluoro;
each R a and R b is independently hydrogen, (C 1 -C 6 )alkyl, aryl, heteroaryl, heterocycle, (C 1 -C 6 )alkylaryl, —S(O) x (C 1 -C 6 )alkyl, —S(O) x aryl, —C(O)(C 1 -C 6 )alkyl;
each R c is independently hydrogen, aryl, heteroaryl, heterocycle or (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro;
each R d is independently hydrogen, halo, oxo, hydroxy, —C(O)NR c R f , cyano, nitro, hydroxy(C 1 -C 6 )alkyl, aryl, aryl(C 1 -C 6 )alkyl, (C 1 -C 6 )alkyl optionally substituted with up to 5 fluoro, (C 1 -C 6 )alkoxy optionally substituted with up to 5 fluoro, (C 1 -C 6 )alkyl substituted with one or more R dd ;
R dd is hydroxyl, alkoxy, alkylamino or halo;
each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, trifluoromethoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle; and
each R e and R f is independently (C 1 -C 6 )alkyl.
In some embodiments, Ar can be:
wherein W is CM or N (nitrogen); and each M is independently hydrogen, halo, CF 3 , CF 2 H, hydroxy, methoxy, cyano, nitro, (C 1 -C 6 )alkyl, hydroxy(C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, —NR a R b , aryl, heteroaryl or heterocycle.
In one embodiment of the method, the modulation can be negative. In another embodiment, the modulation can be positive.
In one embodiment of the method, the GABA A subtypes is GABA A α5. In one embodiment of the method, the modulation can be negative. In another embodiment, the modulation can be positive.
Some embodiments disclosed herein relate to a method of treatment of a cognitive dysfunction in an animal comprising administering to the animal an effective amount of the compounds of the invention, or a pharmaceutically acceptable salt thereof, under conditions wherein the cognitive dysfunction is treated. In one embodiment, the animal is an aged animal. In another embodiment, the cognitive dysfunction is Alzheimer's disease, dementia or another neurodegenerative disease.
Some embodiments disclosed herein relate to a method of treatment of a psychiatric disorder in an animal comprising administering to the animal an effective amount of the compounds of the invention, or a pharmaceutically acceptable salt thereof, under conditions wherein the psychiatric disorder is treated.
Some embodiments disclosed herein relate to the use of the compounds of this invention, or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament useful for modulation of one or more GABA A subtypes in an animal. In one embodiment of the method, the modulation can be negative. In another embodiment, the modulation can be positive. In one embodiment of the method, the GABA A subtypes is GABA A α5. In one embodiment of the method, the modulation can be negative. In another embodiment, the modulation can be positive.
Some embodiments disclosed herein relate to the use of the compounds of this invention, or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament useful for treatment of a cognitive dysfunction in an animal. In one embodiment, the animal is a healthy animal. In another embodiment, the animal is an aged animal. In another embodiment, the cognitive dysfunction is Alzheimer's disease, dementia or another neurodegenerative disease.
Some embodiments disclosed herein relate to the use of the compounds of this invention, or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament useful for treatment of psychiatric disorders in an animal. In one embodiment the psychiatric disorder is an anxiety disorder, sleep disorder, depression, or schizophrenia.
Some embodiments disclosed herein relate to the use of a compound of formula (I), or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament useful for treatment of disorders ameliorated by modulation of GABA A α subunits other than α5 in an animal. In one embodiment, the modulation can be positive. In another embodiment, the modulation can be negative.
Some embodiments disclosed herein relate to a method of increasing cognitive function in an animal comprising administering to the animal an effective amount of a compound of formula (I), or a pharmaceutically acceptable salt thereof, under conditions wherein memory is increased. In one embodiment, the animal is healthy. In one embodiment, the memory is long term memory. In one embodiment, the memory is short term memory.
Some embodiments disclosed herein relate to the use of a compound of formula (I), or a cognitive function in an animal wherein the GABA A α5 subtype in the animal is negatively modulated. In pharmaceutically acceptable salt thereof, for the manufacture of a medicament for increasing one embodiment, the animal is healthy. In one embodiment, the memory is long term memory. In one embodiment, the memory is short term memory.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
As used herein, common organic abbreviations are defined as follows:
Ac Acetyl
aq. Aqueous
Bu n-Butyl
cat. Catalytic
CDI 1,1′-carbonyldiimidazole
° C. Temperature in degrees Centigrade
Dowtherm® eutectic mixture of diphenyl ether and biphenyl
DBN 1,5-Diazabicyclo[4.3.0]non-5-ene
DBU 1,8-Diazabicyclo[5.4.0]undec-7-ene
DIEA Diisopropylethylamine
DMA Dimethylacetamide
DMF N,N′-Dimethylformamide
DMSO Dimethylsulfoxide
Et Ethyl
g Gram(s)
h Hour (hours)
HPLC High performance liquid chromatography
iPr or isopr Isopropyl
LCMS Liquid chromatography-mass spectrometry
Me Methyl
MeOH Methanol
mL Milliliter(s)
Pd/C Palladium on activated carbon
ppt Precipitate
rt Room temperature
TEA Triethylamine
Tert, t tertiary
μL Microliter(s)
As used herein, the term “alkyl” refers to a fully saturated aliphatic hydrocarbon group. The alkyl moiety may be branched, straight chain, or cyclic. Examples of branched alkyl groups include, but are not limited to, isopropyl, sec-butyl, t-butyl and the like. Examples of straight chain alkyl groups include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and the like. Examples of cyclic alkyl groups include, but are not limited to, cyclopropyl, cyclopentyl, cyclohexyl, cycloheptyl, and the like.
The term “alkoxy” used herein refers to straight or branched chain alkyl radical covalently bonded to the parent molecule through an —O— linkage. Examples of alkoxy groups include, but are not limited to, methoxy, ethoxy, propoxy, isopropoxy, butoxy, n-butoxy, sec-butoxy, t-butoxy and the like.
The term “alkenyl” used herein refers to a monovalent straight or branched chain radical of from two to twenty carbon atoms containing a carbon double bond including, but not limited to, 1-propenyl, 2-propenyl, 2-methyl-1-propenyl, 1-butenyl, 2-butenyl, and the like.
The term “alkynyl” used herein refers to a monovalent straight or branched chain radical of from two to twenty carbon atoms containing a carbon triple bond including, but not limited to, 1-propynyl, 1-butynyl, 2-butynyl, and the like.
The term “aryl” used herein refers to homocyclic aromatic radical whether one ring or multiple fused rings. Moreover, the term “aryl” includes fused ring systems wherein at least two aryl rings, or at least one aryl and an ortho-fused bicyclic carbocyclic radical having about nine to ten ring atoms in which at least one ring is aromatic share at least one chemical bond. Examples of “aryl” rings include, but are not limited to, optionally substituted phenyl, biphenyl, naphthalenyl, phenanthrenyl, anthracenyl, tetralinyl, fluorenyl, indenyl, and indanyl.
The term, “heterocycle” or “heterocycle group” used herein refers to an optionally substituted monocyclic, bicyclic, or tricyclic ring system comprising at least one heteroatom in the ring system backbone. The heteroatoms are independently selected from oxygen, sulfur, and nitrogen. The term, “heterocycle” includes multiple fused ring systems. Moreover, the term “heterocycle” includes fused ring systems that may have any degree of saturation provided that at least one ring in the ring system is not aromatic. The monocyclic, bicyclic, or tricyclic ring system may be substituted or unsubstituted, and can be attached to other groups via any available valence, preferably any available carbon or nitrogen. Preferred monocyclic ring systems are of 4, 5, 6, 7, or 8 members. Six membered monocyclic rings contain from up to three heteroatoms wherein each heteroatom is individually selected from oxygen, sulfur, and nitrogen, and wherein when the ring is five membered, preferably it has one or two heteroatoms wherein each heteroatom is individually selected from oxygen, sulfur, and nitrogen. Preferred bicyclic cyclic ring systems are of 8 to 12 members and include spirocycles. An example of an optional substituent includes, but is not limited to, oxo (═O).
The term “heteroaryl” used herein refers to an aromatic heterocyclic group, whether one ring or multiple fused rings. In fused ring systems, the one or more heteroatoms may be present in only one of the rings. Examples of heteroaryl groups include, but are not limited to, benzothiazyl, benzoxazyl, quinazolinyl, quinolinyl, isoquinolinyl, quinoxalinyl, pyridyl, pyrrolyl, oxazolyl, indolyl, thienyl, and the like. The term “heterocycle” encompasses heteroaryl fused to a non-aromatic ring system.
The term “heteroatom” used herein refers to, for example, oxygen, sulfur and nitrogen.
The term “amino” used herein refers to a nitrogen radical substituted with hydrogen, alkyl, aryl, or combinations thereof. Examples of amino groups include, but are not limited to, —NHMethyl, —NH 2 , —NMethyl 2 , —NPhenylMethyl, —NHPhenyl, —NEthylMethyl, and the like.
The term “arylalkyl” used herein refers to one or more aryl groups appended to an alkyl radical. Examples of arylalkyl groups include, but are not limited to, benzyl, phenethyl, phenpropyl, phenbutyl, and the like.
The term “heteroarylalkyl” used herein refers to one or more heteroaryl groups appended to an alkyl radical. Examples of heteroarylalkyl include, but are not limited to, pyridylmethyl, furanylmethyl, thiopheneylethyl, and the like.
The term “aryloxy” used herein refers to an aryl radical covalently bonded to the parent molecule through an —O— linkage.
The term “alkylthio” used herein refers to straight or branched chain alkyl radical covalently bonded to the parent molecule through an —S— inkage.
The term “carbonyl” used herein refers to C═O (i.e. carbon double bonded to oxygen).
The term “oxo” used herein refers to ═O (i.e. double bond to oxygen). For example, cyclohexane substituted with “oxo” is cyclohexanone.
The term “alkanoyl” used herein refers to a “carbonyl” substituted with an “alkyl” group, the “alkanoyl” group is covalently bonded to the parent molecule through the carbon of the “carbonyl” group. Examples of alkanoyl groups include, but are not limited to, methanoyl, ethanoyl, propanoyl, and the like. Methanoyl is commonly known as acetyl.
As used herein, a radical indicates species with a single, unpaired electron such that the species containing the radical can be covalently bonded to another species. Hence, in this context, a radical is not necessarily a free radical. Rather, a radical indicates a specific portion of a larger molecule. The term “radical” can be used interchangeably with the term “group.”
As used herein, a substituted group is derived from the unsubstituted parent structure in which there has been an exchange of one or more hydrogen atoms for another atom or group.
Asymmetric carbon atoms may be present in the compounds described. All such isomers, including diastereomers and enantiomers, as well as the mixtures thereof are intended to be included in the scope of the recited compound. In certain cases, compounds can exist in tautomeric forms. All tautomeric forms are intended to be included in the scope. Likewise, when compounds contain an alkenyl or alkenylene group, there exists the possibility of cis- and trans-isomeric forms of the compounds. Both cis- and trans-isomers, as well as the mixtures of cis- and trans-isomers, are contemplated. Thus, reference herein to a compound includes all of the aforementioned isomeric forms unless the context clearly dictates otherwise.
Various forms are included in the embodiments, including polymorphs, solvates, hydrates, conformers, salts, and prodrug derivatives. A polymorph is a composition having the same chemical formula, but a different structure. A solvate is a composition formed by solvation (the combination of solvent molecules with molecules or ions of the solute). A hydrate is a compound formed by an incorporation of water. A conformer is a structure that is a conformational isomer. Conformational isomerism is the phenomenon of molecules with the same structural formula but different conformations (conformers) of atoms about a rotating bond. Salts of compounds can be prepared by methods known to those skilled in the art. For example, salts of compounds can be prepared by reacting the appropriate base or acid with a stoichiometric equivalent of the compound.
The term “animal” as used herein includes birds, reptiles, and mammals (e.g. domesticated mammals and humans).
The terms “individual,” “host,” “subject,” and “patient” are used interchangeably herein, and refer to a mammal, including, but not limited to, murines, simians, humans, mammalian farm animals, mammalian sport animals, and mammalian pets.
Specific Embodiments
In one embodiment, the compound of formula (I) can be a compound of any of the formulae Ia-In.
Specific values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
In some embodiments, Ar can be phenyl, 4-methoxyphenyl, or 2-pyridyl, 4-chloro-2-pyridyl, 4-trifluoromethyl-phenyl, 3,5-bis(trifluoromethyl)-phenyl, 2,4-difluorophenyl, 2-fluorophenyl, 4-(1-methylethyl)phenyl or 4-chloro-2-fluorophenyl.
In some embodiments, Y can be O (oxygen) or S (sulfur).
The general methods to synthesize these compounds are detailed below.
Process of Preparation
Processes for preparing compounds of formula (I), is provided as further embodiments of the invention and are illustrated by the following procedures in which the meanings of the generic radicals are as given above unless otherwise qualified.
Compounds of the general formula (I) can be prepared using the general synthetic approach illustrated below in Scheme 1.
General Reaction Scheme 1 shows a representative synthetic method for the synthesis of N-alkyl-2-aryl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide. The 3-amino-pyrazole of formula 1 can be reacted with diethyl 2-(ethoxymethylene)malonate under heating to afford an enamine, in an addition-elimination type reaction, which upon thermal cyclization provides the hydroxy-pyrazolopyridine of formula 2. Solvents that can be used in step (b) include but are not limited to diphenyl ether, Dowtherm® and similar high boiling point stable solvents. Conversion of the hydroxyl-hydroxy-pyrazolopyridine of formula 2 to the chloro-pyrazolopyridine of formula 3 can be accomplished using a chlorinating agent in a halogenated solvent and optionally catalytic DMF. Chlorinating agents that can be used in step (c) include but are not limited to oxalyl chloride, P(O)Cl 3 , PCl 5 , thionyl chloride, phosgene, triphosgene, and similar chlorinating agents. Solvents that can be used in step (c) include but are not limited to chlorobenzene, methylene chloride, 1,2-dichloroethane, chloroform, and similar solvents. The chloro-pyrazolopyridine of formula 3 can be reacted with aryl or heteroaryl hydrazine followed by an alkaline cyclization to form the tricyclic dipyrazolopyridine of formula 4. Bases that can be used in step (d and e) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine, sodium hydroxide and the like. Solvents that can be used in step (d and e) include but are not limited to o-xylene, xylenes, chlorobenzene, toluene, ethanol and the like. A reflux under acidic condition provides compound of formula 5. Acids that can be used in step (f) include but are not limited to trifluoroacetic acid, acetic acid, and the like. Step (f) can be performed with solvent or neat. Synthesis of final compound was achieved by reacting compound of formula 5 with alkyl isocyanates in the presence of base. Bases that can be used in step (g) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine and the like. Solvents that can be used in step (g) include but are not limited to chlorobenzene, methylene chloride, 1,2-dichloroethane, chloroform, dimethylformamide and similar solvents.
Additional ureas were prepared as shown in Scheme 2.
Synthesis of compound 7 was achieved in a two step single pot fashion by reacting compound of formula 5 with triphosgene in the presence of base followed by addition of alkyl amine. Bases that can be used in step (h and i) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine and the like. Solvents that can be used in step (h and i) include but are not limited to chlorobenzene, methylene chloride, 1,2-dichloroethane, chloroform, dimethylformamide and similar solvents.
General Reaction Scheme 3 shows a representative synthetic method for the synthesis of N-alkyl-2-aryl-3-oxo-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide.
The hydrochloride salt of 3-amino-pyrrole of Formula 8 can be reacted with diethyl 2-(ethoxymethylene)malonate under heating to afford an enamine of formula 9, in an addition-elimination type reaction in the presence of a base. Bases that can be used in step (a) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine and the like. The cyclization/chlorination in the presence of a chlorinating agent provides the chloro-pyrrolopyridine of formula 10. Chlorinating agents that can be used in step (c) include but are not limited to oxalyl chloride, P(O)Cl 3 , PCl 5 , thionyl chloride, phosgene, triphosgene, and similar chlorinating agents. The reaction can be done either neat or in the presence of a solvent. The chloro-pyrrolopyridine of formula 10 can be reacted with aryl or heteroaryl hydrazine followed by cyclization under basic conditions to form the tricyclic dipyrazolopyridine which was then hydrolyzed to yield dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-carboxylate of formula 11. Bases that can be used in step (c, d and e) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine, sodium hydroxide and the like. Solvents that can be used in step (c, d and e) include but are not limited to o-xylene, xylenes, chlorobenzene, toluene, ethanol and the like. Decarboxylation was achieved by refluxing compound of formula 11 in dimethylformamide. Synthesis of final compound of formula 13 was achieved by reacting compound of formula 12 with alkyl isocyanates in the presence of base. Bases that can be used in step (g) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine and the like. Solvents that can be used in step (g) include but are not limited to chlorobenzene, methylene chloride, 1,2-dichloroethane, chloroform, dimethylformaide and similar solvents.
General Reaction Scheme 4 shows a representative synthetic method for the synthesis of N-alkyl-2-aryl-3-oxo-2,3-dihydropyrazolo[3,4-d]pyrrolo[2,3-b]pyridine-7(5H)-carboxamide
Commercially available carboxylic acid was esterified using a one pot two step procedure of in situ generation of acid chloride followed by a methanol quench. Chlorinating agents that can be used in step (a) include but are not limited to oxalyl chloride, P(O)Cl 3 , PCl 5 , thionyl chloride, phosgene, triphosgene, and similar chlorinating agents. The chloro-pyrrolopyridine of formula 15 can be reacted with aryl or heteroaryl hydrazine followed by cyclization under neutral or basic conditions followed a base catalyzed cyclization to form the tricyclic dipyrrolopyridine of formula 16. Bases that can be used in step (b and c) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine, sodium hydroxide and the like. Solvents that can be used in step (b and c) include but are not limited to o-xylene, xylenes, chlorobenzene, toluene, ethanol and the like. Synthesis of final compound of formula 17 was achieved by reacting compound of formula 16 with alkyl isocyanates in the presence of base. Bases that can be used in step (d) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine and the like. Solvents that can be used in step (d) include but are not limited to chlorobenzene, methylene chloride, 1,2-dichloroethane, chloroform, dimethylformaide and similar solvents.
Conversion of compound 18 to compound 19 can be accomplished using a chlorinating agent in a halogenated solvent and optionally catalytic DMF. Chlorinating agents that can be used in step (a) include but are not limited to oxalyl chloride, P(O)Cl 3 , PCl 5 , thionyl chloride, phosgene, triphosgene, and similar chlorinating agents. Solvents that can be used in step (a) include but are not limited to chlorobenzene, methylene chloride, 1,2-dichloroethane, chloroform, and similar solvents. For example, compound 18 was reacted with oxalyl chloride in the presence of catalytic DMF in chloroform under reflux for 3 h to afford compound 19.
Compound 19 can be reacted with aryl or heteroaryl hydrazine followed by an alkaline cyclization to form the tricyclic dipyrazolopyridine of formula 20. Bases that can be used in step (b and c) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine, sodium hydroxide and the like. Solvents that can be used in step (b and c) include but are not limited to o-xylene, xylenes, chlorobenzene, toluene, ethanol and the like. Synthesis of final compound of formula 21 is achieved by reacting compound of formula 20 with R 1 -isocyanate or R 1 -isothiocyanate in the presence of base. Bases that can be used in step (d) include but are not limited to triethyl amine (TEA), diisopropylethyl amine (DIEA), 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU), 1,5-Diazabicyclo[4.3.0]non-5-ene (DBN), N-methylpiperidine and the like. Solvents that can be used in step (d) include but are not limited to chlorobenzene, methylene chloride, 1,2-dichloroethane, chloroform, dimethylformamide and similar solvents.
General Procedures: Scheme 1 (Compounds 6a-6az)
Step 1:
Ethyl 1-(4-methoxybenzyl)-4-oxo-4,7-dihydro-1H-pyrazolo[3,4-b]pyridine-5-carboxylate (2)
Equimolar amounts of compound 1 and dimethylmethoxy malonate were heated to 100° C. for 16 h. Nitrogen gas was bubbled through the reaction mixture overnight to yield enamine as brown solid which was added to a preheated flask at 245° C. and stirred at that temperature for 45 minutes. The reaction mixture was cooled to room temperature and collected solid was washed repeatedly to yield product 2 as off white solid.
Step 2:
Ethyl 4-chloro-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate (3)
Ethyl 1-(4-methoxybenzyl)-4-oxo-4,7-dihydro-1H-pyrazolo[3,4-b]pyridine-5-carboxylate 2 and POCl 3 were heated at 80° C. in a sealed tube for 3 hours. Reaction mixture was concentrated in vacuo, diluted with diethylether, washed with water, dried over sodium sulfate and concentrated in vacuo to afford product 3 as off white solid.
Step 3:
6-(4-methoxybenzyl)-2-phenyl-5,6-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridin-3(2H)-one (4)
A suspension of compound 3 and 10 equivalents of phenyl hydrazine was stirred at 90° C. for 16 hours. Reaction was quenched with iced water. The aqueous layer was removed, residue was suspended in ethanol and stirred with 1N NaOH solution at room temperature for 1 hour. pH was adjusted to 5 using acetic acid and solvent was removed in vacuo. Compound 4 was collected by filtration.
Step 4:
2-phenyl-5,6-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridin-3(2H)-one.TFA (5a)
Compound 4 was suspended in trifluoroacetic acid and stirred at 100° C. for 40 minutes in a microwave. Excess acid was removed in vacuo. Yellow precipitates were collected, washed with methanol and dried to afford product 5a.
Step 5:
Example 1
N-isopropyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6a)
One equivalent of compound 5a, 1.5 equivalents of triethylamine and 1.2 equivalents of iso-propylisocyanate were suspended in DMF and stirred at room temperature for 15 hours. Solvent was removed in vacuo and the compound was purified using column chromatography to yield product 6a as yellow solid. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.26 (d, J=6.60 Hz, 7H), 4.04 (dq, J=14.12, 6.79 Hz, 1H), 7.17 (t, J=7.34 Hz, 1H), 7.44 (t, J=7.89 Hz, 2H), 8.11 (d, J=8.07 Hz, 2H), 8.41 (d, J=8.44 Hz, 1H), 8.56 (s, 1H), 8.97 (s, 1H).
Example 2
N-ethyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6b)
Compound 6b was synthesized following step 5 using compound 5a and ethylisocyanate instead of iso-propylisocyanate. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.16 (t, J=7.15 Hz, 3H), 3.32-3.38 (m, 2H), 7.10-7.18 (m, 1H), 7.41 (t, J=7.89 Hz, 2H), 8.09 (d, J=8.07 Hz, 2H), 8.53 (s, 1H), 8.65 (t, J=5.69 Hz, 1H), 8.93 (s, 1H).
Example 3
N-butyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide.TFA (6f)
Compound 6f was synthesized following step 5 using compound 5a and butylisocyanate instead of iso-propylisocyanate. 1 H NMR (400 MHz, DMSO-d6) δppm 0.89 (t, J=7.24 Hz, 3H), 1.32 (sxt, J=7.28 Hz, 2H), 1.55 (quin, J=7.24 Hz, 2H), 3.23-3.33 (m, 3H), 7.14 (t, J=7.24 Hz, 1H), 7.41 (t, J=7.63 Hz, 2H), 8.09 (d, J=8.22 Hz, 2H), 8.48-8.56 (m, 1H), 8.58-8.67 (m, 1H), 8.94 (s, 1H), 13.01 (d, J=5.87 Hz, 1H).
Example 4
3-oxo-N,2-diphenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6h)
Compound 6h was synthesized following step 5 using compound 5a and phenylisocyanate instead of iso-propylisocyanate. 1 H NMR (400 MHz, DMSO-d6) δ ppm 7.17 (d, J=12.47 Hz, 2H), 7.41 (q, J=7.58 Hz, 5H), 7.74 (d, J=8.07 Hz, 2H), 8.09 (d, J=8.44 Hz, 2H), 8.54 (s, 1H), 9.10 (s, 1H), 10.55 (s, 1H).
Example 5
N-ethyl-3-oxo-2-(pyridin-2-yl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6m)
Compound 6m was synthesized following step 4 and 5a using compound 4a and pyridylhydrazine and ethylisocyanate instead of phenylhydrazine and iso-propylisocyanante respectively. 1 H NMR (400 MHz, DMSO-d6) δppm 1.13-1.19 (m, 3H), 3.31-3.39 (m, 3H), 7.17-7.24 (m, 1H), 7.83-7.91 (m, 1H), 8.14 (d, J=8.44 Hz, 1H), 8.46 (d, J=4.40 Hz, 1H), 8.55 (s, 1H), 8.61-8.70 (m, 1H), 8.93 (s, 1H).
Example 6
2-(4-chlorophenyl)-5,6-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridin-3(2H)-one.TFA (6o)
Compound 6o was synthesized following step 4 and 5a using compound 4a and 4-chloro-phenylhydrazine and ethylisocyanate instead of phenylhydrazine and iso-propylisocyanante respectively. 1 H NMR (400 MHz, DMSO-d6) δppm 1.15 (t, J=7.04 Hz, 3H), 7.47 (d, J=9.00 Hz, 2H), 8.13 (d, J=9.00 Hz, 2H) 8.56 (s, 1H), 8.66 (t, J=5.87 Hz, 1H), 8.90-8.98 (m, 1H), 13.03-13.14 (m, 1H).
Example 7
2-(5-chloropyridin-2-yl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ay)
Compound 6ay was synthesized following step 4 and 5a using compound 4a and 4-chloro-2-pyridylhydrazine and ethylisocyanate instead of phenylhydrazine and iso-propylisocyanante respectively. 1H NMR (400 MHz, DMSO-d6) δppm 1.15 (t, J=7.24 Hz, 3H), 3.08 (q, J=7.04 Hz, 2H), 7.99 (dd, J=8.80, 2.54 Hz, 1H), 8.24 (d, J=9.00 Hz, 1H), 8.49 (d, J=2.35 Hz, 1H), 8.58 (s, 1H), 8.67 (br. s., 1H), 8.95 (s, 1H), 13.11 (br. s., 1H).
Example 8
2-(4-bromophenyl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide.TFA (6w)
Compound 6w was synthesized following step 4 and 5a using compound 4a and 4-bromophenylhydrazine and ethylisocyanate instead of phenylhydrazine and iso-propylisocyanante respectively. 1H NMR (400 MHz, DMSO-d6) δppm 1.16 (t, J=7.24 Hz, 3H), 3.27-3.37 (m, 2H), 7.60 (d, J=9.00 Hz, 2H), 8.08 (d, J=9.00 Hz, 2H), 8.57 (d, J=5.87 Hz, 1H), 8.66 (t, J=5.87 Hz, 1H), 8.95 (s, 1H), 13.10 (d, J=5.09 Hz, 1H).
Example 9
N-ethyl-2-(4-isopropylphenyl)-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide. TFA (6z)
Compound 6z was synthesized following step 4 and 5a using compound 4a and 4-bromophenylhydrazine and ethylisocyanate instead of phenylhydrazine and iso-propylisocyanante respectively. 1 H NMR (400 MHz, DMSO-d6) δppm 1.09-1.26 (m, 10H), 2.82-2.94 (m, 1H), 3.32 (d, J=7.04 Hz, 3H), 7.28 (d, J=8.61 Hz, 2H), 7.97 (d, J=8.22 Hz, 2H), 8.51 (d, J=5.87 Hz, 1H), 8.65 (t, J=5.67 Hz, 1H), 8.93 (s, 1H), 12.98 (d, J=5.48 Hz, 1H).
General Procedure: Scheme 2 (7a-7c)
Example 10
N,N-dimethyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide. TFA (7c)
A suspension of 5a and 1.2 equivalents of isopropenyl chloroformate in dichloroethane was treated with 1.2 equivalents of diisopropyl ethylamine (0.177 mL, 1.07 mmol). After 15 h stirring at room temperature, 2M dimethylamine in THF (0.196 mL, 0.392 mmol) was added and allowed to stir at room temperature for 18 h. Solvents were removed in vacuo and residue was purified on HPLC. The product was obtained as yellow solids. 1 H NMR (400 MHz, DMSO-d6) δppm 3.12 (br. s., 6H), 7.14 (t, J=7.24 Hz, 1H), 7.41 (t, J=8.61 Hz, 3H), 8.09 (d, J=7.83 Hz, 2H), 8.54 (d, J=5.87 Hz, 1H), 8.90 (s, 1H), 13.17 (d, J=5.48 Hz, 1H).
General Procedures: Scheme 3 (Compounds 13a-13k)
Step 1:
Diethyl 2-((2-(ethoxycarbonyl)-1H-pyrrol-3-ylamino)methylene)malonate (9a)
Equimolar ratios of ethyl 3-methyl-1H-pyrrole-2-carboxylate hydrochloride, diisopropylethylamine and diethyl ethoxymethylenemalonate were mixed in a sealed tube and heated at 100° C. for 15 hours. After cooling to room temperature, column chromatography afforded the title compound as a white solid.
Step 2:
Diethyl 4-chloro-6H-pyrrolo[3,4-b]pyridine-3,7-dicarboxylate (10a)
Diethyl 2-((2-(ethoxycarbonyl)-1H-pyrrol-3-ylamino)methylene)malonate was dissolved in phosphoryl chloride (0.2 M) and heated at 75° C. for 18 hours. Reaction mixture was concentrated to dryness and water and ethyl acetate were added. The aqueous layer was extracted with ethylacetate, the combined organic fractions were washed with brine and dried over magnesium sulfate before concentrating in vacuo to afford the crude compound 10a as an orange solid.
Step 3:
Ethyl 3-oxo-2-phenyl-2,3,5,7-tetrahydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-6-carboxylate
One equivalent of crude diethyl 4-chloro-6H-pyrrolo[3,4-b]pyridine-3,7-dicarboxylate was dissolved in ethanol (0.2 M) under an atmosphere of nitrogen. Following the addition of 2 equivalents of triethylamine and 1.2 equivalents of phenyl hydrazine, the reaction was heated at 75° C. for 21 hours. After cooling to room temperature a large excess of 1 N NaOH was added and after 5 hours the reaction was concentrated to dryness. 10% HCl (aq.) was added and the brown precipitate was collected by filtration and washed with methylene chloride to afford the product as a yellow solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.35 (br. s., 3H) 4.23-4.52 (m, 2H) 6.96-7.22 (m, 1H) 7.26-7.54 (m, 2H) 7.64-7.89 (m, 1H) 7.99-8.27 (m, 3H) 11.60-11.89 (m, 1H) 13.04-13.29 (m, 1H).
3-Oxo-2-phenyl-2,3,5,7-tetrahydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-6-carboxylic acid (11a)
Ethyl 3-oxo-2-phenyl-2,3,5,7-tetrahydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-6-carboxylate was dissolved into a mixture of methanol, THF and H 2 O (1:1:1, 0.2 M). LiOH (5 eq.) was added and the reaction was heated at 45° C. for 17 hours. After cooling to room temperature the reaction was concentrated to dryness. 10% HCl (aq.) was added and the precipitate was collected, affording the title compound as a brown solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 6.87-7.21 (m, 1H) 7.25-7.52 (m, 2H) 7.60-7.85 (m, 1H) 8.13 (br. s., 3H) 11.56-11.92 (m, 1H) 12.90-13.17 (m, 1H)
Step 4:
2-Phenyl-5,7-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridin-3(2H)-one (12a)
3-Oxo-2-phenyl-2,3,5,7-tetrahydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-6-carboxylic acid was dissolved in DMF (0.3 M) and heated at 220° C. in a microwave for 20 minutes. The crude reaction mixture was concentrated and column chromatography afforded the title compound as a brown solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 7.07 (t, J=4.4 Hz, 1H) 7.14 (s, 1H) 7.36 (t, J=4.4 Hz, 2H) 7.44 (s, 1H) (8.15 (d, J=7.6 Hz, 1H) 8.29 (d, J=6.4 Hz 1H) 12.06 (s, 1H) 12.34 (s, 1H).
Step 5:
Example 11
N-Methyl-3-oxo-2-phenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13a)
One equivalent of pyrrolo-pyridine 12a was dissolved in DMF (0.1 M) under an atmosphere of nitrogen. 3 equivalents of di-iso-propylethylamine was added, followed by 1.5 equivalents of methylisocyanate and stirred overnight. The crude reaction mixture was concentrated to dryness and purification by column chromatography afforded the compound 13a. 1 H NMR (400 MHz, DMSO-d6) δ ppm 2.84 (d, J=3.52 Hz, 3H) 7.02-7.18 (m, 1H) 7.30-7.47 (m, 2H) 7.57-7.78 (m, 1H) 7.90-8.04 (m, 1H) 8.05-8.20 (m, 2H) 8.32-8.50 (m, 1H) 8.52-8.68 (m, 1H) 12.28-12.49 (m, 1H)
Example 12
N-Ethyl-3-oxo-2-phenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13b)
The title compound 13b was obtained following procedure described above in step 5 by using ethylisocyanate instead of methylisocyanate. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.00-1.35 (m, 3H) 7.02-7.19 (m, 1H) 7.33-7.46 (m, 2H) 7.60-7.71 (m, 1H) 7.99-8.07 (m, 1H) 8.07-8.18 (m, 2H) 8.36-8.48 (m, 1H) 8.59-8.72 (m, 1H) 12.33-12.47 (m, 1H)
Example 13
3-Oxo-2-phenyl-N-propyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13c)
Following procedure described in step 5 and using n-propyl isocyanate afforded the title compound 13c as a yellow solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 0.81-1.00 (m, 3H) 1.42-1.76 (m, 2H) 3.15-3.26 (m, 2H) 7.00-7.24 (m, 1H) 7.26-7.49 (m, 2H) 7.51-7.73 (m, 1H) 7.97-8.20 (m, 3H) 8.33-8.52 (m, 1H) 8.54-8.71 (m, 1H) 12.27-12.50 (m, 1H).
Example 14
N-Butyl-3-oxo-2-phenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13i)
Following procedure described in step 5 and using n-butyl isocyanate afforded the title compound 13i as a yellow solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 0.78-0.99 (m, 3H) 1.22-1.42 (m, 2H) 1.46-1.66 (m, 2H) 6.98-7.17 (m, 1H) 7.25-7.45 (m, 2H) 7.54-7.73 (m, 1H) 7.97-8.21 (m, 3H) 8.30-8.49 (m, 1H) 8.52-8.70 (m, 1H) 12.30-12.49 (m, 1H)
Example 15
N-Isopropyl-3-oxo-2-phenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13j)
Following procedure described in step 5 and using isopropyl isocyanate afforded the title compound 13j as a yellow solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.21 (d, J=6.65 Hz, 8H) 3.86-4.07 (m, 1H) 7.00-7.16 (m, 1H) 7.29-7.47 (m, 2H) 7.58-7.70 (m, 1H) 7.99-8.22 (m, 3H) 8.30-8.49 (m, 2H) 12.27-12.47 (m, 1H).
Example 16
3-Oxo-N,2-diphenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13k)
Following procedure described in step 5 and using phenyl isocyanate afforded the title compound 13k as a yellow solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 7.01-7.24 (m, 2H) 7.31-7.49 (m, 4H) 7.62-7.75 (m, 2H) 7.73-7.88 (m, 1H) 8.05-8.19 (m, 2H) 8.19-8.33 (m, 1H) 8.37-8.52 (m, 1H) 10.27-10.48 (m, 1H) 12.34-12.53 (m, 1H).
Example 17
N-Ethyl-2-(2-fluorophenyl)-3-oxo-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13d)
Compound 13d was obtained following procedures described in steps 3, 4 and 5 and using 2-fluorophenyl hydrazine and ethylisocyanate instead of phenyl hydrazine and methylisocyanate respectively. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.15 (d, J=2.35 Hz, 3H) 7.12-7.43 (m, 3H) 7.43-7.59 (m, 1H) 7.60-7.72 (m, 1H) 7.83-8.01 (m, 1H) 8.27-8.51 (m, 1H) 8.54-8.73 (m, 1H) 12.17-12.48 (m, 1H)
Example 18
N-Ethyl-2-(4-fluorophenyl)-3-oxo-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13f)
Compound 13f was obtained following procedures described in steps 3, 4 and 5 and using 4-fluorophenyl hydrazine and ethylisocyanate instead of phenyl hydrazine and methylisocyanate respectively. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.05-1.29 (m, 3H) 7.13-7.32 (m, 2H) 7.55-7.70 (m, 1H) 7.96-8.06 (m, 1H) 8.06-8.18 (m, 2H) 8.34-8.53 (m, 1H) 8.57-8.75 (m, 1H) 12.32-12.53 (m, 1H).
Example 19
2-(2,4-Difluorophenyl)-N-ethyl-3-oxo-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13g)
Compound 13g was obtained following procedures described in steps 3, 4 and 5 and using 2,4-difluorophenyl hydrazine and ethylisocyanate instead of phenyl hydrazine and methylisocyanate respectively. 1 H NMR (400 MHz, DMSO-d6) δ ppm 0.97-1.24 (m, 3H) 7.05-7.25 (m, 1H) 7.33-7.48 (m, 1H) 7.48-7.61 (m, 1H) 7.61-7.73 (m, 1H) 7.80-8.02 (m, 1H) 8.29-8.55 (m, 1H) 8.51-8.76 (m, 1H) 12.27-12.54 (m, 1H).
General Procedures: Scheme 4 (Compounds 17a-17f)
Step 1:
Methyl 4-chloro-1H-pyrrolo[2,3-b]pyridine-5-carboxylate (15)
To a solution of carboxylic acid 14 in methylene chloride under an atmosphere of nitrogen was added 1.5 equivalents of oxalyl chloride followed by catalytic amount of dimethylformamide. The reaction was stirred for 18 hours before the addition of an excess of methanol. After 2 hours stiffing the reaction was evaporated to dryness to give the title compound 15 as an off-white solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 3.87 (s, 3H) 6.62-6.63 (m, 1H) 7.68-7.69 (m, 1H) 8.68-8.70 (m, 1H) 12.37 (s, 1H).
Step 2:
2-Phenyl-5,6-dihydropyrazolo[3,4-d]pyrrolo[2,3-b]pyridin-3(2H)-one (16)
A suspension of 1 equivalent of compound 15 and 10 equivalents of phenyl hydrazine was heated to 90° C. for 16 hours. Water was added to the reaction mixture at room temperature and decanted to remove the excess phenyl hydrazine. The crude reaction mixture was dissolved in MeOH and 0.1 N NaOH (2:1, 0.033 M) and stirred for 3.5 hours before concentrating to dryness. Purification by column chromatography afforded the title compound 16 as a yellow solid. 1 H NMR (400 MHz, DMSO-d6) δ ppm 6.43-6.72 (m, 1H) 7.04-7.28 (m, 1H) 7.37-7.56 (m, 4H) 7.84-8.13 (m, 2H) 8.33-8.55 (m, 1H) 11.99 (s, 1H).
Step 3:
Example 20
N-Methyl-3-oxo-2-phenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[2,3-b]pyridine-6(5H)-carboxamide (17a)
A solution of pyrrolo-pyridine 16 in dimethylformamide under an atmosphere of nitrogen and 3 equivalents of di-iso-propylethylamine (3 eq.) was added 3 equivalents of methylisocyanate and stirred overnight. The crude reaction mixture was concentrated to dryness and purification by column chromatography afforded the title compound 17a. 1 H NMR (400 MHz, DMSO-d6) δ ppm 2.83-3.11 (m, 3H) 6.64-6.92 (m, 1H) 7.21-7.43 (m, 1H) 7.44-7.63 (m, 2H) 7.77-8.05 (m, 3H) 8.57-8.81 (m, 1H) 9.48-9.76 (m, 1H).
Example 21
N-Ethyl-3-oxo-2-phenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[2,3-b]pyridine-6(5H)-carboxamide (17b)
The title compound 17b was obtained following procedure described above in step 3 by using ethylisocyanate instead of methylisocyanate. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.22 (br. s., 4H) 3.38-3.51 (m, 3H) 6.63-6.89 (m, 1H) 7.17-7.39 (m, 1H) 7.44-7.67 (m, 2H) 7.78-8.03 (m, 3H) 8.59-8.80 (m, 1H) 9.62-9.88 (m, 1H) 12.23-12.44 (m, 1H).
Example 22
N-Isopropyl-3-oxo-2-phenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[2,3-b]pyridine-6(5H)-carboxamide (17c)
The title compound 17c was obtained following procedure described above in step 3 by using iso-propylisocyanate instead of methylisocyanate. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.22-1.44 (m, 7H) 3.90-4.18 (m, 1H) 6.71-6.87 (m, 1H) 7.18-7.37 (m, 1H) 7.44-7.62 (m, 2H) 7.78-8.03 (m, 3H) 8.58-8.79 (m, 1H) 9.61-9.81 (m, 1H) 12.24-12.43 (m, 1H)
Example 23
3-Oxo-N,2-diphenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[2,3-b]pyridine-6(5H)-carboxamide (17d)
The title compound 17d was obtained following procedure described above in step 3 by using phenylisocyanate instead of methylisocyanate. 1 H NMR (400 MHz, DMSO-d6) δ ppm 6.80-6.95 (m, 1H) 7.13-7.25 (m, 1H) 7.25-7.37 (m, 1H) 7.39-7.49 (m, 2H) 7.49-7.64 (m, 2H) 7.66-7.79 (m, 2H) 7.84-7.97 (m, 2H) 7.98-8.11 (m, 1H) 8.72-9.01 (m, 1H) 12.13-12.35 (m, 1H).
Example 24
N-ethyl-3-oxo-2-phenyl-2,3-dihydropyrazolo[3,4-d]pyrrolo[2,3-b]pyridine-6(5H)-carbothioamide (17e)
To a solution of pyrrolo-pyridine 16 in dimethylformamide under an atmosphere of nitrogen and 3 equivalents of di-iso-propylethylamine (3 eq.) was added 3 equivalents of ethylisothiocyanate. The reaction mixture was stirred in a microwave at 100° C. for 3 hours. The crude reaction mixture was concentrated in vacuo and purified by column chromatography to afford compound 17e. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.22-1.42 (m, 3H) 3.68-3.93 (m, 2H) 6.72-6.90 (m, 1H) 7.19-7.38 (m, 1H) 7.42-7.64 (m, 2H) 7.77-7.96 (m, 2H) 8.27-8.59 (m, 1H) 8.61-8.81 (m, 1H) 12.10-12.38 (m, 1H) 12.37-12.57 (m, 1H).
Example 25
2-(5-Chloropyridin-2-yl)-N-ethyl-3-oxo-2,3-dihydropyrazolo[3,4-d]pyrrolo[2,3-b]pyridine-6(5H)-carboxamide (17f)
Compound 17f was obtained following procedures described in steps (2 and 3) and using 4-chloro-2-pyridylhydrazine and ethylisocyanate instead of phenyl hydrazine and methylisocyanate respectively. 1 H NMR (400 MHz, DMSO-d6) δ ppm 1.09-1.30 (m, 3H) 3.38-3.54 (m, 2H) 6.83-7.00 (m, 1H) 7.73-7.96 (m, 1H) 8.04-8.20 (m, 1H) 8.48-8.66 (m, 2H) 8.65-8.78 (m, 1H) 9.66-9.86 (m, 1H) 13.14-13.35 (m, 1H).
Example 26
N-methyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6c)
Compound 6c can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 2.86-2.91 (m, 3H) 7.16 (d, J=6.65 Hz, 1H) 7.39-7.47 (m, 2H) 8.07-8.13 (m, 2H) 8.52-8.57 (m, 2H) 8.95 (d, J=4.70 Hz, 1H) 13.06 (br. s., 1H).
Example 27
3-oxo-2-phenyl-N-propyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6d)
Compound 6d can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 0.88 (t, J=7.24 Hz, 3H) 1.48-1.64 (m, 2H) 3.26 (q, J=6.52 Hz, 2H) 7.14 (t, J=7.43 Hz, 1H) 7.41 (t, J=7.83 Hz, 2H) 8.08 (d, J=8.22 Hz, 1H) 8.53 (d, J=5.09 Hz, 1H) 8.63 (t, J=5.87 Hz, 1H) 8.94 (s, 1H) 13.02 (d, J=5.09 Hz, 1H).
Example 28
N-isobutyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6e)
Compound 6e can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=13.01 (br. s., 1H), 8.93 (s, 1H), 8.75-8.43 (m, 2H), 8.08 (d, J=7.8 Hz, 2H), 7.41 (t, J=8.0 Hz, 2H), 7.14 (t, J=7.4 Hz, 1H), 1.73-1.50 (m, 1H), 0.90 (d, J=6.3 Hz, 6H).
Example 29
N-isopentyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6g)
Compound 6g can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=13.01 (br. s., 1H), 8.93 (s, 1H), 8.71-8.43 (m, 2H), 8.08 (d, J=7.8 Hz, 2H), 7.41 (t, J=8.0 Hz, 2H), 7.14 (t, J=7.4 Hz, 1H), 1.75-1.35 (m, 3H), 0.90 (d, J=6.3 Hz, 7H).
Example 30
2-(5-chloropyridin-2-yl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6i)
Compound 6i can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.15 (t, J=7.24 Hz, 3H) 3.08 (q, J=7.04 Hz, 2H) 7.99 (dd, J=8.80, 2.54 Hz, 1H) 8.24 (d, J=9.00 Hz, 1H) 8.49 (d, J=2.35 Hz, 1H) 8.58 (s, 1H) 8.67 (br. s., 1H) 8.95 (s, 1H) 13.11 (br. s., 1H).
Example 31
N-(2-(dimethylamino)ethyl)-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (7a)
Compound 7a can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=9.93 (d, J=5.1 Hz, 1H), 8.61-8.44 (m, 1H), 8.33 (s, 1H), 8.30-8.09 (m, 3H), 7.36-7.25 (m, 2H), 7.07-6.94 (m, 1H), 3.53-3.44 (m, 1H), 3.14 (dd, J=6.5, 12.7 Hz, 1H), 2.59-2.48 (m, 2H), 2.31-2.18 (m, 6H).
Example 32
3-oxo-2-phenyl-N-(2,2,2-trifluoroethyl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (7b)
Compound 7b can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=13.05 (br. s., 1H), 9.34-9.13 (m, 1H), 9.04 (s, 1H), 8.56 (s, 1H), 8.08 (d, J=8.2 Hz, 2H), 7.52-7.00 (m, 3H), 4.25-3.94 (m, 2H).
Example 33
6-(4-isopropylpiperazine-1-carbonyl)-2-phenyl-5,6-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridin-3(2H)-one (7d)
Compound 7d can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.25 (d, J=6.24 Hz, 6H) 7.11-7.18 (m, 1H) 7.42 (t, J=7.52 Hz, 2H) 8.08 (d, J=8.07 Hz, 2H) 8.56 (s, 1H) 8.95 (s, 1H).
Example 34
N-cyclopropyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6j)
Compound 6j can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 0.72 (d, J=5.48 Hz, 4H) 2.81 (d, J=4.30 Hz, 1H) 7.08-7.16 (m, 1H) 7.40 (t, J=7.83 Hz, 2H) 8.11 (d, J=8.22 Hz, 2H) 8.47 (s, 1H) 8.73 (d, J=3.52 Hz, 1H) 8.86 (s, 1H).
Example 35
2-phenyl-6-(pyrrolidine-1-carbonyl)-5,6-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridin-3(2H)-one (6k)
Compound 6k can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.86-1.92 (m, 4H) 3.58 (br. S., 4H) 7.13 (t, J=7.43 Hz, 1H) 7.41 (t, J=7.83 Hz, 2H) 8.08 (d, J=8.22 Hz, 2H) 8.54 (d, J=5.09 Hz, 1H) 8.92 (s, 1H).
Example 36
N-ethyl-8-methyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6l)
Compound 6l can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.14 (t, J=7.24 Hz, 3H) 2.96 (s, 3H) 3.25-3.31 (m, 2H) 7.13 (t, J=7.24 Hz, 1H) 7.40 (t, J=7.83 Hz, 2H) 8.10 (d, J=7.83 Hz, 2H) 8.46 (s, 1H) 12.80 (br. s., 1H).
Example 37
N-isopropyl-3-oxo-2-(pyridin-2-yl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6n)
Compound 6n can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.24 (d, J=6.60 Hz, 6H) 4.01 (dt, J=13.66, 6.92 Hz, 1H) 7.21 (dd, J=6.97, 5.14 Hz, 1H) 7.85-7.90 (m, 1H) 8.14 (d, J=8.07 Hz, 1H) 8.46 (d, J=4.77 Hz, 1H) 8.55 (s, 1H) 8.93 (s, 1H).
Example 38
2-(4-chlorophenyl)-N-isopropyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6p)
Compound 6p can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.22 (d, J=6.60 Hz, 6H) 4.01 (dt, J=13.66, 6.92 Hz, 1H) 7.47 (d, J=9.00 Hz, 2H) 8.13 (d, J=9.00 Hz, 2H) 8.39 (d, J=8.89 Hz, 1H) 8.56 (s, 1H) 8.94 (s, 1H) 13.0 (br.s., 1H).
Example 39
2-(3,5-bis(trifluoromethyl)phenyl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6q)
Compound 6q can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.16 (t, J=7.04 Hz, 3H) 7.84 (s, 1H) 8.63-8.71 (m, 2H) 8.79 (s, 2H) 9.08 (s, 1H) 13.31 (br. s., 1H).
Example 40
2-(3,5-bis(trifluoromethyl)phenyl)-N-isopropyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6r)
Compound 6r can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.24 (d, J=6.65 Hz, 6H) 3.96-4.07 (m, 1H) 7.85 (s, 1H) 8.41 (d, J=8.22 Hz, 1H) 8.66 (s, 1H) 8.79 (s, 2H) 9.08 (s, 1H) 13.25 (br. s., 1H).
Example 41
2-(4-chloro-3-(trifluoromethyl)phenyl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6s)
Compound 6s can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.17 (t, J=7.19 Hz, 3H) 3.34 (quin, J=6.67 Hz, 2H) 7.79 (d, J=8.90 Hz, 1H) 8.43 (d, J=8.90 Hz, 1H) 8.64 (br. s., 2H) 8.68 (t, J=5.82 Hz, 1H) 9.02 (s, 1H).
Example 42
2-(4-chloro-3-(trifluoromethyl)phenyl)-N-isopropyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6t)
Compound 6t can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.24 (d, J=6.65 Hz, 6H) 4.01 (dq, J=13.50, 6.72 Hz, 1H) 7.78 (d, J=8.61 Hz, 1H) 8.36-8.45 (m, 2H) 8.62 (d, J=1.96 Hz, 2H) 9.02 (s, 1H) 13.16 (br. s., 1H).
Example 43
N-ethyl-3-oxo-2-(thiophen-3-yl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6u)
Compound 6u can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=9.00-8.78 (m, 1H), 8.74-8.38 (m, 1H), 7.78-7.47 (m, 1H), 7.35 (d, J=4.7 Hz, 1H), 7.19-6.66 (m, 1H), 5.70 (br. s., 1H), 3.17-3.04 (m, 2H), 1.32-1.01 (m, 3H).
Example 44
N-isopropyl-3-oxo-2-(thiophen-3-yl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6v)
Compound 6v can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=8.92 (s, 1H), 8.54 (s, 1H), 8.39 (d, J=8.2 Hz, 1H), 7.80-7.62 (m, 1H), 7.57 (dd, J=3.3, 5.3 Hz, 1H), 7.40-7.29 (m, 1H), 7.11 (s, 1H), 6.79 (d, J=8.6 Hz, 1H), 4.00-3.99 (m, 1H), 1.23 (d, J=6.7 Hz, 6H).
Example 45
2-(4-bromophenyl)-N-isopropyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6x)
Compound 6x can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.23 (d, J=6.65 Hz, 6H) 3.96-4.06 (m, 1H) 7.60 (d, J=9.00 Hz, 2H) 8.08 (d, J=9.00 Hz, 2H) 8.39 (d, J=8.22 Hz, 1H) 8.57 (d, J=5.87 Hz, 1H) 8.95 (s, 1H) 13.03 (d, J=5.48 Hz, 1H).
Example 46
2-(4-bromophenyl)-N-methyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6y)
Compound 6y can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 2.87 (d, J=4.30 Hz, 3H) 7.60 (d, J=8.61 Hz, 2H) 8.08 (d, J=8.61 Hz, 2H) 8.56 (br. s., 2H) 8.94 (s, 1H) 13.13 (br. s., 1H).
Example 47
N-isopropyl-2-(4-isopropylphenyl)-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6aa)
Compound 6aa can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.22 (dd, J=13.30, 6.65 Hz, 12H) 2.83-2.92 (m, 1H) 3.96-4.06 (m, 1H) 7.28 (d, J=8.61 Hz, 2H) 7.97 (d, J=8.61 Hz, 2H) 8.37 (d, J=8.22 Hz, 1H) 8.51 (d, J=5.87 Hz, 1H) 8.94 (s, 1H) 12.92 (d, J=5.48 Hz, 1H).
Example 48
2-(3-chlorophenyl)-N-methyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ab)
Compound 6ab can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 2.87 (d, J=4.70 Hz, 3H) 7.19 (dd, J=7.83, 1.17 Hz, 1H) 7.45 (t, J=8.22 Hz, 1H) 8.07-8.12 (m, 1H) 8.21 (t, J=1.96 Hz, 1H) 8.54-8.58 (m, 2H) 8.96 (s, 1H) 13.17 (br. s., 1H).
Example 49
N-butyl-2-(3-chlorophenyl)-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ac)
Compound 6ac can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 0.89 (t, J=7.43 Hz, 3H) 1.32 (sxt, J=7.36 Hz, 2H) 1.55 (quin, J=7.24 Hz, 2H) 3.25-3.29 (m, 2H) 7.19 (dd, J=7.83, 1.57 Hz, 1H) 7.45 (t, J=8.22 Hz, 1H) 8.10 (d, J=8.22 Hz, 1H) 8.20 (t, J=1.96 Hz, 1H) 8.58 (s, 1H) 8.63 (t, J=6.06 Hz, 1H) 8.97 (s, 1H) 13.12 (br. s., 1H).
Example 50
2-(3-chlorophenyl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ad)
Compound 6ad can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.16 (t, J=7.04 Hz, 3H) 3.34-3.40 (m, 2H) 7.19 (dd, J=7.83, 1.17 Hz, 1H) 7.45 (t, J=8.22 Hz, 1H) 8.07-8.12 (m, 1H) 8.21 (t, J=1.96 Hz, 1H) 8.58 (s, 1H) 8.67 (t, J=5.87 Hz, 1H) 8.97 (s, 1H) 13.13 (br. s., 1H).
Example 51
N-ethyl-3-oxo-2-(4-(trifluoromethyl)phenyl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ae)
Compound 6ae can be obtained following procedures described herein. 1 H NMR (400 MHz, Methanol-d 4 ) δ=8.86 (s, 1H), 8.45 (s, 1H), 8.24 (d, J=8.2 Hz, 2H), 7.67 (d, J=8.6 Hz, 2H), 4.57 (br. s., 2H), 1.23 (t, J=7.0 Hz, 3H).
Example 52
N-isopropyl-3-oxo-2-(4-(trifluoromethyl)phenyl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6af)
Compound 6af can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=9.93 (d, J=5.1 Hz, 1H), 8.61-8.44 (m, 1H), 8.33 (s, 1H), 8.30-8.09 (m, 3H), 7.36-7.25 (m, 2H), 7.07-6.94 (m, 1H), 3.53-3.44 (m, 1H), 3.14 (dd, J=6.5, 12.7 Hz, 1H), 2.59-2.48 (m, 2H), 2.31-2.18 (m, 6H).
Example 53
N-methyl-3-oxo-2-(4-(trifluoromethyl)phenyl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ag)
Compound 6ag can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=9.10 (s, 1H), 8.42 (s, 1H), 7.88 (d, J=8.6 Hz, 1H), 7.50 (d, J=8.6 Hz, 1H), 7.22 (d, J=8.6 Hz, 1H), 6.85 (d, J=8.6 Hz, 1H), 5.66 (s, 1H), 3.68 (s, 3H).
Example 54
N-butyl-3-oxo-2-(4-(trifluoromethyl)phenyl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ah)
Compound 6ah can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=13.17 (br. s., 1H), 8.99 (s, 1H), 8.74-8.53 (m, 2H), 8.37 (d, J=8.6 Hz, 2H), 7.81 (d, J=9.0 Hz, 2H), 1.69-1.15 (m, 4H), 1.09-0.73 (m, 3H).
Example 55
N-ethyl-3-oxo-2-(3-(trifluoromethyl)phenyl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ai)
Compound 6ai can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.16 (t, J=7.04 Hz, 3H) 3.35-3.38 (m, 2H) 7.49 (d, J=7.43 Hz, 1H) 7.67 (t, J=8.02 Hz, 1H) 8.44 (d, J=8.61 Hz, 1H) 8.48 (s, 1H) 8.59 (s, 1H) 8.67 (t, J=5.87 Hz, 1H) 9.01 (s, 1H) 13.16 (br. s., 1H).
Example 56
N-butyl-3-oxo-2-(3-(trifluoromethyl)phenyl)-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6aj)
Compound 6aj can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 0.89 (t, J=7.24 Hz, 3H) 1.32 (sxt, J=7.36 Hz, 2H) 1.55 (quin, J=7.24 Hz, 2H) 3.25-3.29 (m, 2H) 7.49 (d, J=7.83 Hz, 1H) 7.67 (t, J=8.02 Hz, 1H) 8.44 (d, J=8.22 Hz, 1H) 8.47 (s, 1H) 8.59 (s, 1H) 8.64 (t, J=5.87 Hz, 1H) 9.01 (s, 1H) 13.16 (br. s., 1H).
Example 57
N-butyl-2-(4-chloro-2-fluorophenyl)-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ak)
Compound 6ak can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=13.04 (br. s., 1H), 8.90 (s, 1H), 8.69-8.49 (m, 2H), 7.65-7.52 (m, 2H), 7.38 (d, J=8.6 Hz, 1H), 1.54 (quin, J=7.2 Hz, 2H), 1.39-1.24 (m, 2H), 0.89 (t, J=7.4 Hz, 3H).
Example 58
N-butyl-2-(2-fluorophenyl)-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6al)
Compound 6al can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=8.85 (s, 1H), 8.66 (t, J=5.9 Hz, 1H), 8.50 (s, 1H), 7.60-7.21 (m, 4H), 3.06 (q, J=7.0 Hz, 2H), 1.54 (quin, J=7.2 Hz, 2H), 1.39-1.24 (m, 2H), 0.89 (t, J=7.4 Hz, 3H)
Example 59
N-butyl-2-(2-fluorophenyl)-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6am)
Compound 6am can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=8.88 (s, 1H), 8.66 (t, J=5.9 Hz, 1H), 8.52 (s, 1H), 7.60-7.21 (m, 4H), 3.06 (q, J=7.0 Hz, 2H), 1.15 (d, J=1.6 Hz, 3H).
Example 60
N-butyl-2-(2,4-difluorophenyl)-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6an)
Compound 6an can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=9.14-8.96 (m, 1H), 8.91-8.78 (m, 1H), 8.60 (d, J=14.1 Hz, 1H), 7.20 (dd, J=8.0, 11.5 Hz, 1H), 7.08-6.94 (m, 1H), 6.90-6.72 (m, 1H), 1.65-1.31 (m, 3H), 0.98-0.79 (m, 6H).
Example 61
2-(2,4-difluorophenyl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ao)
Compound 6ao can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=12.99 (br. s., 1H), 8.88 (s, 1H), 8.73-8.45 (m, 2H), 7.66-7.08 (m, 4H), 1.15 (t, J=7.0 Hz, 3H).
Example 62
2-(2,4-difluorophenyl)-N-isopentyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ap)
Compound 6ap can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=12.98 (br. s., 1H), 8.88 (s, 1H), 8.67-8.47 (m, 2H), 7.58-7.48 (m, 1H), 7.44-7.23 (m, 3H), 1.65-1.52 (m, 1H), 1.46 (q, J=7.0 Hz, 2H), 0.90 (d, J=6.7 Hz, 6H).
Example 63
2-(2,4-difluorophenyl)-N-isobutyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6aq)
Compound 6aq can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=12.97 (br. s., 1H), 8.89 (s, 1H), 8.62 (t, J=5.9 Hz, 1H), 8.52 (s, 1H), 7.55-7.49 (m, 1H), 7.40-7.35 (m, 1H), 7.31-7.26 (m, 1H), 3.12 (t, J=6.5 Hz, 2H), 1.91 (td, J=6.7, 13.6 Hz, 1H), 0.88 (d, J=6.7 Hz, 6H).
Example 64
N-ethyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carbothioamide (6ar)
Compound 6ar can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=10.43 (br. s., 1H), 9.21 (br. s., 1H), 8.53 (br. s., 1H), 8.08 (d, J=6.7 Hz, 2H), 7.41 (br. s., 2H), 7.14 (br. s., 1H), 3.72 (br. s., 2H), 1.22 (br. s., 3H).
Example 65
2-(4-chlorophenyl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carbothioamide (6as)
Compound 6as can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=13.25-12.90 (m, 1H), 10.60-10.29 (m, 1H), 9.35-9.05 (m, 1H), 8.69-8.43 (m, 1H), 8.26-7.97 (m, 2H), 7.64-7.27 (m, 2H), 3.85-3.62 (m, 2H), 1.39-1.06 (m, 3H).
Example 66
2-(4-bromophenyl)-N-ethyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carbothioamide (6at)
Compound 6at can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=10.60-10.25 (m, 1H), 9.37-9.09 (m, 1H), 8.68-8.42 (m, 1H), 8.23-7.92 (m, 2H), 7.75-7.45 (m, 2H), 3.83-3.59 (m, 2H), 1.45-1.00 (m, 3H).
Example 67
N-ethyl-2-(4-isopropylphenyl)-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carbothioamide (6au)
Compound 6au can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=13.12-12.85 (m, 1H), 10.57-10.32 (m, 1H), 9.31-9.08 (m, 1H), 8.64-8.31 (m, 1H), 8.13-7.78 (m, 2H), 7.46-6.99 (m, 2H), 3.88-3.58 (m, 2H), 3.01-2.74 (m, 1H), 1.20 (d, J=6.3 Hz, 9H).
Example 68
N-ethyl-8-methyl-3-oxo-2-phenyl-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-7(5H)-carboxamide (6av)
Compound 6av can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.15 (t, J=7.04 Hz, 3H) 2.62 (s, 3H) 3.27 (d, J=3.91 Hz, 2H) 7.15 (t, J=7.43 Hz, 1H) 7.42 (t, J=7.83 Hz, 2H) 8.10-8.17 (m, 2H) 8.76 (br. s., 1H) 12.63 (br. s., 1H).
Example 69
2-(5-chloropyridin-2-yl)-N-isopropyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6aw)
Compound 6aw can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 1.24 (d, J=6.65 Hz, 6H) 3.96-4.07 (m, 1H) 7.99 (d, J=8.61 Hz, 1H) 8.23 (d, J=8.61 Hz, 1H) 8.38 (d, J=7.04 Hz, 1H) 8.49 (br. s., 1H) 8.59 (br. s., 1H) 8.96 (s, 1H) 13.02 (br. s., 1H).
Example 70
2-(5-chloropyridin-2-yl)-N-methyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6ax)
Compound 6ax can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 2.87 (d, J=4.70 Hz, 3H) 7.99 (d, J=8.61 Hz, 1H) 8.23 (d, J=8.61 Hz, 1H) 8.38 (d, J=7.04 Hz, 1H) 8.49 (br. s., 1H) 8.59 (br. s., 1H) 8.96 (s, 1H) 13.1 (br. s., 1H).
Example 71
2-(4-bromophenyl)-N-methyl-3-oxo-2,3-dihydrodipyrazolo[3,4-b:3′,4′-d]pyridine-6(5H)-carboxamide (6az)
Compound 6az can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 2.87 (d, J=4.30 Hz, 3H) 7.60 (d, J=8.61 Hz, 2H) 8.08 (d, J=8.61 Hz, 2H) 8.56 (br. s., 2H) 8.94 (s, 1H) 13.13 (br. s., 1H).
Example 72
N-butyl-2-(2-fluorophenyl)-3-oxo-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13e)
Compound 13e can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=8.71-8.49 (m, 1H), 8.49-8.27 (m, 1H), 8.06-7.79 (m, 1H), 7.73-7.58 (m, 1H), 7.58-7.47 (m, 1H), 7.44-6.99 (m, 3H), 3.28-3.19 (m, J=5.9 Hz, 2H), 1.61-1.43 (m, 2H), 1.43-1.17 (m, 2H), 1.01-0.55 (m, 3H).
Example 73
2-(5-chloropyridin-2-yl)-N-ethyl-3-oxo-2,3-dihydropyrazolo[3,4-d]pyrrolo[3,4-b]pyridine-7(5H)-carboxamide (13h)
Compound 13h can be obtained following procedures described herein. 1 H NMR (400 MHz, DMSO-d 6 ) δ=12.53-12.43 (m, 1H), 8.70-8.60 (m, 1H), 8.50-8.41 (m, 1H), 8.20-8.11 (m, 2H), 8.08-7.97 (m, 1H), 7.72-7.63 (m, 1H), 7.51-7.37 (m, 1H), 3.31 (s, 2H), 1.24-1.09 (m, 3H).
Biological Examples
The ability of a compound disclosed herein to act as ligand to the benzodiazepine site of GABA A can be determined using pharmacological models which are well known in the art using the following assay. The IC 50 values for the exemplified compounds range from sub nM to 10 μM in a 3-concentration dose response curve.
Binding assay 1: Whole brain (except cerebellum) of male Wistar derived rats weighing 175±25 g were used to prepare GABA A central benzodiazepine receptor in Na—K phosphate buffer pH 7.4. A 5 mg aliquot was incubated with 1 nM ( 3 H)-flunitrazepam for 60 minutes at 25° C. Experiments were performed in the presence or absence of 30 μM of GABA. Non-specific binding was estimated in the presence of 10 μM of diazepam. Membranes were filtered and washed, the filters were then counted to determine ( 3 H)-flunitrazepam specifically bound. Test compounds were tested in duplicate according to the required concentrations (Damm, H. W., et al. (1978) Res. Comm. Chem. Pathol. Pharmacol. 22: 597-560 incorporated herein in its entirety; Speth, R. C., et al. (1979) Life Sci. 24: 351-357 incorporated herein in its entirety).
Binding Assay 2:
Materials and Methods:
Receptor Source: Bovine hippocampal membranes
Radioligand: [3H]-RY80 (40-80 Ci/mmol)
Final ligand concentration—[0.8 nM]
Non-specific Determinant: L-655,708—[0.5 μM]
Reference Compound: L-655,708
Positive Control: L-655,708
Binding assay 2 followed procedures based on Li and Szabo (Li M., Szabo A., Rosenberg H. Evaluation of native GABAA receptors containing an α5 subunit. Eur. J. Pharmacol. 413: 63-72 (2001)). Incubation Conditions: Reactions are carried out in 50 mM Tris-Citrate (pH 7.8) containing 200 mM NaCl at 0-4° C. for 60 minutes. The reaction is terminated by rapid vacuum filtration onto glass fiber filters. Radioactivity trapped onto the filters is determined and compared to control values in order to ascertain any interactions of test compound with the benzodiazepine (central) binding site.
Electrophysiology Assay
Preparation of RNA
mRNA was prepared from lyophilized plasmid pellets containing cDNA inserts encoding the specific GABA A receptor subunit. cDNAs encoding the α2, α3, and γ3 subunits were subcloned into pBluescript, SK − . cDNAs encoding the α1 and α5 subunits were subcloned into prC while cDNA encoding the β2 subunit was subcloned into pcDNA1. The cDNA construct encoding the γ2s subunit is in the pGH19 expression construct. Overnight cultures of transformed DH5a bacterial cells were performed to grow sufficient quantities for maxiprep isolation of the plasmid cDNA. The resulting plasmid cDNA was linearized by digestion with an appropriate restriction enzyme that cleaves distal to the cDNA insert (XbaI for α1,2, β2, and γ3 or NotI for α3,5 and γ2, respectively). Following digestion, plasmid cDNA was treated with proteinase K and extracted with phenol/chloroform/isoamyl alcohol, followed by ethanol precipitation. cDNA quality was assessed by agarose-gel electrophoresis (1.5% agarose gel). Samples were stored at −20° C. until use. In vitro transcription was performed with T7 RNA polymerase. mRNA was then stored at −80° C. until use. Plasmids were linearized with appropriate restriction enzymes before in vitro transcription using the Message Machine kit (Ambion, Austin, Tex.).
GABA A Receptor Expression in Xenopus oocytes.
GABA A receptor expression in Xenopus oocytes: Following 45 min of 0.15% Tricaine anesthesia, an ovarian section containing the follicular oocytes was removed from the frog through a lateral abdominal incision. Oocytes were immediately placed in a calcium-free solution (NaCl 96 mM, MgCl 2 1 mM, KCl 2 mM, Hepes 50 mM, pyruvate 2.5 mM, gentamycin 100 μg/mL, penicillin-streptomycin 50 U/mL, pH 7.4). Following 1.5-2 hour incubation in 0.2% collagenase (type II, Sigma Chemical Co., St. Louis, Mo.) at room temperature, individual Dumont stage V and VI oocytes were transferred to an incubator and maintained overnight in Barth's solution (NaCl 84 mM, NaHCO 3 2.4 mM, MgSO 4 0.82 mM, KCl 1 mM, Ca(NO 3 ) 2 0.33 mM, CaCl 2 0.41 mM, Tris/HCl 7.5 mM, pyruvate 2.5 mM, gentamycin 50 μg/mL, penicillin-streptomycin, 100 units/mL, pH 7.4) at 18-20° C. and used for experiments 1-5 days post-injection. Oocytes were injected solution using an electronic microinjector (Drummond, Broomall, Pa.) with 50 nL of RNA containing 0.3-0.5 ng of each subunit RNA in a 1:1:1 ratio. The injected oocytes were used for experiments after 1-5 days of incubation in Barth's solution at 18-20° C.
Electrophysiology:
Measurements of ion currents from oocytes expressing GABA A receptors were performed using a Warner two-electrode voltage-clamp amplifier (Warner Instruments, Inc., Foster City, Calif.) (Park-Chung, M., et al. (1999) Brain Res. 830: 72-87 incorporated herein in its entirety). Microelectrodes were fabricated from borosilicate glass capillaries with a programmed pipette puller (Sutter Instrument Co., Calif.). Microelectrode resistance was 1-3 MΩ when filled with 3 M KCl. The oocyte recording chamber was continuously perfused with Ringer solution. Oocytes were clamped at a holding potential of −70 mV during data acquisition. The membrane current was filtered at 10 Hz and sampled at 100 Hz. Compounds were applied by a gravity-driven external perfusion system. The working volume of the recording chamber was 30 μL and the rate of the perfusion was approximately 50 μL/sec. Compound application was 10-20 sec followed by a 90 sec wash. Data acquisition and external perfusion was computer controlled by custom-developed software. All experiments were performed at room temperature (22-24° C.). Dose-response data from each oocyte were fitted to the Hill equation by non-linear regression using the equation:
I GABA =E max/(1+( EC 50 /c ) n H )
Emax is the maximum response, EC 50 is the concentration producing 50% of the maximal response, n H is the Hill coefficient and c is the concentration of agonist. Based on the GABA concentration-response curve fit, an EC 10 for GABA was determined for each subunit combination, and this concentration was used for subsequent modulator concentration-response studies. Peak current measurements were normalized and expressed as a fraction of the peak control current measurements. Control current responses to an EC 10 concentration of GABA were re-determined after every 2-4 modulator applications. Percent modulation was determined by the equation:
% change=( I′/I− 1)×100
where I is the control response at the GABA EC 10 and I′ the response in the presence of modulator (Lippa A, et al. (2005) Proc. Natl. Acad. Sci. USA 102(20): 7380-7385 incorporated herein in its entirety).
Some compounds showed positive modulation and some showed negative modulation at a screening concentration of 10 μM.
wherein:
A indicates % inhibition >80%
B indicates % inhibition <80% and >20%
C indicates % inhibition <20%
EP indicates electrophysiology
D indicates negative modulation >20%
E indicates negative modulation <20%
ND indicates not determined
All compounds disclosed in Table 1 are assumed to be drawn as neutral. If not indicated, a hydrogen atom is assumed to be present on nitrogen atoms to provide a neutral compound. The compounds of Table 1 can exist in additional isomeric forms, for example, the compounds can exist as tautomers of the drawn structures. The compounds disclosed in Table 1 encompass all possible tautomers of the drawn structures. One of skill in the art will understand that a compound can exist in different tautomeric forms or mixtures there of depending on the environment encompassing the compound, that is an equilibrium can exist between the different tautomerics forms of the compounds and the equilibrium between said forms can be influenced by outside factors.
TABLE 1
%
%
Inhibition
Inhibition
at 0.1
EP
at 10 μM
μM
Modulation
6a
B
C
ND
6b
A
A
D
6c
A
B
D
6d
A
ND
E
6e
A
C
ND
6f
A
ND
D
6g
A
B
ND
7a
B
C
E
6h
B
C
D
7b
A
B
D
6i
A
ND
D
7d
C
C
Positive
6j
A
C
E
6k
C
C
ND
7c
B
ND
ND
6l
A
A
D
6m
A
C
D
6n
C
C
E
6o
A
B
E
6p
C
C
ND
6q
C
ND
ND
6r
B
ND
ND
6s
B
ND
ND
6t
C
ND
ND
6u
A
ND
D
6v
B
ND
ND
6w
A
ND
E
6x
A
ND
ND
6y
A
ND
ND
6z
A
ND
E
6aa
B
ND
ND
6ab
A
ND
ND
6ac
A
ND
ND
6ad
A
ND
E
6ae
A
ND
E
6af
B
ND
ND
6ag
B
ND
ND
6ah
B
ND
ND
6ai
A
C
0
6aj
B
C
ND
6ak
A
C
ND
6al
A
C
ND
6am
A
B
ND
6an
A
B
ND
6ao
A
B
ND
6ap
A
C
ND
6aq
B
C
ND
6ar
A
ND
E
6as
A
ND
D
6at
A
A
ND
6au
A
B
ND
6av
A
B
E
13a
A
A
D
13b
A
A
D
13c
A
A
D
13d
A
B
D
13e
A
B
E
13f
A
A
D
13g
A
B
D
13h
A
A
ND
13i
A
A
E
13j
A
B
ND
17a
C
C
ND
17b
B
C
ND
17c
C
C
ND
17d
C
C
ND
17e
B
ND
ND
6aw
B
ND
ND
6ax
A
ND
ND
6ay
A
ND
D
6az
A
ND
ND
13k
A
B
ND
17f
B
ND
ND
21a
C
B
D
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The invention provides a novel chemical series of formula I, as well as methods of use thereof for binding to the benzodiazepine site of the GABA A receptor and negatively modulating the α5 subtype of GABA A , and use of the compound of formula I in the manufacture of a medicament for the treatment of GABA A receptor associated disorders. The invention further provides a method of modulation of one or more GABA A subtypes in an animal comprising administering to the animal an effective amount of a compound of formula (I).
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of co-pending U.S. patent application Ser. No. 13/792,346, filed Mar. 11, 2013, which is a divisional of U.S. patent application Ser. No. 12/946,990, filed on Nov. 16, 2010, now U.S. Pat. No. 8,394,400 which is a divisional of Ser. No. 10/459,895, filed Jun. 12, 2003, which claims the benefit of provisional U.S. patent application Ser. No. 60/388,446, which was filed on Jun. 12, 2002, all of which are incorporated by reference in their entireties herein.
TECHNICAL FIELD
[0002] The invention relates generally to the treatment of mammalian tissue through the process of bulking, and more specifically to the injection of bulking particles into a treatment region of a mammal
BACKGROUND
[0003] Urinary incontinence, vesicourethral reflux, fecal incontinence, and intrinsic sphincter deficiency (ISD), for example, are disorders that have responded to treatments with augmentative materials. Such disorders occur when the resistance to flow of bodily discharges decreases to the point where the resistance can no longer overcome the intra-abdominal pressure. Nearly all procedures developed to restore continence are based on restoring the lost resistance.
[0004] Surgical implantation of artificial sphincters has often been employed to treat patients suffering from urinary incontinence. The surgical implantation of the artificial sphincter commonly requires hospitalization, is relatively complex and expensive, and will usually require six to eight weeks of recovery time. Moreover, the procedure may be unsuccessful if the artificial sphincter malfunctions. As a result, additional surgery is required to adjust, repair, or replace the implant.
[0005] Urinary incontinence can also be treated using nonsurgical means. A common method to treat patients with urinary incontinence is periurethral injection of a bulking materiaL One such bulking composition is a Teflon® paste known commercially as “Polytef” or “Urethrin.” This paste is comprised of a fifty-fifty (50-50) by weight mixture of a glycerin liquid with Teflon® (polytetrafluoroethylene (PTFE)) brand particles sold by DuPont. The glycerin is biodegradable, however, and over a period of time the glycerin dissipates into the body and is then metabolized or eliminated leaving only about fifty percent (50%) of the injected mixture (i.e., the Teflon® particles) at the injection site. Consequently, to achieve the desired result, the surgeon typically overcompensate for the anticipated loss of bulking material by injecting a significantly larger amount of material than initially required. At the extreme, this overcompensation can lead to complete closure of the urethra, which could put the patient into temporary urinary retention. Additionally, the eventual dissipation of the glycerin complicates the surgeon's ability to visually gauge the appropriate amount of bulking material to inject. To avoid these over-bulking side effects, the surgeon may ultimately not inject enough bulking mixture, leading to the likelihood of a second or even a third procedure to inject additional material.
[0006] Further, the particle size in the Teflon® paste bulking material if sufficiently small may allow the particles to migrate to other locations of the body, such as the lungs, brain, etc. Teflon® particles have been known to induce undesirable tissue reaction and form Teflon® induced granulomas in certain individuals.
[0007] In addition, the Teflon® paste is typically highly viscous and can only be injected using a hypodermic needle held by an injection assist device. Use of an injection assist device may be required, because a surgeon would likely not have sufficient strength to force the highly viscous Teflon® paste through a needle of any acceptable size.
[0008] Two alternatives to the Teflon® paste are a collagen gel and carbon coated zirconium beads. One such commercially available product includes Contigen®, available from CR Bard. The collagen gel is injected in the same manner as the Teflon® paste and forms a fibrous mass of tissue around the augmentation site. This fibrous mass created by the collagen injection, however, also dissipates over time and is eventually eliminated by the patient's body. As a result, additional injections are periodically required.
[0009] Yet another bulking procedure includes the injection of swollen hydrogel particles. The swollen hydrogel particles exhibit relatively low injection forces by incorporating low molecular weight water-soluble organic compounds, along with water, in the particles. See, for example, U.S. Pat. Nos. 5,813,411 and 5,902,832 to Van Bladel et al., and U.S. Pat. No. 5,855,615 to Bley et al., the disclosures of which are hereby incorporated herein by reference in their entireties.
[0010] Another alternative to the Teflon paste is a hard particle suspension. One such commercially available product is Durasphere® available from Carbon Medical Technologies. These hard particles, for example carbon coated zirconium beads, are injected in a beta-glucan carrier. The beta-glucan is eliminated by the patient's body over time. As a result, additional injections may be required. Furthermore, hard particle suspensions, depending on the size of the particle, may tend not to be easily dispensed without clogging smaller gauge injection needles.
[0011] Furthermore, available methods of injecting bulking agents require the placement of a needle at a treatment region, for example, peri-urethrally or transperenially. Assisted by visual aids, the bulking agent is injected into a plurality of locations, causing the urethral lining to coapt. In cases where additional applications of bulking agent are required (e.g., when bulking agents are dissipated within the body), the newly added bulking agent may need to be injected at a higher pressure than the pressure at which the initial bulking agent was injected. The higher pressure requirements for subsequent injections may result from the effect of closing off the treatment region by the initial bulking agent, thereby creating backpressure when attempting to insert additional bulking agent(s). Typically, the bulking agent is injected at multiple locations to cause the uretheal lining to coapt with a higher opening pressure than the patient had prior to injection of the bulking agent.
[0012] Bulking agent delivery methods have attempted to address the issue of subsequent injection requirements. One method that has been employed is hydrodissection of tissue in the vicinity of the treatment region, thereby creating tissue voids designed to decrease the injection pressure required when adding additional bulking agent to the voids. Another method used to reduce injection pressures is the Urovive™ device available from American Medical Systems. Urovive™ utilizes a plurality of silicone balloons that are inserted into the treatment region, specifically, the periphery of the sphincter. The balloons are then filled with a hydrogel to effect tissue coaptation.
SUMMARY OF THE INVENTION
[0013] The invention generally relates to an injectable bulking composition that does not degrade or dissipate in the body, has sufficiently low viscosity such that it is easily administered via injection, and will not migrate from the site of injection, thereby enabling the affected tissue to maintain the desired constriction without causing undesirable side effects. In addition, the invention generally relates to an injection method that reduces the injection pressure required to place the bulking agents.
[0014] In one aspect the invention relates to the use of polymeric particles to facilitate bulking in a treatment region of a mammal's body through injection of the particles into the treatment region. The particles are compliant enough to be delivered through a relatively small gauge injection device. Generally, the invention is employed in the treatment of diseases requiring sphincter bulking, e.g., for treating urinary or fecal incontinence; however, the bulking method described herein can also be used for soft tissue bulking for use during, for example, plastic surgery.
[0015] In another aspect the invention relates to a bulking agent for medical applications. The bulking agent includes a carrier and a plurality of substantially spherical polyvinyl alcohol particles dispersed within the carrier. The carrier aids the delivery of the substantially spherical polyvinyl alcohol particles to a site to be bulked.
[0016] In yet another aspect, the invention relates to a method for bulking mammalian tissue. The method includes the steps of introducing a bulking agent to the mammalian tissue to coapt the mammalian tissue with the bulking agent. The bulking agent includes a carrier and a plurality of substantially spherical polyvinyl alcohol particles dispersed within the carrier. The carrier aids the delivery of the substantially spherical polyvinyl alcohol particles to a site to be bulked.
[0017] In various embodiments of the foregoing aspects, the bulking agent comprises a volume. The volume could be, for example, from about 1 ml to about 30 ml, from about 20 ml to about 30 ml, or from about 2 ml to about 16 ml. In additional embodiments, the substantially spherical polyvinyl alcohol particles are sized from about 40 micron to about 1500 microns in diameter, preferably from about 150 micron to about 1100 microns in diameter, and more preferably from about 500 micron to about 900 microns in diameter. Further, the substantially spherical polyvinyl alcohol particles can comprise pores and/or bioreactive agents, such as drugs, proteins, genes, chemo-therapeutic agents, and growth factors. In other embodiments, the substantially spherical polyvinyl alcohol particles can be compressible and/or substantially dimensionally stable.
[0018] In additional embodiments, the carrier can be a water-based solution, such as saline solution. In addition, the carrier can include at least one of a lubricant, a biocompatible thickening agent, or a color. Furthermore, the bulking agent can be delivered through a needle and/or a catheter. In one embodiment, the bulking agent is delivered transuretherally. In addition, the bulking agent can be delivered while viewing the tissue to be bulked with a cytoscope.
[0019] In still another aspect, the invention relates to an apparatus for bulking mammalian tissue. The apparatus includes a needle defining a lumen, an inflation device adapted to advance through the lumen of the needle, and a bulking agent insertable via the lumen of the needle. The needle is adapted to penetrate the mammalian tissue. The inflation device is disposed adjacent to the mammalian tissue after being advanced through the needle. The inflation device is inflatable and subsequently deflatable to create a void in the mammalian tissue. The bulking agent is inserted to fill at least partially the void in the tissue, the bulking agent coapting the mammalian tissue.
[0020] In various embodiments of the foregoing aspect of the invention, the inflation device can include a biocompatible balloon, and/or a color coating for visualization made from at least one of a silicone, an ethylene vinyl alcohol, a polypropylene, a latex rubber, a polyurethane, a polyester, a nylon, or a thermoplastic rubber. Additionally, the inflation device can have a shape selected from the group consisting of substantially round, oval, hemi spherical, spherical, or oblong. In one embodiment, the needle is sized from 16 gauge to 24 gauge, preferably from 18 gauge to 22 gauge.
[0021] In additional embodiments, the bulking agent comprises a plurality of polymeric particles and can be injected into the void by a syringe. In one embodiment, the bulking agent includes a carrier and a plurality of substantially spherical polyvinyl alcohol particles dispersed within the carrier. The carrier aids the delivery of the substantially spherical polyvinyl alcohol particles to a site to be bulked. The bulking agent can further include a color.
[0022] In yet another aspect, the invention relates to a method for bulking mammalian tissue. The method includes the steps of inserting an inflation device within a portion of a mammal, inflating the inflation device to compress the mammalian tissue surrounding the inflated inflation device, thereby creating a void in the tissue, deflating the inflation device, removing the inflation device from the mammal, and providing a bulking agent to at least partially fill the void, the bulking agent coapting the mammalian tissue.
[0023] In various embodiments of this aspect of the invention, the method includes the steps of inserting a needle with a penetration device into the mammalian tissue, removing the penetration device while retaining the inserted needle, and advancing the inflation device through the needle. The needle can be sized from 16 gauge to 24 gauge, preferably 18 gauge to 22 gauge. The method can also include the step of viewing the tissue to be bulked with a cytoscope. In one embodiment, the inflation device can include a biocompatible balloon, and/or a color coating for visualization made from at least one of a silicone, an ethylene vinyl alcohol, a polypropylene, a latex rubber, a polyurethane, a polyester, a nylon and a thermoplastic rubber. Additionally, the inflation device can have a shape selected from the group consisting of substantially round, oval, hemi spherical, spherical, or oblong.
[0024] In additional embodiments, the bulking agent comprises a plurality of polymeric particles and can be injected into the void by a syringe. In another embodiment, the substantially spherical polyvinyl alcohol particles are coated, embedded, or filled with a material that will aid the delivery of the particles to a site to be bulked. In one embodiment, the bulking agent includes a carrier and a plurality of substantially spherical polyvinyl alcohol particles dispersed within the carrier. The carrier aids the delivery of the substantially spherical polyvinyl alcohol particles to a site to be bulked. The bulking agent can further include a color.
[0025] These and other objects, along, with advantages and features of the present invention, will become apparent through reference to the following description, the accompanying drawings, and the claims. Furthermore, it is to he understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
[0027] FIG. 1 depicts a side view of a tissue structure with an enlarged lumen surrounded by muscle tissue;
[0028] FIG. 2 depicts the tissue structure of FIG. 1 immediately ager a bulking agent in accordance with the invention has been injected around the enlarged lumen of the tissue;
[0029] FIG. 3 depicts the tissue structure of FIG. 1 immediately after a bulking agent in accordance with the invention has been injected around the enlarged lumen of the tissue utilizing a cystoscope-aided injection method;
[0030] FIG. 4 is a schematic plan view of a needle assembly in accordance with the invention;
[0031] FIG. 5 is a schematic plan view of the needle assembly of FIG. 4 with the trocar/obtuator assembly being removed;
[0032] FIG. 6 is a schematic plan view of the needle assembly of FIG. 4 with a balloon assembly being inserted into the needle assembly;
[0033] FIG. 7 is a schematic plan view of the needle assembly of FIG. 4 with a syringe attached to the needle assembly for inflating the balloon;
[0034] FIG. 8 is a schematic plan view of the assembly of FIG. 7 with the syringe and balloon assembly being removed;
[0035] FIG. 9 is a schematic plan view of the assembly of FIG. 4 with another syringe attached to the needle assembly for injecting a bulking agent into tissue;
[0036] FIG. 10 is a pictorial representation of a method of creating a void within a patient's tissue by inserting and inflating a balloon; and
[0037] FIG. 11 is a pictorial representation of a method of filling the void within the patient's tissue with a bulking agent.
DESCRIPTION
[0038] Embodiments of the present invention are described below. The invention is not limited, however, to these embodiments. For example, various embodiments of the invention are described in terms of treating incontinence; however, embodiments of the invention may be used in other applications, such as cosmetic reconstruction.
[0039] Referring to FIG. 1 , a tissue structure, more specifically a urethra/ureter 10 , having a wall 20 and an enlarged lumen 30 surrounded by muscle tissue 40 is shown in side view. Before the enlarged lumen 30 is constricted with the bulking composition, a cystoscope 50 comprising a fiberoptic light transmitting element 60 , a working channel 70 and a viewing element 80 encased in a sheath 90 may be inserted in the urethra/ureter 10 to a distance close to the enlarged lumen 30 . The close distance is selected to allow a clear view of the enlarged lumen 30 .
[0040] Referring to FIG. 2 , the urethra/ureter 10 is shown immediately after a bulking agent in accordance with the invention has been injected around the enlarged lumen 30 of the tissue. Once the enlarged lumen 30 is readily in view, a hypodermic needle 100 is inserted through the tissue 40 , preferably over the enlarged lumen 30 , stopping near the wall 20 of the enlarged lumen 30 . Thereafter, a bulking agent 110 including polymeric particles 120 is injected via the hypodermic needle 100 into the tissue 40 adjacent the wall 20 . The result is a constricted region 130 located in the vicinity of the accumulation of the bulking agent 110 .
[0041] Alternatively, referring to FIG. 3 , the urethra/ureter 10 is shown immediately after the bulking agent 110 of the present invention has been injected around the enlarged lumen 30 of the tissue 40 utilizing a cystoscope 50 aided injection method in accordance with another embodiment of the invention. An elongate needle 140 may be inserted through the working channel 70 into the urethra/ureter 10 and the surrounding tissue 40 and the injection can be completed operating solely through the cystoscope 50 . This is generally the preferred method of operation on male patients for the area surrounding the urethra/ureter and is the preferred method for female patients for the area surrounding the ureter.
[0042] Furthermore, the present invention relates to a bulking agent including substantially spherical polyvinyl alcohol particles used to facilitate bulking in a region of the human body through injection of the particles into the treatment region. The particles are compliant enough to be delivered through a substantially small gauge injection device. In one embodiment, the particles are 50% compressible. This is accomplished through the use of particles that are adapted to compress as they pass through the small gauge injection device. In one embodiment, a 16 to 24 gauge needle is used to dispense the bulking composition without clogging. In other applications, other size needles may be preferred, for example 18-22 gauge.
[0043] Filling the space surrounding the urethra/ureter allows the sphincter to be more readily coapted by the patient to maintain continence. Generally, the present invention is employed in the treatment of diseases requiring bulking, e.g., urinary or fecal incontinence. Some examples of conditions that can be treated by way of the present invention include urinary incontinence, vesicourethral reflux, fecal incontinence and intrinsic sphincter deficiency or ISD. However, the bulking method described herein can also be used for soft tissue bulking for use during, for example, plastic surgery.
[0044] In greater detail, the method of providing a bulking agent to the human body includes using polymeric particles, such as polyvinyl alcohol, as a bulking agent and injecting the particles into the treatment region of the human body. An advantage of the present invention is that the particles are substantially non-biodegradable, thereby virtually eliminating the need for replenishing the particles to maintain efficacy. A further advantage of the present invention is that the substantially spherical size and shape of the particles allows for close packing of the particles in the treatment space.
[0045] In one embodiment, the particles are made of a water and polyvinyl alcohol mixture. For a description of particles contemplated for use with the present invention, see U.S. patent application Ser. Nos. 10/232,265, 10/215,594, 10/116,330, 10/109,966, 10/231,664, the disclosures of which are hereby incorporated by reference herein in their entirety. Generally, water, polyvinyl alcohol, and alginate are combined and pumped through a nozzle under pressure, generating substantially spherically-shaped droplets. The substantially spherically-shaped droplets encounter a solution that promotes cross-linking of the polyvinyl alcohol. Subsequently, the alginate is removed from the outer surface. The result is a substantially spherically-shaped particle that is substantially all polyvinyl alcohol.
[0046] To facilitate other treatments, dosages of bio-active agents can be added to the particles. For example, substances, such as drugs, growth factors, proteins, genes, and chemo-therapeutic agents can be added to the particles to enhance localized treatments while still providing significant bulking benefits. The particles themselves are substantially inert in that they do not tend to react with body fluids and/or tissue. For example, many other types of bulking particles swell in use. In contrast thereto, the substantially spherical polyvinyl alcohol particles are substantially dimensionally stable. Some tissue growth on, near, or around the particle surface may occur, but no biological interaction between the tissue and the particles is expected.
[0047] In one embodiment, the particles are substantially solid. In a particular embodiment, the particles are substantially spherically-shaped and are sized in a range of about 40 microns to about 1500 microns in diameter, preferably about 150 microns to about 1100 microns in diameter, and more preferably about 500 microns to about 900 microns in diameter. The size of the particles chosen for a particular application will be determined by a number of factors. Smaller particles are easier to inject with a smaller gauge size needle; however, embolization due to migration of the particles is a concern with the smaller particle sizes. The size of the particles used in a particular procedure will include consideration of the procedure employed, disease progression, the degree of degradation of the affected region, patient size, the disposition of the patient, and the preferences and techniques of the doctor performing the procedure. Similarly, such factors must be considered when determining the proper volume of bulking agent to inject into a patient. In one embodiment of the invention, the volume of bulking composition is about 1 ml to about 30 ml, and preferably about 20 ml to about 30 ml. In another embodiment, the volume of bulking composition injected into a patient is about 2 ml to about 16 ml. However, these amounts can vary significantly based on the doctor's determination as to when the target region is sufficiently bulked up.
[0048] To vary compressibility, provide for absorption of medications, or for the purpose of incorporating the particles into the surrounding tissue, the porosity of the particles may be modified. These effects, if desired, can be enhanced by increasing pore size. For example, tissue in-growth can be encouraged by increasing pore size. Preferably, pore sizes are within a range of about 4 microns to about 5 microns up to about 30 microns to about 50 microns. In one embodiment, the pores cover up to 80% of the surface area of the particle.
[0049] In one embodiment, the bulking particles are injected through a needle. In other embodiments, a cystoscope is used to allow for viewing the injection area. The bulking particles can be supplemented with a contrast agent to enhance their appearance as an aid to the doctor performing the procedure. Other methods of visual enhancement to assist in viewing of the bulking agent can also be employed. Injection of the particles can also be accomplished transuretherally by, for example, using a catheter.
[0050] In another embodiment, the method of providing the bulking agent to the human body further includes mixing the bulking particles with a carrier such that the particles are suspended in the carrier, and then injecting the particles-carrier mix into the treatment portion of the human body. The carrier serves as a lubricant for the particles thereby increasing the ease with which the particles move into the body. In another embodiment, the carrier is a saline solution. In other embodiments bio-compatible thickening agents such as alginate, beta-glucan, glycerin, cellulose, or collagen are added to the carrier or serve as the carrier themselves to modify the viscosity of the carrier. By varying the carrier viscosity, proper disbursement of the bulking particles can be accomplished; however, carriers must not be so viscous that their passage through an injection device is inhibited. In yet another embodiment, the carrier may be bio-active, that is the carrier includes an anti-microbial agent, or the like.
[0051] The present invention also relates to a method used to dilate tissue within a treatment tissue region to facilitate injection of the bulking agent. The method includes: inserting a needle with a penetration device (e.g., a taper point obtuator or trocar) into the treatment region (e.g., the sphincter region) ( FIG. 4 ); removing the penetration device while retaining the inserted needle ( FIG. 5 ); advancing a balloon through the needle ( FIG. 6 ); inflating the balloon, thereby creating a void in the treatment region ( FIG. 7 ); deflating and removing the balloon from the treatment region ( FIG. 8 ); affixing a syringe with a bulking agent to the needle and injecting the bulking agent into the tissue void ( FIG. 9 ). This procedure can be repeated as necessary in order to maximize the effectiveness of the bulking agent and to achieve the desired results.
[0052] The method and apparatus for carrying out the method in a method to treat urinary incontinence by bulking the urethral tissue is described generally with reference to FIGS. 4-11 . A needle 400 , such as a blunt-end hypotube or hypodermic needle having a first end and a second end, is adapted to accept a penetration device 404 , such as a taper point obtuator or a trocar, at the first end of the needle 400 ( FIG. 4 ). The needle 400 may range in size from about 18 gauge to about 22 gauge, and preferably about 20 gauge to about 22 gauge. The penetration device 404 is attached to the needle 400 to enable penetration of the needle 400 into the tissue. The penetration device 404 may be adapted to the needle 400 by way of a luer hub or fitting, and in one embodiment, a male luer hub is used. The needle 400 is inserted with the penetration device 404 into the treatment region 420 (e.g., the sphincter region) ( FIG. 10 ) to the desired depth. In one embodiment, desired penetration depth can be determined by striping 406 located on the penetration device 404 . In one embodiment, the amount of penetration of the penetration device 404 ranges from about 2 cm to about 2.5 cm ( FIG. 4 ). In one embodiment, the amount of tissue penetration of the needle 400 ranges from about 0.5 cm to about 1 cm beyond the tissue line, 407 ( FIG. 5 ). The penetration device 404 is removed while retaining the inserted needle 400 ( FIG. 6 ).
[0053] A luer hub 402 or fitting, or in one embodiment a female luer hub, may be adapted to the second end of the needle 400 , to which a syringe 412 , 418 ( FIGS. 7-9 ) is adapted. Referring to FIG. 4 , the luer hub 402 is depicted in its locked position, and in FIG. 5 the luer hub 402 is depicted in its unlocked position. In the locked position, the luer hub 402 can be positioned for inflating the balloon 408 or injecting a bulking agent 416 . In the unlocked position, the luer hub 402 can be positioned for accepting the balloon 408 for insertion or for removal of the balloon 408 after dilation.
[0054] The balloon 408 is adapted to advance through a lumen of the needle 400 , and an adapter on the balloon 408 provides a means to lock the balloon 408 to the luer hub 402 , which in turn adapts to the syringe 412 ( FIG. 6 ). The balloon 408 may have no tip or, alternatively, the balloon 408 may have a small stump appendage, which may remain from processing of the balloon. In one embodiment, the balloon 408 is affixed to an end of a plastic tube 410 ( FIG. 6 ). In another embodiment, the tip for the balloon 408 is integral with a shaft. In yet another embodiment, balloon 408 includes at least one fill and/or evacuation port.
[0055] In one embodiment, the balloon is a colored balloon (e.g., blue) to facilitate remote visualization of the procedure and proper placement of the balloon. Alternatively, the balloon could be clear to transparent and the inflation media could be colored, for example, a colored saline solution. The balloon may be semi-compliant or non-compliant. The balloon may be manufactured from any suitable material, for example, a polymer. Some examples of suitable balloon materials include: silicone, ethylene vinyl acetate (EVA), polypropylene, latex rubber, polyurethane, polyester, nylon and thermoplastic rubber. In one embodiment, the balloon is inflated to, for example, about 3 cm to about 5 cm in diameter. The balloon may assume a variety of shapes. Some shapes that may be considered, depending upon the attendant requirements of the procedure, include substantially round, oval, hemi spherical, and oblong. The length of the balloon may vary depending upon the procedure. In one embodiment, the inflated balloon may have a length in the range of, for example, about 3 cm to about 10 cm. Other balloon configurations may be employed, and the types and methods used to employ the most suitable balloon configurations for a particular application of this invention will be obvious to those skilled in the art.
[0056] The balloon 408 is then inflated using an inflation device, such as the syringe 412 , creating a void in the treatment region ( FIGS. 7 and 8 ). The balloon may be colored (i.e. blue) to aid in visibility through the tissue. As the balloon 408 expands, the balloon 408 becomes visible to aid in proper balloon placement. For example, the expanding balloon 408 may become visible under the urethra as it thins. In one embodiment, the balloon 408 inflates to a volume of about ice to about 1.5 cc, although such volumes may vary depending upon many factors inherent in the characteristics of the particular application, some of which were discussed previously. In another embodiment, saline is used to inflate the balloon 408 . In yet another embodiment, about 3 cc of saline is placed in the syringe 412 and injected into the balloon 408 for inflation.
[0057] The balloon 408 is then deflated and removed from the treatment region, resulting in a tissue void 414 where the inflated balloon 408 previously resided ( FIGS. 8 and 10 ). The balloon 408 is removable through the lumen of the needle 400 . In one embodiment, a plastic tube or other tip 410 is used to aid in removal of the balloon 408 .
[0058] A syringe or other injection device 418 containing the bulking agent 416 is then affixed to the needle 400 by way of the luer hub 402 . The plunger of the syringe 418 is then depressed, thereby injecting the bulking agent 416 into the tissue void 414 ( FIGS. 9 and 11 ).
[0059] While the invention has been shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
[0060] Having thus described certain embodiments of the present invention, various alterations, modifications, and improvements will be apparent to those of ordinary skill. Such alterations, modifications, and improvements are within the spirit and scope of the invention, and the foregoing description of certain embodiments is not exhaustive or limiting.
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The invention relates to bulking agents and apparatus and methods for using the disclosed bulking agents. The bulking agents can be used to treat such conditions as urinary and fecal incontinence, gastro-esophageal reflux, ancurismal blockages, and cosmetic deformities. The invention also relates to an injection method that reduces the injection pressure required to place the bulking agents.
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RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. § 119(e) to co-pending U.S. application Ser. No. 60/529988, filed on Dec. 15, 2003, entitled “Fullerene Derivatives Useful as Radical Scavengers/Antioxidants,” the contents of which are incorporated in their entirety by reference.
[0002] This application is related to co-pending application entitled “Higher Fullerenes Useful as Radical Scavengers,” and filed on even date herewith, the contents of which are incorporated in their entirety by reference.
FIELD OF THE INVENTION
[0003] This invention relates to fullerene derivatives useful as free radical scavengers.
BACKGROUND
[0004] Underivatized fullerenes and certain fullerene derivatives are known to be effective radical scavengers. Head to head comparisons of the reactivity towards radicals of C 60 and C 60 derivatives in solution have not been performed for radicals of practical interest, (e.g., reactive oxygen species or ROS), due to the differences in solubility. Fullerene derivatives made to date and tested as radical scavengers have been water soluble derivatives, whereas C 60 is water insoluble. Solvent, transport, and other effects thus do not allow direct comparison of the radical scavenging efficiency of these water soluble C 60 derivatives to C 60 .
[0005] The native radical scavenging efficiency of C 60 is significantly altered depending on the properties and/or number of the addends on a derivatized fullerene. Typically, derivatized fullerenes exhibit reduced free radical scavenging efficiencies. Radical scavenging efficiency is reflected in the rate of reaction or the number of radicals scavenged per fullerene radical scavenger molecule. No clear relationship between the radical scavenging efficiency of a fullerene derivative and the type and number of addends has been established. It is also not well understood whether a drop in radical scavengers efficiency observed in derivatized fullerenes is due to a reduction in the rate of reaction or a reduction in the number of radicals scavenged per fullerene.
[0006] Chiang et al. ( Chem. Lett., 465-466 (1998)) report that at low concentrations, a water soluble polyhydroxylated fullerene derivative of average 18 addends has higher radical scavenging efficiency than a hexasulfobutylated fullerene having 6 addends. At higher concentrations, however, the hexasulfobutylated fullerene has a significantly higher radical scavenging efficiency. Chiang postulates that the higher radical scavenging efficiency of the hexasulfobutylated fullerene derivative at higher concentrations is due to smaller alteration of the electron affinity of the fullerene cage because of the smaller number of addends.
[0007] Thus radical scavenging efficiency may be affected by a variety of factors, including an alteration of the number of active sites due to the larger number of substitutions, a decrease in reactivity due to loss of strain in the fullerene cage, or an alteration of electron affinity of the fullerene reactive sites due to intra- and/or inter-molecular electronic interactions, or a combination of these effects. Differing types and/or numbers of addends on the fullerene cage can give significantly different radical scavenging efficiencies due to alterations to the fullerene cage.
[0008] Conjugation of olefins with electron withdrawing groups (e.g. alcohols, carbonyls, etc.) in the vicinity of a radical scavenging carbon-carbon double bond may reduce the rate of radical addition (and resulting radical scavenging efficiency). This reduction is thought to occur by electron withdrawing inductive effects, which alter the electron density of the carbon-carbon double bond, and subsequently decreases the propensity of the carbon-carbon double bond to undergo radical addition reaction.
[0009] The difference in radical scavenging performance between different fullerene derivatives is not well understood. Under some conditions higher addend derivatives perform better than lower numbers of addends, and under other conditions, lower number addends perform better than higher number of addends. Similarly, under some conditions, electron-withdrawing groups perform better than non-electron-withdrawing groups. The nature of the interaction of the fullerene cage and the addends to the cage is not presently well enough understood in the art to provide a clear prediction on the relative performance of different fullerene derivatives relative to the performance of the fullerene cage.
SUMMARY
[0010] In one aspect of the invention, a class of compounds is identified having surprisingly high radical scavenging efficiencies. The compounds preserve the inherent physical and chemical nature of the fullerene cage so as to preserve the high radical scavenging efficiency of the fullerene molecule, while providing derivatization flexibility. Such flexibility provides control over solubility, transport, and other properties in use conditions.
[0011] In another aspect of the invention, a method is provided for the scavenging (or reduction) of free radicals from a target. The target is exposed to a class of fullerene derivatives to reduce the level of free radicals in the target. The class of compounds useful as free radical scavengers may be functionalized with chemical moieties so that the chemical and/or physical properties of the substituent fullerene may be altered without significant alteration of the inherent physical and chemical nature of the fullerene cage so as to preserve the radical scavenging efficiency of the fullerene cage.
[0012] In one aspect of the invention, a method of scavenging free radicals in or on a target includes exposing a target to a compound having the formula:
where the ring, F, comprises a fullerene comprising from about 20 to about 240 carbon atoms, where X is (C′)(R′) n and C′ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons, R′ is independently selected such that X is a non-electron withdrawing group, and n=1, 2, or 3, and where Z is (C″)(R″) n and C″ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons and R″ is independently selected such that Z is a non-electron withdrawing group, and n=1, 2, or 3, or Z is an electron-withdrawing group selected from the group consisting of aldehydes, ketones, esters, anhydrides, nitrites, amides, thioaldehydes, thioketones, thioesters, amidate esters, isocyanides, isocyanates, isothiocyanates, sulfones, sulfonates, and the like.
[0013] In one or more embodiments, C′ is an aryl carbon and X is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl moieties and Z is (C″)(R″) n and C″ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons and R″ is independently selected such that Z is a non-electron withdrawing group.
[0014] In one or more embodiments, C′ is an aryl carbon and X is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl moieties and Z is (C″)(R″) n and C″ is an alkyl carbon and R″ is independently selected from the group consisting of alkyl and alkyl moieties bearing any hetero or functional group.
[0015] In one or more embodiments, wherein Z is a linear or branched, saturated or unsaturated hydrocarbon moiety having at least 7 carbons, or at least 12 carbons, or at least 16 carbons.
[0016] In one or more embodiments, the compound has the formula (F)(C)(X)(Z), wherein
where F is a fullerene ring, and where n is in the range of 1 to 20, and R is any chemical group.
[0017] In one or more embodiments, the compound includes two to four C(X)(Z) adducts on the fullerene ring.
[0018] In one or more embodiments, the fullerene contains from about 60 to about 120 carbon atoms. The fullerene compound can be a [5,6] fulleroid or a [6,6] methanofullerene. X and Z are different.
[0019] In one or more embodiments, X and/or Z is a lipophilic moiety, and the lipophilic moiety is selected from the group consisting of fatty acids, fatty amides, fatty alcohols, and fatty amines, and the compound is capable of transport through lipid phases in a biological system.
[0020] In one or more embodiments, X and/or Z is a hydrophilic moiety, and the compound is capable of transport through aqueous phases in a biological system.
[0021] In one or more embodiments, X and/or Z is a chemical moiety that is independently effective as a free radical scavenger.
[0022] In one or more embodiments, X and/or Z is an amphiphilic moiety.
[0023] In one or more embodiments, X is a lipophilic and Z is a hydrophilic moiety, or vice versa.
[0024] In one or more embodiments, X is a lipophilic and Z is a hydrophilic moiety, or vice versa, such that the fullerene compound is amphiphilic.
[0025] In one aspect of the invention, a method of scavenging free radicals from in or on a target includes reacting a radical species present in a biological system with a compound having the formula:
where the ring, F, comprises a fullerene comprising from about 20 to about 240 carbon atoms, where X′ is selected from the group consisting of aryl group, substituted aryl group, a heteroaryl and a substituted heteroaryl; A is an aliphatic group containing 1 to 20 carbon atoms, or 3 to 12 carbon atoms; Q′ is O, N or S and if Q′ is N, N can be bound to any group; Z′ is bound to C′ and is halogen, O, N, or S, and Y′ is bound to Z′ and is any chemical group or any salts thereof.
[0026] In one or more embodiments, Z′ and Q′ are O.
[0027] In one or more embodiments, Y 40 is a linear or branched, saturated or unsaturated hydrocarbon moiety having at least 7 carbons or at least 8 carbons, or at least 12 carbons, or at least 18 carbons.
[0028] In one or more embodiments, Y′ is a chemical moiety that is independently effective as a free radical scavenger, Y′ is an amphiphilic moiety, or Y′ is selected from the group consisting of sugars, histamines, amino acids and carotenoids.
[0029] In one or more embodiments, —(C′═Q′)(Z′)(Y′) in combination includes a carboxylic acid (or carboxylate), ester, amide, anhydride, acid halide, lactone, or lactam species.
[0030] In one or more embodiments, the compound includes [6,6]-phenyl C 61 -butyric acid methyl ester (PCBM), where X′ is phenyl, A is (CH 2 ) 3 , Q′ is O, Z′ is O, and Y′ is CH 3 .
[0031] In one or more embodiments, the compound includes two or more adducts of C(X′)((A)(C′═Q′)(Z′)(Y′) with the fullerene ring.
[0032] In one or more embodiments, a method of scavenging a free radical further includes exposing the target to at least one additional radical scavenging compound.
[0033] In one or more embodiments, a method of scavenging a free radical further includes including an additive selected to enhance or preserve the efficacy of the compound.
[0034] In one aspect, method for preventing or reducing lipid peroxidation in a biological system, reducing oxidative stress in a biological system, or altering radical mediated chemical pathways in a biological system are provided.
[0035] In one aspect of the invention, a compound is provided having the formula:
wherein the ring F carbon atoms X is selected from the group of aryl, substituted aryl, heteroaryl and substituted heteroaryl moieties and Z contains a linear or branched, saturated or unsaturated hydrocarbon moiety having at least 7 carbons, or 8 carbons, or 12 carbons, or 16 carbons, or 18 carbons.
[0036] In one aspect of the invention, a compound is provided having the formula:
wherein where the ring, F, comprises a fullerene comprising from about 20 to about 240 carbon atoms, where X is (C′)(R′) n and C′ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons, R′ is independently selected such that X is a non-electron withdrawing group, and n=1, 2, or 3, and wherein Z contains O(CH 2 CH 2 O) m CH 2 CH 2 OP, where P is H or alkyl or aryl, and m is in the range of 1 to 100. In one or more embodiments, X is selected from the group of aryl, substituted aryl, heteroaryl and substituted heteroaryl moieties
[0037] In one aspect of the invention, a compound has the formula:
wherein where the ring, F, comprises a fullerene comprising from about 20 to about 240 carbon atoms, X has the formula:
where R is any chemical group, and n is in the range of 1 to 20; and where Z is (C″)(R″) n and C″ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons and R″ is independently selected such that Z is a non-electron withdrawing group, and n=1, 2, or 3, or Z is an electron-withdrawing group selected from the group consisting of aldehydes, ketones, esters, anhydrides, nitrites, amides, thioaldehydes, thioketones, thioesters, amidate esters, isocyanides, isocyanates, isothiocyanates, sulfones, sulfonates, and the like. In one or more embodiments, R is alkyl or R is a linear or branched, saturated or unsaturated hydrocarbon moiety having at least 7 carbons, or at least 8 carbons, or at least 12 carbons, or at least 16 carbons.
[0038] In one aspect of the invention, a composition has the formula:
where X is (C′)(R′) n and C′ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons, R′ is independently selected such that X is a non-electron withdrawing group, and n=1, 2, or 3, and Z contains a radical scavenging moiety selected from the group consisting of carotenoids, flavonoids, anthocyanidins, lipoic acids, ubiquinoids, and retinoids. In one or more embodiments, X is selected from the group of aryl, substituted aryl, heteroaryl and substituted heteroaryl moieties.
[0039] In another aspect of the invention, a composition has the formula:
where X is (C′)(R′) n and C′ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons, R′ is independently selected such that X is a non-electron withdrawing group, and n=1, 2, or 3, and wherein Z contains O(CH 2 CH 2 CH 2 O) m CH 2 CH 2 CH 2 OP, where P is H or alkyl or aryl, and m is in the range of 1 to 100. In one or more embodiments, X is selected from the group of aryl, substituted aryl, heteroaryl and substituted heteroaryl moieties.
BRIEF DESCRIPTION OF THE DRAWING
[0040] Various embodiments of the invention are described with reference to the drawing, which is provided for the purpose of illustration only and is not intended to be limiting of the invention, the full scope of which is set forth in the claims below.
[0041] FIG. 1 is a general scheme for the preparation of a substituted methanofullerene by reaction with a diazo compound.
[0042] FIG. 2 illustrates a reaction scheme for the derivatization of a methanofullerene by acyl halide displacement.
[0043] FIG. 3 illustrates a reaction scheme for the derivatization of a methanofullerene by transesterification from a PCBM molecule.
[0044] FIGS. 4A and 4B illustrate reaction schemes for the direct formation of a derivatized methanofullerene according to one or more embodiments of the present invention.
[0045] FIG. 5 is a schematic illustration of the apparatus used to determine free radical scavenging.
[0046] FIGS. 6A and 6B are plots of fluorescence resulting from the reaction of radicals contained in cigarette smoke with a dye which fluoresces upon reaction with radicals in the presence of various free radical scavenging molecules.
DETAILED DESCRIPTION
[0047] For application of fullerenes as radical scavengers in various settings, it is useful to form fullerene derivatives which preserve to the highest extent possible the high efficiency of the radical scavenging properties of the fullerene cage without detrimentally altering the electron affinity, energetic strain, number of reactive sites, steric availability, etc. of the fullerene cage. Further, it is useful to form fullerene derivative intermediates to allow for formation of a variety of new fullerene derivatives with various functionalities, e.g., lipophilic, hydrophilic or amphiphilic fullerenes, that do not significantly differ in radical scavenging efficiency from their fullerene parent.
[0048] Various methanofullerenes are disclosed having one or more non-electron withdrawing groups as substituents to the methanocarbon. The absence or reduction of electron withdrawal on the fullerene cage helps to maintain the free radical scavenging capability of the fullerene molecule. The chemical and/or physical functionality of the fullerene is adjusted by modification of the methanocarbon adduct instead of the fullerene cage. Modifications are provided to obtain enhanced lipophilicity, hydrophilicity, amphiphilicty or other properties of the methanofullerene.
[0049] By “adduct” as the term is used with reference to methanofullerenes, it is meant the addition of a methylene group to the fullerene cage resulting in the formation of a cyclopropane ring. The carbon atom in the cyclopropanyl adduct is termed the methanocarbon. Functional groups may be attached to the available sites on the methanocarbon.
[0050] The term “fullerene” is used herein to refer to any closed cage carbon compound containing both five- and six-membered carbon rings independent of size and is intended to include, without limitation, the fullerenes C 60 , C 70 , C 72 , C 76 , C 78 , C 82 , C 84 , C 86 , C 90 , C 92 , and C 94 .
[0051] Electron withdrawing groups are groups that are more electronegative than the methanocarbon atom such as groups that contain O, N, P, or S. In close proximity to the methanocarbon, they may have electron withdrawing inductive effects on the fullerene cage. Electron withdrawing groups that are one carbon removed from the methanocarbon may also contribute inductive effects to the fullerene carbon atoms, and it is possible that some functional groups at larger distances from the fullerene may show electron withdrawing effects through space. Electron withdrawing groups include groups having a carbon atom directly bonded to the methanocarbon (an “alpha-carbon”), which form a double or triple bond with the alpha-carbon. Electron withdrawing groups include groups which contain O, N, P, or S atoms, such as COOH, COOR, C(O)SR, CON(H)R, C(O)N(R 1 )(R 2 ), CHO, COR, CSR, CN, P(O)(OR), SO 2 R, NO 2 , and the like.
[0052] Exemplary non-electron withdrawing groups are obtained by including an alpha-carbon lacking a double or triple bond to an electronegative atom such as O, N or S in one or more of the functional groups pendant to the methanocarbon. Aromatic, alkyl, alkenyl, and alkynyl alpha-carbons are linked to an additional chemical moiety or H. By directly linking electron donating or electron neutral moieties at the methanocarbon, the electronic and chemical integrity of the fullerene cage is better preserved. Electron withdrawing groups or other moieties may be tethered to the fullerene at a distance from the fullerene, without these groups being in close proximity to the fullerene cage, so as to preserve the inherent radical scavenging efficiency of the fullerene. Such electron withdrawing functional groups may be desirable to accomplish other objectives of the molecule, such as, attaining desired solubility, transport or binding characteristics.
[0053] A free radical may be scavenged from on or in a target by exposing the target to a compound having the formula,
where the ring, F, is a fullerene comprising from about 20 to about 240 carbon atoms, or about 60 to about 120 carbon atoms; where X is (C′)(R′) n and C′ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons, R′ is selected such that X is a non-electron withdrawing group, and n=1, 2, or 3, and where Z is (C″)(R″) n and C″ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons and R″ is selected such that Z is a non-electron withdrawing group, and n=1, 2, or 3, or Z is an electron-withdrawing group selected from the group consisting of aldehydes, ketones, esters, anhydrides, nitrites, amides, thioaldehydes, thioketones, thioesters, amidate esters, isocyanides, isocyanates, isothiocyanates, sulfones, sulfonates, and the like.
[0054] In one or more embodiments, C′ is an aryl carbon and X is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl moieties and Z is (C″)(R″) n and C″ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons and R″ is selected such that Z is a non-electron withdrawing group.
[0055] In one or more embodiments, C′ is an aryl carbon and X is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl moieties and Z is (C″)(R″) n and C″ is an alkyl carbon and R″ is selected from the group consisting of alkyl and alkyl moieties bearing any hetero or functional group.
[0056] The groups (C′)(R′) n and (C″)(R″) n define non-electron withdrawing functional moieties. By way of example, the groups may include alkyls, cyclic alkyls, and substituted alkyls, alkylaryls, alkyl ethers, alkylaryl ethers, alkyl thioethers, alkylaryl thioethers, alkyl esters, alkylaryl esters, alkyl thioesters, alkylaryl thioesters, alkyl amides, alkylaryl amides, alkyl amines, alkylaryl amines, alkyl anhydrides, alkylaryl anhydrides, alkyl carbonates (or carboxylic acids) and alkylaryl carbonates. By way of example, the groups may include substituted aryls such as arylalkyls, aryl ethers, arylalkyl ethers, aryl thioethers, arylalkyl thioethers, aryl esters, arylalkyl esters, aryl thioesters, arylalkyl thioesters, aryl amides, arylalkyl amides, aryl amines, arylalkyl amines, aryl anhydrides, arylalkyl anhydrides, aryl carbonates (or carboxylic acids) and arylalkyl carbonates. Other substitutes are contemplated within the scope of the invention.
[0057] In one or more embodiments, X and/or Y of compound 1 include chemical moieties that provide lipophilic (or hydrophobic) functionality, i.e., having an affinity for lipid-like materials. Lipids include fatlike substances characterized by being water insoluble and being extractable by nonpolar (or organic) solvents such as alcohol, ether, chloroform, benzene, etc. All contain as a major constituent aliphatic hydrocarbons. Suitable lipophilic moieties for use in free radical scavenging include long-chain alkanes or substituted long-chain alkanes (6 or more carbon atoms, preferably 12 or more carbon atoms), which may be branched, and which may contain various other chemical groups have affinity with lipids. Compounds containing lipophilic moieties are useful in the transport of the free radical scavenging compound through lipid phases in a biological system or hydrophobic phases in a chemical system.
[0058] Exemplary lipophilic groups include fatty alcohol and fatty acid ester, fatty amide, fatty amine moieties, such as isostearic acid derivatives, or functional groups derived from molecules such as isopropyl palmitate, isopropyl isostearate, stearyl stearate, diisopropyl adipate, octyl palmitate, isopropyl palmitate, cetyl lactate, cetyl ricinoleate, tocopheryl acetate, acetylated lanolin alcohol, cetyl acetate, glyceryl oleate, methyl oleate, isobutyl oleate, tocopheryl linoleate, arachidyl propionate, myristyl lactate, decyl oleate, isopropyl lanolate, neopentylglycol dicaprylate/dicaprate, isononyl isononanoate, isotridecyl isononanoate, myristyl myristate, octyl dodecanol, sucrose esters of fatty acids, octyl hydroxystearate, stearamide, oleamide, and erucamide.
[0059] In one or more embodiments, X and/or Y of compound 1 include chemical moieties that provide hydrophilic functionality, i.e., having an affinity to water or hydrophilic materials. Groups which may provide hydrophilic functionality include poly-(ethylene oxide)s, mono-, di- or poly-hydroxylated alkanes, mono-, di- or poly-hydroxylated cycloalkanes, amino alkanes, diamino alkanes, mono-, di-, or poly-saccharides, ammonium groups, alkylated ammonium groups, phosphates, alkylphosphates, sulfonates, and alkylsulfonates. Compounds containing hydrophilic moieties are useful in the transport of the free radical scavenging compound through aqueous phases in a biological or chemical system.
[0060] In one or more embodiments, X and/or Y of compound 1 include chemical moieties that provide amphiphilic functionality. Amphiphilic functionality refers to molecules that have both lipophilicity and hydrophilicity. Groups which provide amphiphilic functionality include polyethylene glycol, poly(ethylene oxide)s, propylene glycol, hexylene glycol, diethylene glycol, propylene glycol n-alkanols, and other glycols. Alternatively, amphiphilic properties may be obtained by selecting lipophilic and hydrophilic properties for the X- and Y-substituents of compound 1, respectively, or vice versa.
[0061] In still other embodiments, X and/or Y of compound 1 include chemical moieties that provide biofunctionality. Thus X and/or Y may be a sugar, histamine, amino acid or carotenoid and the like. The X and/or Y groups of compound 1 may also include a chemical moiety that is independently effective as a free radical, for example, flavenoids, carotenoids, anthocyanidins, lipoic acids, ubiquinoids, retinoids or Vitamin E moieties.
[0062] Methanofullerenes having a minimal number of adducts, e.g., a monoadduct or 2-3 adducts, allows the alteration of the chemical and physical properties of the fullerene in a desirable way, while preserving to a great degree the strain and number of olefin bonds, steric availability, and other properties of the fullerene cage. The absence or reduction of electron-withdrawing groups adjacent to the fullerene cage also maintains or enhances free radical scavenging efficiencies.
[0063] Steric hindrance is also minimized through a small number of addends to the fullerene cage. At the same time, the molecules described here conveniently allow for various modifications to the chemical and physical functionality of the fullerene molecule, while maintaining a constant configuration adjacent to the fullerene cage (the methano bridge), allowing for the reliable synthesis of new high efficiency fullerene-based radical scavengers for application in a variety of settings.
[0064] In particular, monoadducts provide for the least disruption of the chemical and physical nature of the fullerene cage, and allow for convenient synthesis of single isomers. However, di, tri and higher adducts may be used in the radical scavenging processes described herein.
[0065] Further still, it is useful to have a common addition chemistry through which chemical moieties having various functionalities may be added to a fullerene.
[0066] Various methanofullerenes are known in the art, and synthesis of these compounds through diazoalkane addition chemistry has the advantage of being simple synthetic chemistry and providing monoadducts in high yield. This reaction is illustrated schematically in FIG. 1 . A fullerene compound is reacted with a diazo compound 2 to provide a functionalized methanofullerene 1 . Diazoalkane addition results first in [6,6] diazoline adducts that can expel N 2 and yield [5,6] fulleroids, which can be isomerized to [6,6].methano-bridged fullerenes. The diazoalkane precursors are typically formed in situ. By way of example, X and Z of the diazo compound 2 can be moieties as described herein for the methanofullerene compound or they may be intermediates containing reactive groups capable of further reaction to form the desired X, Z functional groups of the methanocarbon. Further, similar diazoalkane addition chemistry may be used to form multiple methanocarbon adducts on the fullerene cage, fullerene derivatives using either the same or different diazoalkane precursors. This provides a synthetic route to variously substituted methanofullerene compounds that may be used in the free radical scavenging processes described herein.
[0067] The fullerene derivative [6,6]-phenyl C 61 -butyric acid methyl ester (PCBM) 3 is an example of a fullerene derivative formed through diazoalkane addition chemistry, where the diazoalkane is a 1-phenyl-1-(3-(methoxycarbonyl)propyl)diazomethane. The synthesis by diazoalkane addition of cyclopropanyl-based fullerene derivatives (methanofullerenes) such as PCBM 3 may be accomplished by combining, with stirring, the diazocompound and fullerene C 60 .
[0068] The ester functional group (e.g., methyl ester in compound 3) allows for convenient synthesis of a large number of compounds, through displacement pathways illustrated in the reaction scheme of FIG. 2 , or transesterifications illustrated FIG. 3 . PCBM 3 can be used as a chemical intermediate to synthesize an unlimited number of new fullerene derivatives having various functionalities. The compound 3 is first converted using reaction steps (a) [aqueous HCUACoH/1,2-dichlorobenzene (ODCB)]and (b) [SOCl 2 /CS 2 ] into the corresponding acid chloride 3 a . The acid chloride 3a is then displaced by various groups to form a wide range of functionalized ester derivatives. Examples of this can be found in the literature (for example, see Hummelen et al., J. Org. Chem. 1995, 60, 532). Thus, in FIG. 2 , the methyl group is displaced to form a C12 alkyl ester 4 using reaction steps (c) [ROH/pyridine; R=C12] or a polyethylene glycol ester 5 using reaction step (d) [ROH/pyridine; R=C 8 H 17 O 4 ]. Alternatively, PCBM 3 is transesterified using reaction step (e) [ROH/Bu 2 SuO/1,2-dichlorobenzene/heat] to obtain a transesterification compound 6. The synthesis of several compounds, including compounds 4 and 5, by this method is described below.
[0069] A preferred method for transesterification of any fullerene compound having carboxylic esters anywhere or in any number is the use of dibutyltin oxide as catalyst for the reaction. This reaction gives high conversions from one ester group into another ester group and can also be used for mild deprotection conditions(e.g., when removing an acetate group in the presence of another ester moiety). The advantage of direct transesterification over the route using acid halides as shown for compound 3a is the reduction of the number of reactions that is required to prepare the desired carboxylic ester group. Other transesterification techniques that have been tried with fullerene esters such as acid catalysis do not give satisfactory conversions. Anionic transesterications also are not satisfactory with fullerene esters because fullerenes react with the anion and give side products. Dibutyltin oxide surprisingly gives very satasifactory yields under mild conditions for transesterification of fullerenes.
[0070] Alternatively, diazoalkane addition chemistry can be used by forming the desired functionalized diazo compound before reaction with the fullerene molecule. See FIGS. 4A and 4B , where the appropriate diazo compound is selected to provide alkyl ester functionalized methanofullerenes 7 and aryl functionalized methanofullerenes containing ester groups bound to a substituent of the aryl group 8 . The ester group may also be bound directly to the aryl group.
[0071] The above methods allow for forming part (for example as shown in FIGS. 2 and 3 ) or all (for example as shown in FIGS. 4A and 4B ) of the adduct added to the fullerene molecule of the following general form 1 all through diazoalkane addition chemistry,
where the ring, F, comprises a fullerene comprising from about 20 to about 240 carbon atoms, where X is (C′)(R′) n and C′ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons, R′ is selected such that X is a non-electron withdrawing group, and n=1, 2, or 3, and where Z is (C″)(R″) n and C″ is a carbon atom selected from the group consisting of alkyl, alkenyl, alkynyl, and aromatic carbons and R″ is selected such that Z is a non-electron withdrawing group, and n=1, 2, or 3, or Z is an electron-withdrawing group selected from the group consisting of aldehydes, ketones, esters, anhydrides, nitriles, amides, thioaldehydes, thioketones, thioesters, amidate esters, isocyanides, isocyanates, isothiocyanates, sulfones, sulfonates, and the like.
[0072] A specific embodiment of compound 1 is shown below (compound 7), where Y′ is any substituent on the aryl group; Ar is any aryl group; m greater than or equal to zero and indicates the total number of independent substituents Y′ on the aryl group; n=1 to 20; Z′ is any heteroatom (e.g., O, N, S); X′ is any chemical group; and F is a closed cage all-carbon molecule (fullerene) with 20 to 240 carbon atoms (preferably 60 to 120).
[0073] Methanofullerenes containing an aryl functional group at the X-position in compound 1 may be conveniently synthesized from the precursor diazoalkane because common aromatic chemistry, such as Friedel Crafts acylation, can be used to prepare the diazo precursor. Also, it has been observed that aryl-substituted methanofullerenes are more amenable to photoisomerization from [5,6] fulleroids to [6,6] methano bridges.
[0074] Another specific embodiment of compound 1 is shown below (compound 8). Longer and shorter alkyl chains are contemplated and the alkyl chain may contain between about 2 to 20 carbon atoms. In addition, R may be aryl or a long chain, branched or linear, saturated or unsaturated carbon chain having 1-20 carbons.
[0075] The fullerene molecules used in the present invention, may be any fullerene, preferably fullerenes commonly synthesized such as C 60 , C 70 , C 72 , C 76 , C 78 , C 82 , C 84 , C 86 , C 90 , C 92 , and C 94 . Different fullerenes may be more desirable than others for different applications.
[0076] The molecules described above are useful for scavenging any type of radical, such as, but not limited to, radicals of biological importance, such as reactive oxygen species: —OH, —O 2 —, ROO—; NO x radicals; products of biological radical pathways such as fatty acid radicals and the products of biological radical scavengers reacting with radicals, such as tocopherol, ubiquinol, and ascorbyl radicals; auto-oxidation and products of auto-oxidation in polymer and other systems, such as food; radicals of environmental sources such as cigarette smoke and environmental combustion sources, such as automobile exhaust. Also, the present molecules may be used to scavenge radicals in radical polymerization reactions, to form co-polymers, enhance cross-linking, or to act as polymer stabilizers.
[0077] In various applications, it is desirable to vector or target a fullerene to particular environments, e.g., for application in biological systems. For example, the target can be a dermal or other membrane surface or organ. The present invention provides a convenient means to synthesize new molecules with chemical functionalities for such vectoring. Examples include but are not limited to the formation of lipophilic, hydrophilic, amphiphilic, or bio-site specific (enzyme or antibodies) compounds. For example, compound 4 is lipophilic, and could be used to vector a fullerene to lipophilic environments, such as cell membranes, and/or to pass through cell membranes, and/or to penetrate the stratum corneum of the skin through the lipophilic phases of mammalian skin. The compound can be delivered to the target in a carrier vehicle. Suitable carrier vehicles include those typically employed in the dermal application of pharmaceutical and cosmetic materials.
[0078] As another example, a more highly hydrophilic moiety could be attached as in compound 5 (or a poly-(ethylene glycol), a poly(ethylene oxide), mono-, di-, or poly-saccharides, or other hydrophilic moiety for enhanced hydrophilicity) for vectoring of fullerenes to hydrophilic regions, such as in the hydrophilic phases of mammalian skin or to allow for biodistribution in the bloodstream, and/or absorption through the gastrointestinal tract. As yet another example, an amphiphilic molecule can be conveniently synthesized by attaching a hydrophilic moiety at the X position and a lipophilic moiety at the Y position in compound 1 or vice versa, or at any of the alternative points of substitution in compounds 7 or 9.
[0079] Any constituent for vectoring, including the hydro- and lipophilic moieties above, or any other such moieties, may be substituted at any of the substitution positions in compounds 1, 7 or 9, such as at X, Z, X′, Y′, or Z′. Alternatively, other moieties important for biological vectoring, such as but not limited to monoclonal antibodies may be substituted at X, Z, X′, Y′, or Z′ in compounds 1, 7 or 9.
[0080] Likewise, other chemical or physical functionalities may be added to a fullerene radical scavenging molecule by substitution at X, Z, X′, Y′, or Z′ in compounds 1, 7 or 9, such as the following:
1. Enhanced solubility in media such as oils, alcohols, water, or aromatics, etc.; 2. Additional chemical reactivity, for example, the addition of other radical scavenging moieties, such as other antioxidants (e.g., carotenoids, flavinoids, anthocyanidins, lipoic acids, ubiquinoids, retinoids), for the formation of combination antioxidants in the form of molecular dyads, 3. Enhanced radical scavenging efficacy against a given radical, or to provide an effective multi-functional radical scavenger effective against different radicals (e.g., β-carotene, an efficient scavenger of singlet oxygen, but not of peroxyl, substituted at X, Z, X′, Y′, or Z′ in compounds 1, 7 or 9 to provide a single radical scavenging molecule effective against both singlet oxygen and peroxyl, against which fullerenes are effective); 4. For the formation of co-polymers to scavenge radicals in radical polymerization reactions, to form co-polymers, enhance cross-linking, or to act as polymer stabilizers; 5. The modification of physical properties, such as enhanced optical absorption; 6. To quench the singlet excited state of the fullerenes so that intersystem crossing to the excited triplet state of the fullerene does not occur and thus singlet oxygen is not generated.
[0087] The molecules of the instant invention can be used in compositions which contain these molecules, such as, but not limited to, salts of the molecules of the instant invention; formulations containing molecules of the instant invention, including but not limited to compositions used in personal care, such as oil/water or water/oil emulsions; liposomal formulations, etc.; host-guest inclusions such as cyclodextrin complexes, etc.
[0088] The molecules of the present invention may be used in compositions with other reactive compounds, in particular in combination with other radical scavengers, such as tocopherols, ascorbates, ubiquinone, carotenoids, anthocyanidins, flavinoids, lipoic acids, etc. Fullerene molecules of the present invention may provide synergistic chemical effects, whereby the fullerene enhances or preserves the efficacy of one or more of the other substituent radical scavengers of the composition. Also, it is contemplated that the fullerenes described herein can be used to vector another radical scavenger such as those mentioned here by chemical substitution of the radical scavenger at X, Z, X′, Y′, or Z′ in compounds 1, 7 or 9 above, to various environments, and/or preserve or enhance the efficacy in various environments. The fullerenes of the present invention may also be used in combination with other formulation agents such as stabilizers, surfactants, emulsifiers, preservative agents, UV absorbing agents, anti-inflammatory agents, or anti-microbial agents.
EXAMPLE 1
[0089] Tests were conducted to study the effectiveness of methanofullerene derivatives against radicals present in cigarette smoke (predominantly peroxyl radical). The cigarette smoke was bubbled through a glass frit into a solvent (decalin) in which radical scavengers were dissolved. The smoke then exited this solvent and was passed through a second flask, in which a fluorescent probe that fluoresces upon oxidation by radicals was used (Dihydrorhodamine 6G (DHR 6G), purchased from Molecular Probes). See FIG. 5 . The variation of fluorescent signal corresponds directly to the radical content of the cigarette smoke, and thus a measure of the reduction of radicals by the radical scavenger is measured. Signals were measured every 10 seconds. FIG. 6A shows a comparison of the fluorescent signal measured under identical conditions for Molecule A, i.e., PCBM (compound 3), and Vitamin E, a commonly used radical scavenger, and also known to be effective against peroxyl radical.
[0090] It can be seen that PCBM clearly scavenges significantly more of the radicals present in the cigarette smoke than Vitamin E. Since peroxyl radicals are the major radical species present in cigarette smoke, molecules of the instant invention are also effective to prevent oxidative damage in biological systems, where peroxyl radical oxidation is a major pathway in lipid peroxidation. Hydroxyl radical is also present in cigarette smoke, and likewise is an important cause of oxidative stress in biological systems.
EXAMPLE 2
[0091] Tests were conducted to study the sensitivity of the test apparatus in Example 1 to varying concentrations of Vitamin E as a radical scavenger to scavenge radicals present in cigarette smoke (predominantly peroxyl radical). The cigarette smoke was bubbled through a cylindrical, coarse glass frit into a solvent (decalin) in which radical scavengers were dissolved. The smoke then exited this solvent and was passed through a second flask, in which a fluorescent probe that fluoresces upon oxidation by radicals was used (Dihydrorhodamine 6G (DHR 6G), purchased from Molecular Probes). See FIG. 6B . The variation of fluorescent signal corresponds directly to the radical content of the cigarette smoke, and thus a measure of the reduction of radicals by the radical scavenger is measured. Signals were measured every 10 seconds. FIG. 6B shows a comparison of the fluorescent signal measured under identical conditions for 150 μM and 300 μM Vitamin E, a commonly used radical scavenger, and also known to be effective against peroxyl radical. It can be clearly seen that doubling the Vitamin E concentration from 150 μM to 300 μM gives a very small deflection. The difference in fluorescence signal between 300 μM PCBM and 300 μM Vitamin E thus corresponds to a very large difference in radical scavenging efficiency.
EXAMPLE 3
[0092] Synthesis of PCB-C18 ([6,6]-phenyl C 61 -butyric acid octadecyl ester) by transesterification of PCBM is described.
[0093] A mixture of 1.90 g of PCBM (compound 3), 6.0 g of 1-octadecanol, 250 mg of dibutyltin oxide, and 50 mL of ortho-dichlorobenzene was heated at 80° C. under an N2 atmosphere for 3 days. The reaction was cooled down and the crude product was isolated by column chromatography (silica gel; cyclohexane/toluene=1:1 (v/v) as eluent). The crude fullerene derivative was then further purified by a second column chromatography (silica gel; cyclohexane/toluene=1:1 (v/v) as eluent). The fractions that were >99% purity (HPLC analysis) were combined and concentrated in vacuo. The residue was redissolved in ortho-xylene, the fullerene derivative was precipitated with methanol, and isolated by centrifugation. The precipitate was washed repeatedly with methanol and small portions of pentane, each time precipitating the material by centrifugation. After drying in vacuo, 822 mg of PCB-C18 was obtained.
EXAMPLE 4
[0094] Synthesis of PCB-C12 (compound 4) by transesterification of PCBM is described.
[0095] A mixture of 1.83 g of PCBM (compound 3), 4.6 g of 1-dodecanol, 148 mg of dibutyltin oxide, and 20 mL of ortho-dichlorobenzene was heated at 80° C. under an N2 atmosphere for 24 hours. The reaction was cooled down and the product was isolated by column chromatography (silica gel; cyclohexane/toluene=1:1 (v/v) as eluent). The fractions containing PCB-C12 were combined and concentrated in vacuo. The resulting material was redissolved in 15 mL of chlorobenzene, the fullerene derivative was precipitated with methanol, and isolated by centrifugation. The precipitate was washed with methanol and dried in vacuo. This procedure of washing and drying was repeated once. The product was then redissolved in 20 mL of chloroform, precipitated with methanol, and isolated by centrifugation. The precipitate was washed with methanol and dried in vacuo. This gave 1.58 g of PCB-C12 (compound 4) as a fine, black powder.
EXAMPLE 5
[0096] Synthesis of PCB-EO4 (compound 5) by transesterification of PCBM is described.
[0097] A mixture of 182 mg of PCBM (compound 3), 2.0 mL of tetraethylene glycol, 11 mg of dibutyltin oxide, and 5 mL of ortho-dichlorobenzene was heated at 95° C. under an N2 atmosphere for 3 days. The reaction was cooled down and the crude product was isolated by column chromatography (silica gel; chloroform as eluent). It was then further purified by a second column chromatography (silica gel; first chloroform/ethyl acetate (95:5 (v/v)), then chloroform/ethyl acetate (9:1 (v/v)), then chloroform/ethyl acetate (4:1 (v/v)) as eluent). The fractions containing the product were combined and concentrated in vacuo. The resulting material was redissolved in 15 mL of toluene, precipitated with methanol, washed with methanol, and dried in vacuo. Subsequently, the fullerene derivative was washed once more with methanol and dried again in vacuo. This gave 105 mg of PCB-EO4 (compound 5).
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Chemically functionalized fullerenes are useful in various applications as radical scavengers. These chemically functionalized fullerenes offer the advantages of preservation of the high innate radical scavenging efficiency of the fullerene cage and ease of synthesis of fullerene derivatives of desirably altered chemical and physical properties and single isomers. Further, they are based on a common intermediate chemistry and intermediates can be easily functionalized and tailored to various requirements.
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BACKGROUND OF THE INVENTION
This invention is concerned with thermochemical-energy transport processes and, more particularly, with the CO 2 --CH 4 reforming-mathanation chemical cycle of transporting energy, such as solar energy, to a place of use from a place of generation.
Thermochemical energy transport loops can provide an effective means of transportation energy. Such closed cycle loops, using chemical fluids which undergo reversible heat-absorbing and -liberating reactions are key elements in energy transport systems, whether solar, nuclear, or other energy sources are being harnessed. The invention herein disclosed has been developed in conjunction with a complete system of harnessing solar energy gathered from scattered solar collectors and transported to a central energy-storage station from which on-demand power is generated as needed; however, it is emphasized that the process described is amenable for transporting energy from virtually any source to an energy use area, and the scope of the invention should be so understood.
This invention is particularly concerned with modifications and improvements in the CO 2 reforming-methanation chemical cycle, CO 2 +CH 4 ⃡2CO+2H 2 . Such a reaction cycle I have found to be particularly well-suited to the collection and transport of solar energy, such as exhibited by the teachings of my earier U.S. Pat. No. 3,972,183. The CO 2 reforming-methanation cycle has been studied before, particularly by Wentorf, U.S. Pat. No. 3,958,625, as a possible alternative to the steam reforming-methanation cycle, H 2 O+CH 4 ⃡CO+3H 2 in conjunction with a nuclear energy transport loop. However, this process has several serious flaws; for example, the chemical conduits connected to the energy source must be operated at relatively high temperatures to prevent steam condensation in the lines. Such a process also necessitates the use of costly liquid-gas separators, as well as various steam addition and condensation steps. Further, the transport fluid used in Wentorf has a higher carbon removal temperature, necessitating the transport fluid to operate at higher temperatures than would be preferred.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an attractive, economical means of transporting energy from a place of generation to a place of use.
A further object of the invention is to provide a closed loop chemical process in which the reversible reaction
CO.sub.2 +CH.sub.4 ⃡2CO+2H.sub.2
is used to transport energy from collection sites to a place of storage and eventual use.
Still another object of the invention is to design an energy transport thermochemical process using non-toxic fluids, employing a working fluid which is devoid of condensables at 20° C. and is free from carbon formation under standard operating conditions.
Activated by energy from a heat source, such as a group of solar receivers, methane is reacted with an excess mixture of CO 2 (mole ratios ranging from 2.0-7.0) as well as an excess of CO (CO to CH 4 mole ratios of 0.0-0.4), at temperatures ranging from 700°-900° C. in the presence of a suitable catalyst to form a mixture of CO and H 2 , together with excess CO 2 , in the endothermic reforming reaction. The reformed gas is cooled to about 80° C. in a countercurrent heat exchanger with incoming cold CH 4 and CO 2 , and pumped under substantially isobaric conditions to the place of energy use. Upon arrival the reformed gas mixture is heated in a delivery heat exchanger to about 350°-550° C., in the presence of a suitable catalyst. CO and H 2 react exothermically and form CH 4 and CO 2 reaction products, the heat that is liberated being used to create process heat for later conversion to electricity or other uses. The methanated fluid is cooled to 100° C. in the heat chamber. Later additionally cooled to 20° C. in a line clamp heat exchanger, and pumped to the receiver heat exchanger, where a repetition of the process above described is continued.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of the equilibrium dissociation fraction for two possible CO 2 --CH 4 feedstocks as a function of temperature.
FIG. 2 is a triangular partition diagram showing the atomic fractions of carbon, oxygen, and hydrogen, used by this process as well as the prior art.
FIG. 3 is a flow diagram illustration the preferred reforming methanation CO 2 --CH 4 energy transport cycle used in the invention.
DESCRIPTION OF THE INVENTION
A thermochemical process of transporting energy requires a working fluid which will undergo a reversible, catalytically controlled reaction at high temperatures. One such fluid is a gas mixture of CO 2 and CH 4 . At temperatures above 700° C., the gas mixture favors the reforming reaction which produces CO and H 2 ; while at temperatures of 600° C. and lower, CO and H 2 , in the presence of a suitable catalyst, favor the methanation reaction and react to produce CO 2 and CH 4 .
Any discussion of the chemistry of the carbon oxides and hydrogen must consider the equilibrium and thermodynamic limitations of the system. In this chemical system, the partial equilibrium pressures of the component gases are determined by the standard equilibrium equations as applied to the reforming-methanation and the shift reactions. For the reaction CO 2 +CH 4 ⃡2CO+2H 2 , it is ##EQU1## and for the reaction H 2 O+CO⃡CO 2 +H 2 ##EQU2## The precise values for K p and K 1 have been calculated as a function of temperature, and as they are known, the equilibrium values of p(H 2 ), p(H 2 O), p(CO), p(CO 2 ) and p(CH 4 ) can also be calculated provided the total pressure of the system is known, which is equal to the sum of the partial gas pressures; the C/H atom ratio of the feedstock, R c ; ##EQU3## as well as the O/H atom ratio of the feedstock R o ; ##EQU4## In FIG. 1 the equilibrium dissociation fraction for two possible CO 2 --CH 4 feedstocks has been plotted as a function of temperature. The figure further discloses that an increase in pressure provides a corresponding increase in the temperature at which CH 4 is 50% dissociated and that an increase in CO 2 concentration provides an increase in CH 4 dissociation for a particular given temperature and pressure.
In addition to the gaseous equilibrium considerations, there may exist an equilibrium between the gaseous mixture and solid carbon. Below a single temperature, known as the "carbon-removal temperature", carbon is thermodynamically stable and forms deposits, while above it carbon deposits are unstable and disappear. Carbon deposition can cause severe problems, including reduced catalyst performance, to the system. In FIG. 1 points A, B, C and D indicate the increasing carbon-removal temperature for each mixture at the indicated system pressure. For a gas mixture with a molar composition corresponding to 3 CO 2 :O:2CO:1CH 4 , the carbon removal temperature is 747° C. at 4 atmospheres pressure.
FIG. 2 is a triangular diagram illustrating C-H-O atom fractions. One way of classifying thermochemical working fluids involving carbon dioxide, methane and steam is to characterize the fluids by their carbon, hydrogen, and oxygen atomic fractions. The atomic fractions do not change during methanation or reforming chemical reactions, and they are unaffected by the shift reaction.
In FIG. 2 several compositions, corresponding to prior art mixtures, have been plotted. In the diagram, point 1 corresponds to a fully methanated mix of 1 pt CO 2 to 1 pt CH 4 , as used by Wentorf. Point 2 corresponds to a fully methanated mix of 1 pt H 2 O to 1 pt CO 2 . Line segment A corresponds to steam-rich mixes as used in the steam methane reforming-methanation cycle described in several of applicants' earlier writings. Such a mixture is also used in the German Eva Adam process, which is also characterized by water removal before gas transport and water addition prior to the methanation chemical reaction. The region "B" comprises the range of atomic fractions used in this invention.
Certain areas of the triangular atomic partition diagram also correspond to particular problems which arise in the energy transport process. Relevant to pure gas phase energy transmission, the problem with compositions near point 1 is the excessively high carbon removal temperature encountered. The problem with region 2 is the high temperature that must be used in the gas lines to prevent steam condensation. Region B alleviates these problems and therefore has unique value in the energy transport process.
In FIG. 3, the preferred process flow chart for the transport system is illustrated. Heat supply, or endothermic reactor 2 is located adjacent a high temperature source 4 such as the heat supplied from a group of solar cavity type thermochemical receivers each of which operates as an energy trap and chemically processes all the energy, i.e., sunlight, captured. This trapped solar energy is conducted through the cylindrical walls of the solar receiver onto surfaces interfacing with the gas stream of the working fluid and transported to the reactor. This energy from source 4 heats reactor 2 to about 700°-900° C., preferably about 800° C. In optimizing the gas feed for CO 2 reforming, it is important not to use a mixture which results in a system having too high a carbon removal temperature. The following compositions with their corresponding atom fractions, as set forth in Table I, have been studied.
TABLE I______________________________________ Atom FractionMolecular Feedstocks H C O______________________________________CO.sub.2 + CH.sub.4 Point 1 0.5 0.25 0.25H.sub.2 O + CH.sub.4 Point 2 0.75 0.125 0.1252H.sub.2 O + CH.sub.4 0.727 0.91 0.182 Region B5H.sub.2 O + CH.sub.4 0.700 0.50 0.2502CO.sub.2 + CH.sub.4 0.364 0.273 0.3647CO.sub.2 + CH.sub.4 0.154 0.308 0.538 Region C2CO.sub.2 + CH.sub.4 + 0.4 CO 0.339 0.288 0.3737CO.sub.2 + CH.sub.4 + 0.4 CO 0.149 0.313 0.537______________________________________
A suitable catalyst, preferably nickel on a porous alumina substrate, accelerates the gas-reforming reaction. A critical element of the process is the utilization of an excess amount of CO 2 in the gas mixture. This excess CO 2 , ranging from 2 to 7 moles per mole of CH 4 , would initially appear to be detrimental, since it increases the amount of gas in the system, and hence adds to the pumping requirements. However, this flow is more than offset by the following advantage; it overcomes the side-reaction problem which complicates the chemistry of CO 2 +CH 4 by producing carbon. When the reaction occurs at a sufficiently high temperature, CO 2 reacts with the carbon:
CO.sub.2 +C→2CO
For every gas mixture and pressure there exists a corresponding carbon-removal temperature. Using an excess amount of CO 2 in the mixture has been found to significantly raise the carbon removal temperature of the system. Thus, using an excess of CO 2 permits the system to be operated without the introduction of steam, as well as, providing the ability to maintain the chemical lines at a relatively low temperature without harmful steam condensation.
Returning our view to FIG. 3, the reformed gas reaction products as modified by the simultaneously occurring shift reaction, namely CO, H 2 and subatmospheric pressure steam, together with excess CO 2 and unreacted CH 4 exit reactor 2 and are cooled in countercurrent receiver heat exchanger 6 by the cold incoming methanated fluid, to a temperature of about 80° C. The reformed gas travels through pipeline 8, which is constructed preferably from a tough, durable, economic plastic. Line 8 is kept at substantially constant, low pressures (1-10 atms, with about 4 atmospheres the preferred). Higher-pressure operation is also possible if higher-temperature transport lines are employed. Upon reaching the energy-use area, the fluid enters delivery heat exchanger 10 where it is heated by the countercurrent contact with the hot, methanated, reacted gas mixture now exiting reactor 12. The reformed gas mixture exits the heat exchanger at a temperature of about 350° C., whereupon it enters exothermic reactor 12. It is important to choose a suitable catalyst for the methanation reaction. Such a catalyst can aid in preventing carbon build-up and avoid an excessive temperature build up in the reactor. Nickel, nickel-on-alumina, ruthenium, tungsten, tungsten sulfide and molybdenum sulfide have all exhibited favorable methanation promoting qualities. Since high reactivity is not a requirement in this process there is substantial flexibility in choice of catalyst. In general, it is believed that catalytic methanation is achievable without excess carbon formation below about 550° using a 0.5 H 2 :1CO feedstock. Steam addition would not be required for methanation at temperatures below 600° C., which is out of the expected operating range of reactor temperatures.
The reaction of CO+H 2 to produce CH 4 and CO 2 in reactor 12 is an exothermic reaction, and the heat release is removed by a separate fluid stream 14, in a heat-exchanging relationship with the reacting gases in the reactor. This heated fluid stream, 14, preferably steam, carries the heat away to be used in whatever manner is desired, such as the production of electricity.
The methanated gas mixture exiting the reactor 12 is passed through delivery heat exchanger 10 for cooling, while simultaneously heating the incoming reformed gas mixture. The methanated gas mixture, which now primarily consists of CH 4 and CO 2 , exits heat exchanger 10 at about 100° C. into plastic line 16. The fluid is further cooled to 20° C. by line clamp heat exchanger 18 in which heat is exchanged with air or cold water, and continues in line 20 to blower 22, which supplies the needed small pressure driving force to circulate the gaseous mixture. The methanated fluid enters plastic line 24 until being heated by entering receiver heat exchanger 6 in a similar manner as was done at the methanator end, where upon the process is repeated indefinitely.
There are several significant advantages in using this process over that of the prior art, some of which have already been enumerated. This process operates substantially isobarically at a low pressure using only a small pressure increment to maintain proper circulation. There are no steam addition or condensation steps, thus allowing the system to operate without such expensive equipment as a liquid gas separator. The gas conduits are kept at low temperatures and can be made from economical plastic. Finally, the fluid used has a comparatively low carbon removal temperature.
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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The CO 2 --CH 4 reforming-methanation chemical cycle provides an ractive means of transporting energy, such as solar energy, from the place of generation to the place of use. CO 2 /CH 4 molar ratios of 2.0-7.0 permit the use of low-temperature pipelines, while lowering the carbon removal temperature of the system. Catalyst specificity is required to provide high methanation reaction temperature without carbon deposition.
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FIELD OF THE INVENTION
This invention relates to an adjustable elastic strap and fastener suitable for securely retaining protective eyewear, such as swim goggles, to the head of the wearer.
BACKGROUND OF THE INVENTION
A variety of activities are safer and more enjoyable when they are performed with some form of eye protection. Eye protection is used routinely for activities such as swimming, snow skiing, welding and the like. Swimmers, for instance, often find it beneficial to their performance if they swim with the aid of swim goggles. Not only do these swim goggles help keep the chlorine and salt out of a swimmers' eyes, they also help swimmers to see the proper course they wish to traverse. Likewise snow skiers frequently use ski goggles to keep the cold wind, snow, drizzle, and ice out of the their eyes while skiing down the slopes.
These protective goggles typically are secured onto the head of the wearer by an elastic strap. This strap is attached to either side of the goggles and then placed around the wearer's head. The strap usually includes some form of adjustment which allows the goggles to be conveniently fitted to wearers having different sized heads.
Generally the strap used on a pair of swim goggles is made from an elastic material, such as rubber or silicone, much like a general purpose rubber band. The elastic band is laced through holes located on either side of the goggles, forming a single semicircular loop suitable for slipping over the user's head. Simple frictional slide adjusters are employed to facilitate size adjustments for the band.
The known elastic band designs, however, have several disadvantages. Swimmers need to adjust the length of the band to assure proper fit and securement of the goggles to their heads. Known frictional slide adjusters are difficult to manipulate, leading to the inability to quickly and efficiently adjust the size of the strap to properly fit the swimmer's head. Because of this, proper fit is often not achieved. As a result, the goggles are often either too tight or too loose, leading to either discomfort or loss of the goggles altogether. Additionally, because the known elastic bands are typically not exceptionally strong, over-tightening the band often results, causing it to break while being put on or during use. Also, the integrity of the typical rubber or silicone band diminishes with prolonged exposure to sunlight, salt, chlorine and the like. Such exposure weakens the bands and ultimately causes failure. The deterioration is so aggressive that frequent competitive swimmers, such as high school and college swim team members, often must replace the band as many as two to three times a year.
SUMMARY OF THE INVENTION
An object of this invention is to provide an elastic strap that is easy to attach to protective goggles, simple to adjust to different sized heads, and remains adjusted and securely in place on the wearer's head once adjusted.
Another object of this invention is to provide an elastic goggle strap that is durable, not easily damaged by misuse, and unaffected by exposure to sunlight, salt, and chemicals such as chlorine.
The present invention, in accordance with a preferred embodiment achieves these objectives via an elastic adjustable protective eyewear strap which includes an elastic cord used in conjunction with a cord lock to provide length adjustment. The elastic cord which can be implemented on a wide variety of protective eyewear such as swimmers goggles, ski goggles, industrial safety glasses and the like, includes an elastic core provided with a stretchable cover which terminates at first and second ends. A selectively releasable cord lock with a throughhole through which the ends are threaded forms a loop of selectively variable size, providing the requisite size adjustment. The free ends of the covered elastic core are first threaded through apertured tabs attached to opposite sides of the goggles, and then threaded through the throughhole of the cord lock. This arrangement forms two approximately semicircular loops for placing around the head of the user.
In accordance with a further aspect of the invention, the stretchable cover is nylon mesh, and extends beyond the ends of the elastic core which it encases. To prevent fraying of the nylon mesh extensions, heat is applied to their outer ends, causing the mesh to melt. Upon solidification, the ends are protected against fraying. The nylon cover extensions, since they extend beyond the ends of the elastic core, have a reduced diameter as compared to that of the covered core, permitting the opposite ends of the strap to be readily threaded through the throughhole in the adjustable lock and the apertured goggle tabs.
The advantages and other features of the invention will become more fully apparent from the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of the goggle strap used in conjunction with swim goggles.
FIG. 2 is a cross sectional view taken along lines 2--2 of FIG. 1.
FIG. 3 is a perspective view of a pair of swim goggles equipped with the strap of this invention shown in use placed around a swimmer's head.
FIG. 4 is a cross sectional view of the lock used to provide easy adjustment to the strap's length.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, the preferred embodiment of the elastic adjustable protective eyewear strap 5 of this invention includes a covered elastic cord 10 and a cord lock 15. As best illustrated in FIG. 2, the elastic cord 10 is made up of an elongated elastic core 20 and a stretchable mesh cover 25. Although FIG. 2 shows the cross-section of the elastic core 20 as circular, the elastic core 20 can be of any suitable cross-section such as trapezoidal or rectangular. The elastic core 20 can be made of any elastomeric compound which provides sufficient strength and durability. Preferably, the elastic core 20 is made from natural rubber. In the present invention, the core 20 of the cord 10, also sometimes referred to as shock cord or bungee cord, is made up of 9-15 interwoven rubber strands. While the diameter of the cord can vary with the application of the strap 5, a cord diameter of at least 1/8" is preferred.
The elastic core 20 is encased in a tubular mesh cover 25 to protect the elastic core. The cover 25 is flexible and by reason of its mesh construction can stretch or lengthen as the elastic core 20 lengthens. In addition, the cover 25 is unaffected by misuse typically encountered, and will not deteriorate when repeatedly exposed to sunlight, salt, chlorine and the like. Preferably, the mesh cover 25 is made of nylon. In a presently preferred embodiment, the cover 25 extends some distance beyond each end of the elastic core 20, forming extensions or tips 30 of reduced diameter. To prevent fraying of the outer ends 30a of the tips 30 during use, sufficient heat is applied to the end of each tip 30 to melt the tip ends 30a, providing finished fray-free ends to the cover 25.
The cord lock 15, as shown in FIG. 4, includes a housing 35 and a plunger 40. The housing 35 contains therein a throughhole 45, and plunger 40 also contains a throughhole 50. Throughholes 45 and 50 are substantially of the same dimensions. Cord lock 15 also includes a spring 55 which connects plunger 40 to housing 35. The plunger 40 is normally biased by the spring 55 such that throughholes 45 and 50 are not aligned. To align throughholes 45 and 50, the plunger 40 and housing 35 are pushed together until the throughholes 45 and 50 are aligned. When throughholes 45 and 50 are aligned, at least two sections of the cord 10 can pass through the throughholes. After releasing the plunger 40 and the housing 35, the sections of cord 10 passing through the throughholes 45 and 50 are frictionally gripped and locked it their respective positions as the spring 55 attempts to misalign throughholes 45 and 50. The throughholes 45 and 50 in their unaligned positions act like a frictional cord gripping element which are normally biased against the cord 10 for selectively releasably inhibiting the sections of the cord 10 from passing through the lock when the cord 10 is in an adjusted position relative thereto and the gripping element is in a released condition.
The strap 5 is used in conjunction with a pair of goggles 60. Generally, any standard goggle that affords protective cover for the user's eyes can be provided with the strap 5. For instance, swim goggles, ski goggles, industrial safety glasses such as for welding or machining, and the like are contemplated for use with the strap of the present invention. While the strap 5 can be used with several different kinds of goggles, the present invention is especially suited for, but not limited to, swim goggles. The goggles 60 of FIG. 1 are representative of swim goggles. The goggles 60 are generally made of an opposed pair of transparent eye shields 65 which are shaped to conform to the area surrounding the wearer's eye. The eye shields 65 are attached to one another with a connecting strap 70. Each transparent shield 65 has a least one apertured tab 75 provided with a throughhole 80 located at the outside edge thereof. Opposite ends 30a of the strap 5 are threaded through the throughholes 80 of the opposite tabs 75. The ends are then both threaded through throughholes 45 and 50 in cord lock 15 until a sufficient length of each end of the strap 5 is passed through the cord lock 15, forming two semicircular loops L1 and L2. The two loops are now ready for placement around the wearer's head 85 as illustrated in FIG. 3. The strap is now adjusted to the wearer's head by temporarily depressing the plunger 40 of the cord lock 15 and pulling the ends 30 of the strap to shorten the loops L1 and L2 as desired to cause them to snugly grip the wearer's head. When the appropriate degree of snugness has been achieved, the plunger 40 is released to frictionally grip and lock the strap sections passing through the lock 15 in their respective adjusted positions. The loops L1 and L2 of the strap 5 are preferably separated at the back of the wearer's head 85 a comfortable distance D to provide maximum stability during use.
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An adjustable elastic protective eyewear strap for swimwear goggles and the like includes an elongated elastic cord having an elastic core encased in a stretchable cover. The goggle strap uses a releasable lock providing quick and convenient length adjustment for the goggle strap. The goggle strap is used in conjunction with a pair of goggles to provide a dependable and durable method for securing the goggles to the user's head.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional patent application Ser. No. 62/218,562 filed Sep. 14, 2015, entitled “Flow Meter System,” which is hereby incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] Flow meters are used in various industries to measure flow rates of moving fluids. For example, flow meters are used in the hydrocarbon exploration and production industry to measure various fluids moving in pipelines or other conduits during the process of drilling and producing an oil and gas well. A well is drilled to below the surface of the earth such that oil, natural gas, and water can be extracted via the well. Some wells are used to inject materials below the surface of the earth. For example, materials or fluids can be injected below the surface of the earth to sequester carbon dioxide, store natural gas for later use, or to inject steam or other substances near an oil well to enhance recovery. In some cases, a well can be maintained or enhanced using a chemical injection management system. A chemical injection management system may inject corrosion-inhibiting materials, foam-inhibiting materials, wax-inhibiting materials, antifreeze, and/or other similar chemicals to extend the life of a well or increase the rate at which resources are extracted from a well. Such materials may be injected into the well in a controlled manner over a period of time. The chemical injection management system may include a flow meter to measure and help regulate the injected material flow rate.
SUMMARY
[0004] In some embodiments, a flow meter system includes a first flow sensor and first and second fluid flow conduits extending from the first flow sensor. The second fluid flow conduit may be disposed inside the first fluid flow conduit thereby forming a fluid annulus between the first and second fluid flow conduits. The first fluid flow conduit may be metal to resist a fluid pressure differential and the second fluid flow conduit may be non-metal to balance a fluid pressure across the second fluid flow conduit and attenuate noise therein. The second fluid flow conduit is attenuative to absorb ultrasound along non-fluid paths. The fluid annulus may be configured to receive a fluid to balance the fluid pressure across the second fluid flow conduit. The second fluid flow conduit may include an internal bore to receive a process fluid that is also the received fluid of the fluid annulus. The flow meter system may further include a second flow sensor, wherein the first and second fluid flow conduits extend between the first and second flow sensors.
[0005] In some embodiments, the flow meter system may further include a housing surrounding the first flow sensor and an axial distance between an end face of the first and second fluid flow conduits and the first flow sensor in the first flow sensor housing. The axial distance forms a fluid chamber, and in some embodiments, the fluid chamber disposed between the fluid flow conduits and the sensor is operable to reduce fluid cavitation. The axial distance may be a pre-determined focal length for the first flow sensor. The first flow sensor may include a pre-determined window thickness.
[0006] In some embodiments, the flow meter system further includes a housing surrounding the first flow sensor and a fluid inlet in the first flow sensor housing having an angled junction. In some embodiments, the angled junction serves to reduce fluid cavitation. The angled inlet may serve as a flow passage directing fluid into a fluid chamber of the sensor housing.
[0007] In some embodiments, the noise attenuation of the second fluid flow conduit allows the first flow sensor to measure a laminar flow rate at high pressure. In some embodiments, the first flow sensor is configured to measure a fluid viscosity. In some embodiments, an internal bore of the second fluid flow conduit is adjustable. In further embodiments, the internal bore is configured to flow a fluid in a viscosity range of 0.1 cP to 500 cP. In some embodiments, a seal is disposed between the first and second fluid flow conduits to stagnate the received fluid in the fluid annulus.
[0008] In some embodiments, a flow meter system includes metal seals axially offset from an ultrasonic piezoelectric crystal. The flow meter system may include a housing surrounding the first flow sensor and having a first metal seal between the housing and the first flow sensor, and a second metal seal between the housing and the first fluid flow conduit, wherein the first and second metal seals are axially offset relative to a crystal of the first flow sensor. In some embodiments, the flow meter system includes a first housing surrounding the first flow sensor and having a first metal seal between the first housing and the first flow sensor, a second metal seal between the first housing and the first fluid flow conduit, wherein the first and second metal seals are axially offset relative to a crystal of the first flow sensor, a second housing surrounding the second flow sensor and having a third metal seal between the second housing and the second flow sensor, a fourth metal seal between the second housing and the second fluid flow conduit, wherein the third and fourth metal seals are axially offset relative to a crystal of the second flow sensor. In some embodiments, the flow meter system is coupled to a chemical injection management system
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a detailed description of exemplary embodiments, reference will now be made to the accompanying drawings in which:
[0010] FIG. 1 is a schematic view of an embodiment of a well system;
[0011] FIG. 2 is a schematic view of an embodiment of wellhead and chemical injection management system of the well system of FIG. 1 ;
[0012] FIG. 3 is a perspective, partial phantom view of a flow meter and valve or regulator assembly of FIG. 2 ;
[0013] FIG. 4 is a schematic of the architecture of the flow meter and valve or regulator assembly of FIG. 3 ;
[0014] FIG. 5 is a side and end views of an embodiment of a flow meter system in accordance with principles disclosed herein;
[0015] FIG. 6 is an enlarged, cross-section view of an inlet sensor body of the flow meter system of FIG. 5 ;
[0016] FIG. 7 is an enlarged, cross-section view of an outlet sensor body of the flow meter system of FIG. 5 ;
[0017] FIG. 8 is a cross-section view of an alternative embodiment of an inlet sensor body;
[0018] FIG. 9 is a cross-section view of another alternative embodiment of an inlet sensor body and an outlet sensor body of a flow meter system;
[0019] FIG. 10 is a cross-section view of a further alternative embodiment of an inlet sensor body and an outlet sensor body of a flow meter system; and
[0020] FIG. 11 is a perspective view of an alternative embodiment of a flow meter and valve assembly including a plurality of flow meter assemblies or cores.
DETAILED DESCRIPTION
[0021] In the drawings and description that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals. The drawing figures are not necessarily to scale. Certain features of the disclosed embodiments 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 disclosure includes embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure 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 desired results.
[0022] Unless otherwise specified, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Any use of any form of the terms “connect”, “engage”, “couple”, “attach”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
[0023] FIG. 1 is a schematic diagram showing an embodiment of a well system 100 . The well system 100 can be configured to extract various minerals and natural resources, including hydrocarbons (e.g., oil and/or natural gas), or configured to inject substances into an earthen surface 110 and an earthen formation 112 via a well or wellbore 114 . In some embodiments, the well system 100 is land-based, such that the surface 110 is land surface, or subsea, such that the surface 110 is the sea floor. The system 100 includes a wellhead 115 disposed over the wellbore 114 . The system 100 may be used to extract oil, natural gas, and other related resources from the wellbore 114 and the wellhead 115 , through a conduit 106 , and to an extraction point 104 at a surface location 102 . The extraction point 104 may be an on-shore processing facility, an off-shore rig, or any other extraction point. The system 100 may also be used to inject fluids, such as the materials noted above, into the wellbore 114 . The injected fluids may be supplied to the subsea equipment using the conduit 106 , which may include flexible jumper or umbilical lines. The conduit may comprise reinforced polymer and small diameter steel supply lines, which are interstitially spaced into a larger reinforced polymer liner. As the working pressure of the subsea equipment increases, the supply pressures and injection pressures also increase.
[0024] Referring now to FIG. 2 , the wellhead 115 includes a Christmas tree or tree 108 . The tree 108 includes a valve receptacle 116 and a chemical injection management system (CIMS) 118 . When assembled, the tree 108 may couple to the well 114 and include a variety of valves, fittings, and controls for operating the well 114 . The chemical injection management system 118 is coupled to the tree 108 via the valve receptacle 116 . The tree 108 provides fluid communication between the chemical injection management system 118 and the well 114 . The chemical injection management system 118 further includes a flow valve or flow regulator assembly 120 , and as explained below, the chemical injection management system 118 may be configured to regulate the flow of a fluid through the tree 108 and into the well 114 using the flow valve assembly 120 .
[0025] Referring now to FIG. 3 , a perspective and partial phantom view of the flow meter and valve assembly 120 is shown. The flow valve assembly 120 includes a housing 112 with a handle 124 , a first coupling interface 126 , and a second coupling interface 128 . In some embodiments, the coupling interfaces 126 , 128 are used to couple to the chemical injection management system 118 , the tree 108 , an ROV (remotely operated vehicle), or other portions of the wellhead 115 equipment. The housing 122 contains a flow meter 130 , a valve actuator assembly 132 , and a conduit or flowline 134 fluidly coupling an inlet 150 of the valve actuator assembly 132 to an outlet 138 of the flow meter 130 . The housing 122 may also contain other mechanical, electrical, and hydraulic components of the flow meter and valve assembly 120 . For example, and referring to FIG. 4 , the flow meter and valve assembly 120 includes an inlet or hydraulic coupler 136 fluidly coupled to the flow meter 130 . A control module 146 and a first pressure sensor 142 are electrically coupled to the flow meter 130 . In some embodiments, the flow meter 130 is an ultrasonic flow meter, and thus the control module 146 is an ultrasonic control module. An electronic control module 148 and a second pressure sensor 144 are also electrically coupled to the flow meter 130 . Fluid directed through the flow meter 130 exits the flow meter 130 at the outlet 138 , travels through the flowline 134 , and enters the valve actuator assembly 132 at the inlet 150 . In some embodiments, the valve actuator assembly 132 is a motor actuated control valve with position feedback. The valve actuator assembly 132 is fluidly coupled to an outlet or hydraulic coupler 152 of the flow valve assembly 120 . The ultrasonic control module 146 , the electronic control module 148 , and the pressure sensors 142 , 144 are used to operate the flow valve assembly 120 , and are electrically coupled to an electrical connector 140 for signal and power communication to and from the flow valve assembly 120 .
[0026] Referring next to FIG. 5 , a side and end views of an embodiment of a flow meter system 200 is shown in accordance with principles of the present disclosure. In some embodiments, the flow meter system 200 is an ultrasonic flow meter system. In some embodiments, the flow meter system 200 can be used to replace the flow meter 130 of the above-described flow valve assembly 120 . The flow meter system 200 includes a first sensor or transducer end 202 and a second sensor or transducer end 204 . Coupled between the sensor ends 202 , 204 is a fluid pipe or conduit 210 . The first sensor end 202 , which may also be referred to as an inlet or upstream sensor body, includes an inlet interface 206 having a fluid inlet 220 . The second sensor end 204 , which may also be referred to as an outlet or downstream sensor body, includes an outlet interface 208 having a fluid outlet 218 and other interface mechanisms 217 , 219 . A control module canister 212 is mounted on the flow meter system 200 using clamps 214 and retainers 216 . In some embodiments, the canister 212 includes an ultrasonic control module. In some embodiments, the canister 212 is retained on the pipe 210 .
[0027] Referring now to FIG. 6 , an enlarged, cross-section view of the inlet sensor body 202 is shown. The inlet sensor body 202 includes a housing 222 , a retainer plate 224 , a retainer or screw 226 , and a retainer ring 236 , which help to couple the pipe 210 to the housing 222 . The pipe 210 may be sealed against the housing 222 by a first seal ring 264 , a seal ring 265 , and a backup ring 267 . The pipe 210 includes an outer pipe or tube 228 and an inner pipe or tube 230 . Disposed between the outer pipe 228 and the inner pipe 230 is an annular gap or flow passage 232 . The inner pipe 230 includes an inner bore or flow passage 234 having an axis 235 . In some embodiments, the outer pipe 228 comprises metal. In some embodiments, the metal is steel. In certain embodiments, the metal is stainless steel. In some embodiments, the inner pipe 230 comprises a non-metal material. In some embodiments, the non-metal material is an attenuative material. In some embodiments, the non-metal material is a polymer. In certain embodiments, the non-metal material is a thermoplastic polymer. In certain embodiments, the inner pipe 230 is made from polyether ether ketone (PEEK), or glass filled PEEK.
[0028] The housing 222 includes an internal bore 238 , and a sensor or transducer assembly 250 is mounted in the bore 238 . The sensor assembly 250 includes a sensor housing 252 , a piezoelectric crystal 254 , an inner support member 256 , and a biasing or retention member 258 which can be, for example, a Bellville spring. The sensor housing 252 may be sealed against the housing 222 by a second seal ring 266 , a seal ring 269 , and a backup ring 271 . In some embodiments, a threaded connection couples the sensor housing 252 to the housing 222 . The sensor housing 252 , the pipe 210 , and the housing bore 238 form a fluid chamber or cavity 240 in the sensor body housing 222 . A first dimension of the fluid chamber 240 is an axial distance D 1 between an end face 260 of the sensor housing 252 and an end face 262 of the pipe 210 . A second dimension of the fluid chamber 240 is an axial distance D 2 between the first seal ring 264 and the piezoelectric crystal 254 . In some embodiments, the first seal ring 264 is disposed adjacent the pipe end face 262 . A third dimension of the fluid chamber 240 is an axial distance D 3 between the second seal ring 266 and the piezoelectric crystal 254 . In some embodiments, the second seal ring 266 is disposed adjacent an intermediate portion of the sensor housing 252 and axially offset from the housing end face 262 and the piezoelectric crystal 254 . In some embodiments, the second seal ring 266 is axially offset upstream of or backed away from the piezoelectric crystal 254 . In some embodiments, the seal rings 264 , 266 are made from metal. The fluid chamber 240 and the sensor assembly 250 are sealed inside the sensor body housing 222 by a wired connector 270 sealed against a radial bore 272 . The wired connector 270 provides power and communications to and from the sensor assembly 250 . In some embodiments, the wired connector 270 also seals the sensor assembly 250 from the external environment.
[0029] The fluid inlet 220 and the fluid chamber 240 are in fluid communication via the flow bore or passage 274 and the flow bore or passage 276 that come together at an angled junction 278 . In some embodiments, the fluid inlet 220 includes an enlarged diameter as compared to the reduced diameters of the flow passages 274 , 276 .
[0030] Referring next to FIG. 7 , the second or outlet sensor end 204 is shown enlarged and in cross-section. The outlet sensor end 204 shares many of the same components as the inlet sensor end 202 , with some differences. In the interest of clarity, similar components will not be described in detail while others will be focused on. For example, the outlet sensor end 204 , like the inlet sensor end 202 , includes a housing 322 , a retainer plate 324 , a retainer or screw 326 , and a retainer ring 336 , which help to couple the pipe 210 to the housing 322 . The pipe 210 connection may further comprise an additional connection member 337 . The pipe 210 may be sealed against the housing 322 by a first seal ring 364 , a seal ring 365 , and a backup ring 367 . Furthermore, a seal ring 373 may be disposed in the fluid annulus 232 to provide a seal between the outer pipe 228 and the inner pipe 230 .
[0031] The housing 322 includes an internal bore 338 , and a sensor or transducer assembly 350 is mounted in the bore 338 . The sensor assembly 350 includes a sensor housing 352 , a piezoelectric crystal 354 , an inner support member 356 , and a biasing or retention member 358 which can be, for example, a Bellville spring. The sensor housing 352 may be sealed against the housing 322 by a second seal ring 366 , a seal ring 369 , and a backup ring 371 . In some embodiments, a threaded connection couples the sensor housing 352 to the housing 322 . The sensor housing 352 , the pipe 210 , and the housing bore 338 form a fluid chamber or cavity 340 in the sensor body housing 322 . A first dimension of the fluid chamber 340 is an axial distance D 4 between an end face 360 of the sensor housing 352 and an end face 362 of the pipe 210 . A second dimension of the fluid chamber 340 is an axial distance D 5 between the first seal ring 364 and the piezoelectric crystal 354 . In some embodiments, the first seal ring 364 is disposed adjacent the pipe end face 362 . A third dimension of the fluid chamber 340 is an axial distance D 6 between the second seal ring 366 and the piezoelectric crystal 354 . In some embodiments, the second seal ring 366 is disposed adjacent an intermediate portion of the sensor housing 352 and axially offset from the housing end face 362 and the piezoelectric crystal 354 . In some embodiments, the second seal ring 366 is axially offset downstream of or backed away from the piezoelectric crystal 354 . In some embodiments, the seal rings 364 , 366 are made from metal. The fluid chamber 340 and the sensor assembly 350 are sealed inside the sensor body housing 322 by a wired connector 370 sealed against a radial bore 372 . The wired connector 370 provides power and communications to and from the sensor assembly 350 . In some embodiments, the wired connector 370 also seals the sensor assembly 350 from the external environment
[0032] The fluid chamber 340 is in fluid communication with a fluid outlet 320 of the sensor body housing 322 .
[0033] In operation, a fluid, such as a chemical injection or other process fluid, is directed to the fluid inlet 220 of the inlet sensor end 202 . The fluid then flows through the passage 274 , through the angled junction 278 , through the passage 276 , and into the fluid chamber 240 . In some embodiments, the angled junction 278 is designed to reduce cavitation in the fluid flowing therethrough and that is entering the fluid chamber 240 . In some embodiments, one or more of the fluid passages 274 , 276 are adjustable in diameter. For example, the diameters are adjustable between 5 mm, 6 mm, 7 mm, 8 mm, and other desirable diameters. In some embodiments, the fluid chamber 240 provides a volume in which the flowing fluid is allowed to slow down. In some embodiments, the reduction in velocity of the flowing fluid reduces cavitation in the fluid. In some embodiments, the velocity reduction causes the fluid to reach a steady state just prior to entering the tube flow bore 234 . Consequently, in some embodiments, the fluid chamber 240 is an anti-cavitation, pro-steady state fluid chamber providing a more stable fluid flow to the internal bore 234 of the pipe 210 . The angled flow passage just prior to the fluid chamber 240 can aid in the anti-cavitation effects in the fluid. The volume of the fluid chamber is determined by the diameter of the internal bore 238 and the axial distance D 1 . In some embodiments, the axial distance D 1 is 0.5 in., but can also be other distances.
[0034] Fluid then flows from the fluid chamber 240 and into the pipe flow bore 234 as well as the fluid annulus 232 between the outer pipe 228 and the inner pipe 230 . In some embodiments, the process fluid directed into the annulus 232 is allowed to stagnate therein because of the sealing of the seal ring 373 at the outlet sensor end 204 . In some embodiments, the seal 373 prevents an unmetered flow of fluid through the annulus 232 . Thus, the process fluid in the annulus 232 is at the same or substantially the same pressure as the process fluid flowing in the bore 234 . Consequently, there is little or no pressure differential across the inner pipe 230 , i.e., the inner pipe 230 is pressure-balanced. Because the inner pipe 230 is preferably made from an attenuative material, it absorbs ultrasound waves such that non-fluid paths of sound are absorbed while the inner pipe 230 is not subjected to high stress. Instead, because the annulus 232 fluid is at the process fluid pressure, the outer metal pipe 228 withstands the high stresses generated by the process fluid pressure differential. Thus, in one aspect, the outer pipe 228 is a pressure backup pipe to the inner attenuative pipe 230 . In some embodiments, the process fluid pressures are 30,000 psi or above. In some embodiments, the internal flow bore 234 is adjustable in diameter. For example, the diameter is adjustable between 5 mm, 6 mm, 7 mm, 8 mm, and other desirable diameters.
[0035] As shown by the distances axial D 2 , D 3 , D 5 , and D 6 , the metal seals are axially offset from the piezoelectric crystals. Distancing the metal seals form the piezoelectric crystals helps to increase acoustic isolation of the piezoelectric crystals.
[0036] The flow meter system embodiments described above can be used to measure laminar fluid flow in high pressure systems with ultrasound. In some embodiments, the process fluid being measured ranges in viscosity from 0.1 cP to 500 cP, and such viscosities can be measured by the flow meter systems described herein. At laminar, and super laminar, flow rates the fluid velocity is low. Consequently, the time difference between pulses of ultrasound travelling upstream and downstream can be small (for example, nanoseconds) which makes repeatable measurement of the time difference (and thus velocity) challenging due to the noise that transmits between the two ultrasonic transducers via non-fluid paths. Such noise can affect processing of the ultrasonic signals. Further, high fluid pressure (such as 30,000 psi) will affect the materials of the pipes and transducers, which must be able to withstand high stresses generated by such high pressures. As described above, the inner pipe is made of an attenuative material that will absorb the non-fluid path noise, such as the sounds transmitted by solid components. The attenuative, non-metal inner pipe is surrounded by process fluid such that it is pressure-balanced, and the high pressure of the process fluid is transferred to the more robust outer metal pipe. The pressure-balancing annulus is disposed between the inner and outer pipes, thus it extends along the pipe 210 . In some embodiments, the pressure-balancing is along the pipe 210 only, meaning the pressure-balancing is limited to the metering run only.
[0037] In the embodiments described above, the distances D 1 and D 2 can be pre-determined or chosen for optimum focal lengths between the transducer face and the pipe face. In some embodiments, the pre-determined optimum focal length is 0.5 in., though other focal lengths are chosen for desired results in other embodiments. In some embodiments, one or more of the transducers may include a pre-determined window thickness, for example, of 0.375 in. In some embodiments, a window thickness is the portion of the sensor housing 252 having an axial length of D 2 minus D 1 in FIG. 6 . In some embodiments, a window thickness is the portion of the sensor housing 352 having an axial length of D 5 minus D 4 in FIG. 7 .
[0038] Referring to FIG. 8 , an alternative embodiment of an inlet sensor body 400 is shown in cross-section. In certain embodiments, features of the sensor assembly are adjusted as compared to embodiments described above. For example, the size and shape of a sensor housing 452 of a sensor assembly 450 can vary at such locations as an end face 460 and a threaded connection 455 . Other features are similar or vary only slightly from other embodiments described herein. For example, a fluid chamber 440 separates the sensor assembly 450 from an end face 462 of the pipe 210 . The pipe 210 includes the fluid annulus 232 which can receive and stagnate process fluid for pressure balancing. An angled fluid inlet 478 carries fluid to the fluid chamber 440 .
[0039] Referring to FIG. 9 , a cross-section view of another alternative embodiment of an inlet sensor body 502 and an outlet sensor body 504 of a flow meter system 500 is shown. Certain features are adjusted as compared to embodiments described above. For example, the physical configurations of the sensor assemblies and adjacent structure are adjusted. A sensor assembly 550 next to an angled fluid inlet 578 includes an end face 560 that is in close proximity to an end face 562 of a flow conduit or metering pipe 510 . In the outlet sensor body 504 , a sensor assembly 552 includes an end face 554 that is in close proximity to an end face 556 of the metering pipe 510 . Further, the piezoelectric crystals of the sensor assemblies 550 , 552 are in-line and are not loaded or are uncompressed. Additionally, the angled fluid inlet 578 is directly coupled into the metering pipe 510 at a fluid connection 515 .
[0040] Referring next to FIG. 10 , a cross-section view of a further alternative embodiment of an inlet sensor body 602 and an outlet sensor body 604 of a flow meter system 600 is shown. Certain features are adjusted as compared to embodiments described above. For example, the physical configurations of the sensor assemblies and adjacent structure are adjusted. A sensor assembly 650 next to an angled fluid inlet 678 includes an end face 660 that is in close proximity to an end face 662 of a flow conduit or metering pipe 610 . In the outlet sensor body 604 , a sensor assembly 652 includes an end face 654 that is in close proximity to an end face 656 of the metering pipe 610 . Further, the piezoelectric crystals of the sensor assemblies 650 , 652 are not in-line but at right angles, and are loaded or are compressed. Additionally, the angled fluid inlet 678 is directly coupled into the metering pipe 610 at a fluid connection 615 .
[0041] Referring to FIG. 11 , a perspective view of an alternative flow meter system 700 is shown, having a plurality of flow meter assemblies or cores 702 , 704 in a single assembly.
[0042] According to various embodiments disclosed herein, a flow meter system is presented which can accurately measure low or very low flow rate or velocity of the process fluid using ultrasonic transducers. Further, various embodiments of the flow meter system can accurately measure viscous fluids with ultrasonic transducers. The flow meter system embodiments are configurable to variously measure fluid velocity, fluid flow rate, fluid viscosity, fluid pressure, and other fluid characteristics, or a combination thereof.
[0043] The above discussion is meant to be illustrative of the principles and various embodiments of the present disclosure. While certain embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are exemplary only, and are not limiting. Accordingly, the scope of protection is not limited by the description set out above, but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims.
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A flow meter system is disclosed that includes a first flow sensor and first and second fluid flow conduits extending from the first flow sensor. The second fluid flow conduit may be disposed inside the first fluid flow conduit thereby forming a fluid annulus between the first and second fluid flow conduits. The first fluid flow conduit may be metal to resist a fluid pressure differential and the second fluid flow conduit may be non-metal to balance a fluid pressure across the second fluid flow conduit and attenuate noise therein. The fluid annulus may be configured to receive a fluid to balance the fluid pressure across the second fluid flow conduit.
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CROSS-REFERENCED TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 08/131,396, filed Oct. 5, 1993, and entitled "Adjustable Cycling Apparatus", now U.S. Pat. No. 5,342,261.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an exercise device and more particularly to a cycling apparatus with a position adjustable pedal mechanism.
2. Description of the Prior Art
Presently there exists many variations of home cycling devices designed specifically for indoor use. While these conventional devices offer a relatively effective means for providing cycling exercise, most are one dimensional, i.e. the pedal mechanism is always positioned at one location, with the pedal mechanism usually located substantially below the user. Also, most of the cycling units presently available are not very comfortable and may prove hard to balance upon. Other cycling units which have the pedal mechanism placed in front of the user are low to the ground, providing inadequate access for some people, such as those with physical disabilities. Cycling device which offer some adjustability are known.
U.S. Pat. No. 3,057,201 to Jaeger discloses a cycling device with a pedal unit which can only be adjusted about a single pivot point.
U.S. Pat. No. 4,770,411 to Armstrong discloses a cycling device which has an adjustable seat and a fixed position pedal unit.
U.S. Pat. No. 4,838,547 to Sterling discloses a cycling apparatus with a pedal unit which can be pivotally adjusted and folded under the frame for storage.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
The present invention is a cycling apparatus, intended for indoor use, which comprises a structural frame unit and a pedal mechanism assembly unit.
The structural frame unit comprises an adjustable seat, from which the user operates the device, mounted on a rigid frame, and an assembly support for supporting and/or connecting the pedal mechanism assembly unit with the rigid frame.
The pedal mechanism assembly unit comprises a pedal assembly, resistance means, an assembly structure for supporting the pedal assembly and resistance means, and an attachment means for connecting the assembly unit with the assembly support of the structural frame unit. Optionally, an exercise data collection and display means, such as an exercise computer, may be attached.
The pedal mechanism assembly unit and the structural frame unit are moveably and pivotally coupled together so that the pedal assembly may be positioned at various horizontal, vertical, and angled alignments with respect to the structural frame unit, then reversible secured in place for the duration of the cycling routine.
Accordingly, it is a principle object of the invention to provide a cycling apparatus which is comfortable to operate and which allows the user to position a pedal mechanism at various horizontal, vertical, and angled positions thereby allowing for a versatile exercise cycling routine.
It is another object of the invention to provide a cycling apparatus which is collapseable into a more compact configuration to facilitate storage and transport.
It is a further object of the invention to provide improved elements and arrangements thereof in an apparatus for the purpose described which is inexpensive, dependable, and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF DRAWING
FIGS. 1A, 1B, and 1C are side view of the embodiment of the present apparatus.
FIG. 2A is a side view of the embodiment of the structural frame unit of the adjustable cycling apparatus.
FIG. 2B is a front view of the same.
FIG. 2C is a top view of the same.
FIG. 3A is a partial cutout side view of the embodiment of the pedal mechanism assembly unit.
FIG. 3B is a front view of the same.
FIG. 3C is a top view of the same.
FIG. 4A is a side view displaying the attachment means which couples the pedal mechanism assembly unit with the assembly support of the structural frame unit.
FIG. 4B is a front view of the same.
FIG. 4C is a top view of the same.
FIG. 5A is a side view displaying another version of the attachment means which couples the pedal mechanism assembly unit with the assembly support of the structural frame unit.
FIG. 5B is a front view of the same.
FIG. 5C is a top view of the same.
FIG. 6A is a side view displaying a portion of the substantially vertical members of the assembly support of the structural frame unit which is also used to support the pedal mechanism assembly unit.
FIG. 6B is a front view of the same.
FIG. 6C is a top view of the same.
FIG. 7A is a side view which shows the collapseability of the present invention.
FIG. 7B is a side view which shows the present apparatus equipped with wheels.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention can best be seen by reference to the drawings, and in particular to FIGS. 1A through 1C. The cycling apparatus that forms the bases of the present invention is designated by the reference numeral 10. Cycling apparatus 10 comprises a structural frame unit 11 and a pedal mechanism assembly unit 12.
As shown in FIGS. 2A through 2C, the structural frame unit 11 comprises an adjustable seat, which includes seating means 13 from which the user operates the apparatus, a back support means 15, and an optional arm rest means 16; a rigid frame; and an assembly support for supporting and/or connecting pedal mechanism assembly unit 12 to the rigid frame of the structural frame unit 11.
As shown in FIGS. 3A through 3C, the pedal mechanism assembly unit 12 comprises an assembly structure 18 for supporting a pedal assembly 19 and resistance means 20. Attachment means 21 is used to connect said assembly structure 18 to the assembly support of structural frame unit 11.
Resistance means 20 may be any type used in conventional cycling apparatus which increase the work necessary for a user to rotate the pedals of the pedal assembly in a cycling manner. The preferred resistance means is the flywheel type. FIG. 3A shows a pedal mechanism assembly unit employing a flywheel type resistance means. Therein the pedal assembly 19 comprises pedals and a hub to which the pedals are attached; and said resistance means 20 comprises a flywheel, a friction belt, and tension adjustment means. Said hub and flywheel are part of a conventional chain and sprocket or belt and pulley system 24, which is used to turn flywheel 25 around an axle fixed to assembly structure 18. A friction belt 26 in contact with said flywheel is tightened or loosened against the flywheel by any conventional tension adjustment means to provide variable resistance to rotational motion of the flywheel, and correspondingly to the pedals of the pedal assembly.
Optionally, an exercise data collection and display means, such as an exercise computer, may be attached. Said data collection and display means may be of any conventional type and can have inputs for collecting and/or measuring rotations per minute and resistant levels from the pedaling assembly; calculation means to process said inputs to give outputs such as work done, simulated linear speed, and/or calories consumed; and means for displaying the collected, measured, and/or calculated data.
The pedal mechanism assembly unit is moveably and pivotally coupled to the assembly support of the structural frame unit such that a portion of said pedal mechanism assembly unit is positioned within the structural frame unit. As shown in FIGS. 1A-4C, the attachment means 21 of the pedal mechanism assembly unit 12 comprises two sleeve members, whose hollow portion is of constant inner dimension, one on each side of assembly structure 18. Said sleeve members are pivotally attached to said assembly structure while maintaining a constant distance. Said sleeves may be separately or jointly rotatable. In a most preferred embodiment, the axle around which flywheel 25 turns, extends through assembly structure 18 to provide a pin upon which attachment means 21 is pivotally attached. In this embodiment of the present invention, the assembly support of the structural frame unit consists of two substantially horizontal members 30, fixedly joined at the forward and back ends by four substantially vertical members 14. Said horizontal members 30 are sized to moveably fit within the hollow of the sleeves of attachment means 21 of the pedal mechanism assembly unit. The sleeves of attachment means 21 may also contain a bearing, such as a roller or ball bearing, although neither may prove beneficial since there will be very little movement along the horizontal members 30. A great majority of the time the pedal mechanism assembly unit will be secured to the structural frame unit and remain stationary.
In another embodiment, the attachment means 21 of the pedal mechanism assembly unit 12 may be comprised of wheel members 28, as shown in FIGS. 5A-5C. The axle around which the flywheel turns and which extends through the assembly structure may have a wheel member 28 turnably mounted at each end, instead of the above mentioned sleeve members. The substantially horizontal member 30 may now be a type of track, rail, or channel upon which the wheel member 28 moves. The track, rail, or channel would allow for only forward and backward motion of the wheel member, not for any substantial upward or downward motion. The wheel members should prove to offer no real improvement over the sleeve members, but just demonstrates that different methods exist for moving the pedal mechanism assembly unit along the structural frame unit.
As seen in FIGS. 1A-3C and 6A-6C, substantially vertical members 14 which are located towards the front of the device are also used to support the pedal mechanism assembly unit 12. These do not have to be the same members which support the substantially horizontal members 30 as shown, but it would prove more efficient to utilize them. Mounted on the pedal mechanism assembly unit 12 may be at least one rod member 22, which extends outward on each side of assembly structure 18. Mounted on the inside of each of the front substantially vertical members 14 may be at least one bracket support member 23. Bracket support members 23 may be generally U-shaped or V-shaped brackets in which the ends of rod member 22 are placed. Because of its shape, bracket support member 23 will support the rod member and thus the pedal mechanism assembly unit in the forward, backward, and downward directions. The unit is allowed to be moved in an upward direction, which is the only desired direction. The user may lift the pedal mechanism assembly unit 12 upward, and then move the unit backward and forward along substantially horizontal supports members 30, and/or pivot the assembly, in order to reposition the same rod member in another set of brackets, or place a different rod member in the same brackets. Multiple sets of bracket members may be used with a single rod member, multiple rod members may be used with a single set of bracket members, or multiple sets of bracket members may be used with multiple rod members, all to allow the pedal assembly to be positioned at various horizontal, vertical, and angled levels.
The adjustable seat of the present invention comprises a substantially horizontal seating means, a back support means, and optionally an arm rest means, which can be adjusted to allow the user to be seated and supported at various positions in at least the forward and backward direction. These components of said adjustable seat, which are said seating means, back support means, and arm rest means, may be individually or collectively adjusted utilizing any conventional arrangement. For example, all three, two, or none of said components may be attached together rigidly, pivotally, or hingely.
In one embodiment of the present apparatus the adjustable seat comprises: a seating means 13 secured to the rigid frame; a back support means; and arm rest support means. Back support means 15 may be adjusted in a backward and forward direction. Optional arm rest support means 16 may be raised or lowered, being substantially T-shaped in the side dimension, such that the vertical portion of said arm rest means is respectively, to a lesser or greater extent, contained in a vertical sleeve of the rigid frame.
In other embodiments, seating means and back support means may be attached to each other, and may be together moved in a forward or backward direction. The optional arm rest means may be the same in the embodiment above, or in the alternative be pivotally attached to the back support, in a conventional manner.
In all embodiments the adjustable seat moves to accommodate the range in size of intended users, as well as to compensate for different positions of the pedal mechanism assembly unit, but will stay fixed during the actual cycling exercise. Movement of the seating means, in a forward or backward direction with respect to the rigid frame, is accomplished through any appropriate means and are preferably through: 1) guiding rails fixed to the rigid frame and glides or wheels fixed to a substantially horizontal portion of the back support means or back support/seating means, or 2) a pair of sleeves fixed to the rigid frame and a portion of the back support means or back support/seating means comprising two horizontal members sized to slideably move within said sleeves; wherein said horizontal portion or members may be optionally hingedly attached to the rest of the back support means. Optionally, friction applying means such as a screw may be utilized through any sleeve supra which allows variation of the friction between said sleeve and the slideable member within the sleeve.
As shown in FIGS. 7A, the present apparatus may be collapsed into a more compact form for storage purposes. Pedal mechanism assembly unit 12 may be moved under the adjustable seat, within the structural frame unit 11, to significantly reduce the overall length of the apparatus. In one embodiment, back support means 15 may be folded downward and arm rest support means 16 may be lowered, both of which will reduce the overall height of the apparatus. Alternatively, back support means 15 may be removed from contact with the rigid frame, inverted, and replaced.
Wheel assemblies may optionally be attached to the rigid frame of the structural frame unit in any appropriate manner to allow the present apparatus to be thereupon transported. These wheel assemblies are of any conventional type, and are either removeable or have conventional means for locking the wheels such that, in one state, rotational motion of said wheels is substantially blocked, and in another, said wheels are free to rotate. Preferrably at least two such wheel assemblies are attached to the lower portion of the rigid frame. FIG. 7B show conventional wheel assemblies 27 attached to the rigid frame of the present invention.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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An adjustable cycling apparatus comprising a pedal mechanism which may be adjusted to various horizontal and vertical positions for a more versatile cycling exercise routine. The cycling apparatus includes a frame unit upon which the pedal mechanism is mounted. The pedal mechanism is collapseable into the frame unit for easy storage. The frame unit supports a seat with adjustable back and arm supports whereby cycling exercise routines may be performed from a comfortable seated position. The back and arm supports may also be lowered to add to the collapseability of the apparatus.
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REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of U.S. patent application Ser. No. 14/815232, filed on Jul. 31, 2015, entitled “Physiological Measurement Communications Adapter,” which is a continuation of U.S. patent application Ser. No. 14/217,788, filed on Mar. 18, 2014, entitled “Wrist-Mounted Physiological Measurement Device,” now U.S. Pat. No. 9,113,832, which is a continuation of U.S. patent application Ser. No. 14/037,137, filed on Sep. 25, 2013, entitled “Physiological Measurement Communications Adapter,” now U.S. Pat. No. 9,113,831, which is a continuation of U.S. patent application Ser. No. 12/955,826, filed on Nov. 29, 2010, entitled “Physiological Measurement Communications Adapter,” now U.S. Pat. No. 8,548,548, which is a continuation of U.S. patent application Ser. No. 11/417,006, filed on May 3, 2006, entitled “Physiological Measurement Communications Adapter,” now U.S. Pat. No. 7,844,315, which claims priority benefit under 35 U.S.C. §120 to, and is a continuation of, U.S. patent application Ser. No. 11/048,330, filed Feb. 1, 2005, entitled “Physiological Measurement Communications Adapter,” now U.S. Pat. No. 7,844,314, which is a continuation of U.S. patent application Ser. No. 10/377,933, entitled “Physiological Measurement Communications Adapter,” now U.S. Pat. No. 6,850,788, which claims priority benefit under 35 U.S.C. §119(e) from U.S. Provisional Application No. 60/367,428, filed Mar. 25, 2002, entitled “Physiological Measurement Communications Adapter.” The present application also incorporates the foregoing utility disclosures herein by reference.
BACKGROUND OF THE INVENTION
[0002] Patient vital sign monitoring may include measurements of blood oxygen, blood pressure, respiratory gas, and EKG among other parameters. Each of these physiological parameters typically requires a sensor in contact with a patient and a cable connecting the sensor to a monitoring device. For example, FIGS. 1-2 illustrate a conventional pulse oximetry system 100 used for the measurement of blood oxygen. As shown in FIG. 1 , a pulse oximetry system has a sensor 110 , a patient cable 140 and a monitor 160 . The sensor 110 is typically attached to a finger 10 as shown. The sensor 110 has a plug 118 that inserts into a patient cable socket 142 . The monitor 160 has a socket 162 that accepts a patient cable plug 144 . The patient cable 140 transmits an LED drive signal 252 ( FIG. 2 ) from the monitor 160 to the sensor 110 and a resulting detector signal 254 ( FIG. 2 ) from the sensor 110 to the monitor 160 . The monitor 160 processes the detector signal 254 ( FIG. 2 ) to provide, typically, a numerical readout of the patient's oxygen saturation, a numerical readout of pulse rate, and an audible indicator or “beep” that occurs in response to each arterial pulse.
[0003] As shown in FIG. 2 , the sensor 110 has both red and infrared LED emitters 212 and a photodiode detector 214 . The monitor 160 has a sensor interface 271 , a signal processor 273 , a controller 275 , output drivers 276 , a display and audible indicator 278 , and a keypad 279 . The monitor 160 determines oxygen saturation by computing the differential absorption by arterial blood of the two wavelengths emitted by the sensor emitters 212 , as is well-known in the art. The sensor interface 271 provides LED drive current 252 which alternately activates the red and IR LED emitters 212 . The photodiode detector 214 generates a signal 254 corresponding to the red and infrared light energy attenuated from transmission through the patient finger 10 ( FIG. 1 ). The sensor interface 271 also has input circuitry for amplification, filtering and digitization of the detector signal 254 . The signal processor 273 calculates a ratio of detected red and infrared intensities, and an arterial oxygen saturation value is empirically determined based on that ratio. The controller 275 provides hardware and software interfaces for managing the display and audible indicator 278 and keypad 279 . The display and audible indicator 278 shows the computed oxygen status, as described above, and provides the pulse beep as well as alarms indicating oxygen desaturation events. The keypad 279 provides a user interface for setting alarm thresholds, alarm enablement, and display options, to name a few.
SUMMARY OF THE INVENTION
[0004] Conventional physiological measurement systems are limited by the patient cable connection between sensor and monitor. A patient must be located in the immediate vicinity of the monitor. Also, patient relocation requires either disconnection of monitoring equipment and a corresponding loss of measurements or an awkward simultaneous movement of patient equipment and cables. Various devices have been proposed or implemented to provide wireless communication links between sensors and monitors, freeing patients from the patient cable tether. These devices, however, are incapable of working with the large installed base of existing monitors and sensors, requiring caregivers and medical institutions to suffer expensive wireless upgrades. It is desirable, therefore, to provide a communications adapter that is plug-compatible both with existing sensors and monitors and that implements a wireless link replacement for the patient cable.
[0005] An aspect of a physiological measurement communications adapter comprises a sensor interface configured to receive a sensor signal. A transmitter modulates a first baseband signal responsive to the sensor signal so as to generate a transmit signal. A receiver demodulates a receive signal corresponding to the transmit signal so as to generate a second baseband signal corresponding to the first baseband signal. Further, a monitor interface is configured to communicate a waveform responsive to the second baseband signal to a sensor port of a monitor. The waveform is adapted to the monitor so that measurements derived by the monitor from the waveform are generally equivalent to measurements derivable from the sensor signal. The communications adapter may further comprise a signal processor having an input in communications with the sensor interface, where the signal processor is operable to derive a parameter responsive to the sensor signal and where the first baseband signal is responsive to the parameter. The parameter may correspond to at least one of a measured oxygen saturation and a pulse rate.
[0006] One embodiment may further comprise a waveform generator that synthesizes the waveform from a predetermined shape. The waveform generator synthesizes the waveform at a frequency adjusted to be generally equivalent to the pulse rate. The waveform may have a first amplitude and a second amplitude, and the waveform generator may be configured to adjusted the amplitudes so that measurements derived by the monitor are generally equivalent to a measured oxygen saturation.
[0007] In another embodiment, the sensor interface is operable on the sensor signal to provide a plethysmograph signal output, where the first baseband signal is responsive to the plethysmograph signal. This embodiment may further comprise a waveform modulator that modifies a decoded signal responsive to the second baseband signal to provide the waveform. The waveform modulator may comprise a demodulator that separates a first signal and a second signal from the decoded signal, an amplifier that adjusts amplitudes of the first and second signals to generate a first adjusted signal and a second adjusted signal, and a modulator that combines the first and second adjusted signals into the waveform. The amplitudes of the first and second signals may be responsive to predetermined calibration data for the sensor and the monitor.
[0008] An aspect of a physiological measurement communications adapter method comprises the steps of inputting a sensor signal at a patient location, communicating patient data derived from the sensor signal between the patient location and a monitor location, constructing a waveform at the monitor location responsive to the sensor signal, and providing the waveform to a monitor via a sensor port. The waveform is constructed so that the monitor calculates a parameter generally equivalent to a measurement derivable from the sensor signal.
[0009] In one embodiment, the communicating step may comprise the substeps of deriving a conditioned signal from the sensor signal, calculating a parameter signal from the conditioned signal, and transmitting the parameter signal from the patient location to the monitor location. The constructing step may comprise the substep of synthesizing the waveform from the parameter signal. In an alternative embodiment, the communicating step may comprise the substeps of deriving a conditioned signal from said sensor signal and transmitting the conditioned signal from the patient location to the monitor location. The constructing step may comprise the substeps of demodulating the conditioned signal and re-modulating the conditioned signal to generate the waveform. The providing step may comprise the substeps of inputting a monitor signal from an LED drive output of the sensor port, modulating the waveform in response to the monitor signal, and outputting the waveform on a detector input of the sensor port.
[0010] Another aspect of a physiological measurement communications adapter comprises a sensor interface means for inputting a sensor signal and outputting a conditioned signal, a transmitter means for sending data responsive to the sensor signal, and a receiver means for receiving the data. The communications adapter further comprises a waveform processor means for constructing a waveform from the data so that measurements derived by a monitor from the waveform are generally equivalent to measurements derivable from the sensor signal, and a monitor interface means for communicating the waveform to a sensor port of the monitor. The communications adapter may further comprise a signal processor means for deriving a parameter signal from the conditioned signal, where the data comprises the parameter signal. The waveform processor means may comprise a means for synthesizing the waveform from the parameter signal. The data may comprise the conditioned signal, and the waveform processor means may comprise a means for modulating the conditioned signal in response to the monitor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an illustration of a prior art pulse oximetry system;
[0012] FIG. 2 is a functional block diagram of a prior art pulse oximetry system;
[0013] FIG. 3 is an illustration of a physiological measurement communications adapter;
[0014] FIGS. 4A-B are illustrations of communications adapter sensor modules;
[0015] FIGS. 5A-C are illustrations of communications adapter monitor modules;
[0016] FIG. 6 is a functional block diagram of a communications adapter sensor module;
[0017] FIG. 7 is a functional block diagram of a communications adapter monitor module;
[0018] FIG. 8 is a functional block diagram of a sensor module configured to transmit measured pulse oximeter parameters;
[0019] FIG. 9 is a functional block diagram of a monitor module configured to received measured pulse oximeter parameters;
[0020] FIG. 10 is a functional block diagram of a sensor module configured to transmit a plethysmograph;
[0021] FIG. 11 is a functional block diagram of a monitor module configured to receive a plethysmograph;
[0022] FIG. 12 is a functional block diagram of a waveform modulator;
[0023] FIG. 13 is a functional block diagram of a sensor module configured for multiple sensors; and
[0024] FIG. 14 is a functional block diagram of a monitor module configured for multiple sensors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Overview
[0025] FIG. 3 illustrates one embodiment of a communications adapter. FIGS. 4-5 illustrate physical configurations for a communications adapter. In particular, FIGS. 4A-B illustrate sensor module configurations and FIGS. 5A-C illustrate monitor module configurations. FIGS. 6-14 illustrate communications adapter functions. In particular, FIGS. 6-7 illustrate general functions for a sensor module and a monitor module, respectively. FIGS. 8-9 functionally illustrate a communications adapter where derived pulse oximetry parameters, such as saturation and pulse rate are transmitted between a sensor module and a monitor module. Also, FIGS. 10-12 functionally illustrate a communications adapter where a plethysmograph is transmitted between a sensor module and a monitor module. FIGS. 13-14 functionally illustrate a multiple-parameter communications adapter.
[0026] FIG. 3 illustrates a communications adapter 300 having a sensor module 400 and a monitor module 500 . The communications adapter 300 communicates patient data derived from a sensor 310 between the sensor module 400 , which is located proximate a patient 20 and the monitor module 500 , which is located proximate a monitor 360 . A wireless link 340 is provided between the sensor module 400 and the monitor module 500 , replacing the conventional patient cable, such as a pulse oximetry patient cable 140 ( FIG. 1 ). Advantageously, the sensor module 400 is plug-compatible with a conventional sensor 310 . In particular, the sensor connector 318 connects to the sensor module 400 in a similar manner as to a patient cable. Further, the sensor module 400 outputs a drive signal to the sensor 310 and inputs a sensor signal from the sensor 310 in an equivalent manner as a conventional monitor 360 . The sensor module 400 may be battery powered or externally powered. External power may be for recharging internal batteries or for powering the sensor module during operation or both.
[0027] As shown in FIG. 3 , the monitor module 500 is advantageously plug-compatible with a conventional monitor 360 . In particular, the monitor's sensor port 362 connects to the monitor module 500 in a similar manner as to a patient cable, such as a pulse oximetry patient cable 140 ( FIG. 1 ). Further, the monitor module 500 inputs a drive signal from the monitor 360 and outputs a corresponding sensor signal to the monitor 360 in an equivalent manner as a conventional sensor 310 . As such, the combination sensor module 400 and monitor module 500 provide a plug-compatible wireless replacement for a patient cable, adapting an existing wired physiological measurement system into a wireless physiological measurement system. The monitor module 500 may be battery powered, powered from the monitor, such as by tapping current from a monitor's LED drive, or externally powered from an independent AC or DC power source.
[0028] Although a communications adapter 300 is described herein with respect to a pulse oximetry sensor and monitor, one of ordinary skill in the art will recognize that a communications adapter may provide a plug-compatible wireless replace for a patient cable that connects any physiological sensor and corresponding monitor. For example, a communications adapter 300 may be applied to a biopotential sensor, a non-invasive blood pressure (NIBP) sensor, a respiratory rate sensor, a glucose sensor and the corresponding monitors, to name a few.
Sensor Module Physical Configurations
[0029] FIGS. 4A-B illustrate physical embodiments of a sensor module 400 . FIG. 4A illustrates a wrist-mounted module 410 having a wrist strap 411 , a case 412 and an auxiliary cable 420 . The case 412 contains the sensor module electronics, which are functionally described with respect to FIG. 6 , below. The case 412 is mounted to the wrist strap 411 , which attaches the wrist-mounted module 410 to a patient 20 . The auxiliary cable 420 mates to a sensor connector 318 and a module connector 414 , providing a wired link between a conventional sensor 310 and the wrist-mounted module 410 . Alternatively, the auxiliary cable 420 is directly wired to the sensor module 400 . The wrist-mounted module 410 may have a display 415 that shows sensor measurements, module status and other visual indicators, such as monitor status. The wrist-mounted module 410 may also have keys (not shown) or other input mechanisms to control its operational mode and characteristics. In an alternative embodiment, the sensor 310 may have a tail (not shown) that connects directly to the wrist-mounted module 410 , eliminating the auxiliary cable 420 .
[0030] FIG. 4B illustrates a clip-on module 460 having a clip 461 , a case 462 and an auxiliary cable 470 . The clip 461 attaches the clip-on module 460 to patient clothing or objects near a patient 20 , such as a bed frame. The auxiliary cable 470 mates to the sensor connector 318 and functions as for the auxiliary cable 420 ( FIG. 4A ) of the wrist-mounted module 410 ( FIG. 4A ), described above. The clip-on module 460 may have a display 463 and keys 464 as for the wrist-mounted module 410 ( FIG. 4A ). Either the wrist-mounted module 410 or the clip-on module 460 may have other input or output ports (not shown) that download software, configure the module, or provide a wired connection to other measurement instruments or computing devices, to name a few examples.
Monitor Module Physical Configurations
[0031] FIGS. 5A-C illustrate physical embodiments of a monitor module 500 . FIG. 5A illustrates a direct-connect module 510 having a case 512 and an integrated monitor connector 514 . The case 512 contains the monitor module electronics, which are functionally described with respect to FIG. 7 , below. The monitor connector 514 mimics that of the monitor end of a patient cable, such as a pulse oximetry patient cable 140 ( FIG. 1 ), and electrically and mechanically connects the monitor module 510 to the monitor 360 via the monitor's sensor port 362 .
[0032] FIG. 5B illustrates a cable-connect module 540 having a case 542 and an auxiliary cable 550 . The case 542 functions as for the direct-connect module 510 ( FIG. 5A ), described above. Instead of directly plugging into the monitor 360 , the cable-connect module 540 utilizes the auxiliary cable 550 , which mimics the monitor end of a patient cable, such as a pulse oximetry patient cable 140 ( FIG. 1 ), and electrically connects the cable-connect module 540 to the monitor sensor port 362 .
[0033] FIG. 5C illustrates a plug-in module 570 having a plug-in case 572 and an auxiliary cable 580 . The plug-in case 572 is mechanically compatible with the plug-in chassis of a multiparameter monitor 370 and may or may not electrically connect to the chassis backplane. The auxiliary cable 580 mimics a patient cable and electrically connects the plug-in module 570 to the sensor port 372 of another plug-in device. A direct-connect module 510 ( FIG. 5A ) or a cable-connect module 540 ( FIG. 5B ) may also be used with a multiparameter monitor 370 .
[0034] In a multiparameter embodiment, such as described with respect to FIGS. 13-14 , below, a monitor module 500 may connect to multiple plug-in devices of a multiparameter monitor 370 . For example, a cable-connect module 540 ( FIG. 5B ) may have multiple auxiliary cables 550 ( FIG. 5B ) that connect to multiple plug-in devices installed within a multiparameter monitor chassis. Similarly, a plug-in module 570 may have one or more auxiliary cables 580 with multiple connectors for attaching to the sensor ports 372 of multiple plug-in devices.
Communications Adapter Functions
[0035] FIGS. 6-7 illustrate functional embodiments of a communications adapter. FIG. 6 illustrates a sensor module 400 having a sensor interface 610 , a signal processor 630 , an encoder 640 , a transmitter 650 and a transmitting antenna 670 . A physiological sensor 310 provides an input sensor signal 612 at the sensor connector 318 . Depending on the sensor 310 , the sensor module 400 may provide one or more drive signals 618 to the sensor 310 . The sensor interface 610 inputs the sensor signal 612 and outputs a conditioned signal 614 . The conditioned signal 614 may be coupled to the transmitter 650 or further processed by a signal processor 630 . If the sensor module configuration utilizes a signal processor 630 , it derives a parameter signal 632 responsive to the sensor signal 612 , which is then coupled to the transmitter 650 . Regardless, the transmitter 650 inputs a baseband signal 642 that is responsive to the sensor signal 612 . The transmitter 650 modulates the baseband signal 642 with a carrier to generate a transmit signal 654 . The transmit signal 654 may be derived by various amplitude, frequency or phase modulation schemes, as is well known in the art. The transmit signal 654 is coupled to the transmit antenna 670 , which provides wireless communications to a corresponding receive antenna 770 ( FIG. 7 ), as described below.
[0036] As shown in FIG. 6 , the sensor interface 610 conditions and digitizes the sensor signal 612 to generate the conditioned signal 614 . Sensor signal conditioning may be performed in the analog domain or digital domain or both and may include amplification and filtering in the analog domain and filtering, buffering and data rate modification in the digital domain, to name a few. The resulting conditioned signal 614 is responsive to the sensor signal 612 and may be used to calculate or derive a parameter signal 632 .
[0037] Further shown in FIG. 6 , the signal processor 630 performs signal processing on the conditioned signal 614 to generate the parameter signal 632 . The signal processing may include buffering, digital filtering, smoothing, averaging, adaptive filtering and frequency transforms to name a few. The resulting parameter signal 632 may be a measurement calculated or derived from the conditioned signal, such as oxygen saturation, pulse rate, blood glucose, blood pressure and EKG to name a few. Also, the parameter signal 632 may be an intermediate result from which the above-stated measurements may be calculated or derived.
[0038] As described above, the sensor interface 610 performs mixed analog and digital pre-processing of an analog sensor signal and provides a digital output signal to the signal processor 630 . The signal processor 630 then performs digital post-processing of the front-end processor output. In alternative embodiments, the input sensor signal 612 and the output conditioned signal 614 may be either analog or digital, the front-end processing may be purely analog or purely digital, and the back-end processing may be purely analog or mixed analog or digital.
[0039] In addition, FIG. 6 shows an encoder 640 , which translates a digital word or serial bit stream, for example, into the baseband signal 642 , as is well-known in the art. The baseband signal 642 comprises the symbol stream that drives the transmit signal 654 modulation, and may be a single signal or multiple related signal components, such as in-phase and quadrature signals. The encoder 640 may include data compression and redundancy, also well-known in the art.
[0040] FIG. 7 illustrates a monitor module 500 having a receive antenna 770 , a receiver 710 , a decoder 720 , a waveform processor 730 and a monitor interface 750 . A receive signal 712 is coupled from the receive antenna 770 , which provides wireless communications to a corresponding transmit antenna 670 ( FIG. 6 ), as described above. The receiver 710 inputs the receive signal 712 , which corresponds to the transmit signal 654 ( FIG. 6 ). The receiver 710 demodulates the receive signal to generate a baseband signal 714 . The decoder 720 translates the symbols of the demodulated baseband signal 714 into a decoded signal 724 , such as a digital word stream or bit stream. The waveform processor 730 inputs the decoded signal 724 and generates a constructed signal 732 . The monitor interface 750 is configured to communicate the constructed signal 732 to a sensor port 362 of a monitor 360 . The monitor 360 may output a sensor drive signal 754 , which the monitor interface 750 inputs to the waveform processor 730 as a monitor drive signal 734 . The waveform processor 730 may utilize the monitor drive signal 734 to generate the constructed signal 732 . The monitor interface 750 may also provide characterization information 758 to the waveform processor 730 , relating to the monitor 360 , the sensor 310 or both, that the waveform processor 730 utilizes to generate the constructed signal 732 .
[0041] The constructed signal 732 is adapted to the monitor 360 so that measurements derived by the monitor 360 from the constructed signal 732 are generally equivalent to measurements derivable from the sensor signal 612 ( FIG. 6 ). Note that the sensor 310 ( FIG. 6 ) may or may not be directly compatible with the monitor 360 . If the sensor 310 ( FIG. 6 ) is compatible with the monitor 360 , the constructed signal 732 is generated so that measurements derived by the monitor 360 from the constructed signal 732 are generally equivalent (within clinical significance) with those derivable directly from the sensor signal 612 ( FIG. 6 ). If the sensor 310 ( FIG. 6 ) is not compatible with the monitor 360 , the constructed signal 732 is generated so that measurements derived by the monitor 360 from the constructed signal 732 are generally equivalent to those derivable directly from the sensor signal 612 ( FIG. 6 ) using a compatible monitor.
Wireless Pulse Oximetry
[0042] FIGS. 8-11 illustrate pulse oximeter embodiments of a communications adapter. FIGS. 8-9 illustrate a sensor module and a monitor module, respectively, configured to communicate measured pulse oximeter parameters. FIG. 10-11 illustrate a sensor module and a monitor module, respectively, configured to communicate a plethysmograph signal.
Parameter Transmission
[0043] FIG. 8 illustrates a pulse oximetry sensor module 800 having a sensor interface 810 , signal processor 830 , encoder 840 , transmitter 850 , transmitting antenna 870 and controller 890 . The sensor interface 810 , signal processor 830 and controller 890 function as described with respect to FIG. 2 , above. The sensor interface 810 communicates with a standard pulse oximetry sensor 310 , providing an LED drive signal 818 to the LED emitters 312 and receiving a sensor signal 812 from the detector 314 in response. The sensor interface 810 provides front-end processing of the sensor signal 812 , also described above, providing a plethysmograph signal 814 to the signal processor 830 . The signal processor 830 then derives a parameter signal 832 that comprises a real time measurement of oxygen saturation and pulse rate. The parameter signal 832 may include other parameters, such as measurements of perfusion index and signal quality. In one embodiment, the signal processor is an MS-5 or MS-7 board available from Masimo Corporation, Irvine, Calif.
[0044] As shown in FIG. 8 , the encoder 840 , the transmitter 850 and the transmitting antenna 870 function as described with respect to FIG. 6 , above. For example, the parameter signal 832 may be a digital word stream that is serialized into a bit stream and encoded into a baseband signal 842 . The baseband signal 842 may be, for example, two bit symbols that drive a quadrature phase shift keyed (QPSK) modulator in the transmitter 850 . Other encodings and modulations are also applicable, as described above. The transmitter 850 inputs the baseband signal 842 and generates a transmit signal 854 that is a modulated carrier having a frequency suitable for short-range transmission, such as within a hospital room, doctor's office, emergency vehicle or critical care ward, to name a few. The transmit signal 854 is coupled to the transmit antenna 870 , which provides wireless communications to a corresponding receive antenna 970 ( FIG. 9 ), as described below.
[0045] FIG. 9 illustrates a monitor module 900 having a receive antenna 970 , a receiver 910 , a decoder 920 , a waveform generator 930 and an interface cable 950 . The receive antenna 970 , receiver 910 and decoder 920 function as described with respect to FIG. 7 , above. In particular, the receive signal 912 is coupled from the receive antenna 970 , which provides wireless communications to a corresponding transmit antenna 870 ( FIG. 8 ). The receiver 910 inputs the receive signal 912 , which corresponds to the transmit signal 854 ( FIG. 8 ). The receiver 810 demodulates the receive signal 912 to generate a baseband signal 914 . Not accounting for transmission errors, the baseband signal 914 corresponds to the sensor module baseband signal 842 ( FIG. 8 ), for example a symbol stream of two bits each. The decoder 920 assembles the baseband signal 914 into a parameter signal 924 , which, for example, may be a sequence of digital words corresponding to oxygen saturation and pulse rate. Again, not accounting for transmission errors, the monitor module parameter signal 924 corresponds to the sensor module parameter signal 832 ( FIG. 8 ), derived by the signal processor 830 ( FIG. 8 ).
[0046] Also shown in FIG. 9 , the waveform generator 930 is a particular embodiment of the waveform processor 730 ( FIG. 7 ) described above. The waveform generator 930 generates a synthesized waveform 932 that the pulse oximeter monitor 360 can process to calculate SpO 2 and pulse rate values or exception messages. In the present embodiment, the waveform generator output does not reflect a physiological waveform. In particular, the synthesized waveform is not physiological data from the sensor module 800 , but is a waveform synthesized from predetermined stored waveform data to cause the monitor 360 to calculate oxygen saturation and pulse rate equivalent to or generally equivalent (within clinical significance) to that calculated by the signal processor 830 ( FIG. 8 ). The actual intensity signal from the patient received by the detector 314 ( FIG. 8 ) is not provided to the monitor 360 in the present embodiment. Indeed, the waveform provided to the monitor 360 will usually not resemble a plethysmographic waveform or other physiological data from the patient to whom the sensor module 800 ( FIG. 8 ) is attached.
[0047] The synthesized waveform 932 is modulated according to the drive signal input 934 . That is, the pulse oximeter monitor 360 expects to receive a red and IR modulated intensity signal originating from a detector, as described with respect to FIGS. 1-2 , above. The waveform generator 930 generates the synthesized waveform 932 with a predetermined shape, such as a triangular or sawtooth waveform stored in waveform generator memory or derived by a waveform generator algorithm. The waveform is modulated synchronously with the drive input 934 with first and second amplitudes that are processed in the monitor 360 as red and IR portions of a sensor signal. The frequency and the first and second amplitudes are adjusted so that pulse rate and oxygen saturation measurements derived by the pulse oximeter monitor 360 are generally equivalent to the parameter measurements derived by the signal processor 830 ( FIG. 8 ), as described above. One embodiment of a waveform generator 930 is described in U.S. Patent Application No. 60/117,097 entitled “Universal/Upgrading Pulse Oximeter,” assigned to Masimo Corporation, Irvine, Calif. and incorporated by reference herein. Although the waveform generator 930 is described above as synthesizing a waveform that does not resemble a physiological signal, one of ordinary skill will recognize that another embodiment of the waveform generator 930 could incorporate, for example, a plethysmograph simulator or other physiological signal simulator.
[0048] Further shown in FIG. 9 , the interface cable 950 functions in a manner similar to the monitor interface 750 ( FIG. 7 ) described above. The interface cable 950 is configured to communicate the synthesized waveform 932 to the monitor 360 sensor port and to communicate the sensor drive signal 934 to the waveform generator 930 . The interface cable 950 may include a ROM 960 that contains monitor and sensor characterization data. The ROM 960 is read by the waveform generator 930 so that the synthesized waveform 932 is adapted to a particular monitor 360 . For example, the ROM 960 may contain calibration data of red/IR versus oxygen saturation, waveform amplitude and waveform shape information. An interface cable is described in U.S. Patent Application No. 60/117,092, referenced above. Monitor-specific SatShare™ brand interface cables are available from Masimo Corporation, Irvine, Calif. In an alternative embodiment, such as a direct connect monitor module as illustrated in FIG. 5A , an interface cable 950 is not used and the ROM 960 may be incorporated within the monitor module 900 itself.
Plethysmograph Transmission
[0049] FIG. 10 illustrates another pulse oximetry sensor module 1000 having a sensor interface 1010 , encoder 1040 , transmitter 1050 , transmitting antenna 1070 and controller 1090 , which have the corresponding functions as those described with respect to FIG. 8 , above. The encoder 1040 , however, inputs a plethysmograph signal 1014 rather than oxygen saturation and pulse rate measurements 832 ( FIG. 8 ). Thus, the sensor module 1000 according to this embodiment encodes and transmits a plethysmograph signal 1014 to a corresponding monitor module 1100 ( FIG. 11 ) in contrast to derived physiological parameters, such as oxygen saturation and pulse rate. The plethysmograph signal 1014 is illustrated in FIG. 10 as being a direct output from the sensor interface 1010 . In another embodiment, the sensor module 1000 incorporates a decimation processor, not shown, after the sensor interface 1010 so as to provide a plethysmograph signal 1014 having a reduced sample rate.
[0050] FIG. 11 illustrates another pulse oximetry monitor module 1100 having a receive antenna 1170 , a receiver 1110 , a decoder 1120 and an interface cable 1150 , which have the corresponding functions as those described with respect to FIG. 9 , above. This monitor module embodiment 1100 , however, has a waveform modulator 1200 rather than a waveform generator 930 ( FIG. 9 ), as described above. The waveform modulator 1200 inputs a plethysmograph signal from the decoder 1120 rather than oxygen saturation and pulse rate measurements, as described with respect to FIG. 9 , above. Further, the waveform modulator 1200 provides an modulated waveform 1132 to the pulse oximeter monitor 360 rather than a synthesized waveform, as described with respect to FIG. 9 . The modulated waveform 1132 is a plethysmographic waveform modulated according to the monitor drive signal input 1134 . That is, the waveform modulator 1200 does not synthesize a waveform, but rather modifies the received plethysmograph signal 1124 to cause the monitor 360 to calculate oxygen saturation and pulse rate generally equivalent (within clinical significance) to that derivable by a compatible, calibrated pulse oximeter directly from the sensor signal 1012 ( FIG. 10 ). The waveform modulator 1200 is described in further detail with respect to FIG. 12 , below.
[0051] FIG. 12 shows a waveform modulator 1200 having a demodulator 1210 , a red digital-to-analog converter (DAC) 1220 , an IR DAC 1230 , a red amplifier 1240 , an IR amplifier 1250 , a modulator 1260 , a modulator control 1270 , a look-up table (LUT) 1280 and a ratio calculator 1290 . The waveform modulator 1200 demodulates red and IR plethysmographs (“pleths”) from the decoder output 1124 into a separate red pleth 1222 and IR pleth 1232 . The waveform modulator 1200 also adjusts the amplitudes of the pleths 1222 , 1232 according to stored calibration curves for the sensor 310 ( FIG. 10 ) and the monitor 360 ( FIG. 11 ). Further, the waveform modulator 1200 re-modulates the adjusted red pleth 1242 and adjusted IR pleth 1252 , generating a modulated waveform 1132 to the monitor 360 ( FIG. 11 ).
[0052] As shown in FIG. 12 , the demodulator 1210 performs the demodulation function described above, generating digital red and IR pleth signals 1212 , 1214 . The DACs 1220 , 1230 convert the digital pleth signals 1212 , 1214 to corresponding analog pleth signals 1222 , 1232 . The amplifiers 1240 , 1250 have variable gain control inputs 1262 , 1264 and perform the amplitude adjustment function described above, generating adjusted red and IR pleth signals 1242 , 1252 . The modulator 1260 performs the re-modulation function described above, combining the adjusted red and IR pleth signals 1242 , 1252 according to a control signal 1272 . The modulator control 1270 generates the control signal 1272 synchronously with the LED drive signal(s) 1134 from the monitor 360 .
[0053] Also shown in FIG. 12 , the ratio calculator 1290 derives a red/IR ratio from the demodulator outputs 1212 , 1214 . The LUT 1280 stores empirical calibration data for the sensor 310 ( FIG. 10 ). The LUT 1280 also downloads monitor-specific calibration data from the ROM 1160 ( FIG. 11 ) via the ROM output 1158 . From this calibration data, the LUT 1280 determines a desired red/IR ratio for the modulated waveform 1132 and generates red and IR gain outputs 1262 , 1264 to the corresponding amplifiers 1240 , 1250 , accordingly. A desired red/IR ratio is one that allows the monitor 360 ( FIG. 11 ) to derive oxygen saturation measurements from the modulated waveform 1132 that are generally equivalent to that derivable directly from the sensor signal 1012 ( FIG. 10 ).
[0054] One of ordinary skill in the art will recognize that some of the signal processing functions described with respect to FIGS. 8-11 may be performed either within a sensor module or within a monitor module. Signal processing functions performed within a sensor module may advantageously reduce the transmission bandwidth to a monitor module at a cost of increased sensor module size and power consumption. Likewise, signal processing functions performed within a monitor module may reduce sensor module size and power consumption at a cost of increase transmission bandwidth.
[0055] For example, a monitor module embodiment 900 ( FIG. 9 ) described above receives measured pulse oximeter parameters, such as oxygen saturation and pulse rate, and generates a corresponding synthesized waveform. In that embodiment, the oxygen saturation and pulse rate computations are performed within a sensor module 800 ( FIG. 8 ). Another monitor module embodiment 1100 ( FIG. 11 ), also described above, receives a plethysmograph waveform and generates a remodulated waveform. In that embodiment, minimal signal processing is performed within a sensor module 1000 ( FIG. 10 ). In yet another embodiment, not shown, a sensor module transmits a plethysmograph waveform or a decimated plethysmograph waveform having a reduced sample rate. A corresponding monitor module has a signal processor, such as described with respect to FIG. 8 , in addition to a waveform generator, as described with respect to FIG. 9 . The signal processor computes pulse oximeter parameters and the waveform generator generates a corresponding synthesized waveform, as described above. In this embodiment, minimal signal processing is performed within the sensor module, and the monitor module functions are performed on the pulse oximeter parameters computed within the monitor module.
Wireless Multiple Parameter Measurements
[0056] FIGS. 13-14 illustrate a multiple parameter communications adapter. FIG. 13 illustrates a multiple parameter sensor module 1300 having sensor interfaces 1310 , one or more signal processors 1330 , a multiplexer and encoder 1340 , a transmitter 1350 , a transmitting antenna 1370 and a controller 1390 . One or more physiological sensors 1301 provide input sensor signals 1312 to the sensor module 1300 . Depending on the particular sensors 1301 , the sensor module 1300 may provide one or more drive signals 1312 to the sensors 1301 as determined by the controller 1390 . The sensor interfaces 1310 input the sensor signals 1312 and output one or more conditioned signals 1314 . The conditioned signals 1314 may be coupled to the transmitter 1350 or further processed by the signal processors 1330 . If the sensor module configuration utilizes signal processors 1330 , it derives multiple parameter signals 1332 responsive to the sensor signals 1312 , which are then coupled to the transmitter 1350 . Regardless, the transmitter 1350 inputs a baseband signal 1342 that is responsive to the sensor signals 1312 . The transmitter 1350 modulates the baseband signal 1342 with a carrier to generate a transmit signal 1354 , which is coupled to the transmit antenna 1370 and communicated to a corresponding receive antenna 1470 ( FIG. 14 ), as described with respect to FIG. 6 , above. Alternatively, there may be multiple baseband signals 1342 , and the transmitter 1350 may transmit on multiple frequency channels, where each channel coveys data responsive to one or more of the sensor signals 1314 .
[0057] As shown in FIG. 13 , the sensor interface 1310 conditions and digitizes the sensor signals 1312 as described for a single sensor with respect to FIG. 6 , above. The resulting conditioned signals 1314 are responsive to the sensor signals 1312 . The signal processors 1330 perform signal processing on the conditioned signals 1314 to derive parameter signals 1332 , as described for a single conditioned signal with respect to FIG. 6 , above. The parameter signals 1332 may be physiological measurements such as oxygen saturation, pulse rate, blood glucose, blood pressure, EKG, respiration rate and body temperature to name a few, or may be intermediate results from which the above-stated measurements may be calculated or derived. The multiplexer and encoder 1340 combines multiple digital word or serial bit streams into a single digital word or bit stream. The multiplexer and encoder also encodes the digital word or bit stream to generate the baseband signal 1342 , as described with respect to FIG. 6 , above.
[0058] FIG. 14 illustrates a multiple parameter monitor module 1400 having a receive antenna 1470 , a receiver 1410 , a demultiplexer and decoder 1420 , one or more waveform processors 1430 and a monitor interface 1450 . The receiver 1410 inputs and demodulates the receive signal 1412 corresponding to the transmit signal 1354 ( FIG. 13 ) to generate a baseband signal 1414 as described with respect to FIG. 7 , above. The demultiplexer and decoder 1420 separates the symbol streams corresponding to the multiple conditioned signals 1314 ( FIG. 13 ) and/or parameter signals 1332 ( FIG. 13 ) and translates these symbol streams into multiple decoded signals 1422 , as described for a single symbol stream with respect to FIG. 7 , above. Alternatively, multiple frequency channels are received to generate multiple baseband signals, each of which are decoded to yield multiple decoded signals 1422 . The waveform processors 1430 input the decoded signals 1422 and generate multiple constructed signals 1432 , as described for a single decoded signal with respect to FIGS. 7-12 , above. The monitor interface 1450 is configured to communicate the constructed signals 1432 to the sensor ports of a multiple parameter monitor 1401 or multiple single parameter monitors, in a manner similar to that for a single constructed signal, as described with respect to FIGS. 7-12 , above. In particular, the constructed signals 1432 are adapted to the monitor 1401 so that measurements derived by the monitor 1401 from the constructed signals 1432 are generally equivalent to measurements derivable directly from the sensor signals 1312 ( FIG. 13 ).
[0059] A physiological measurement communications adapter is described above with respect to wireless communications and, in particular, radio frequency communications. A sensor module and monitor module, however, may also communicate via wired communications, such as telephone, Internet or fiberoptic cable to name a few. Further, wireless communications can also utilize light frequencies, such as IR or laser to name a few.
[0060] A physiological measurement communications adapter has been disclosed in detail in connection with various embodiments. These embodiments are disclosed by way of examples only. One of ordinary skill in the art will appreciate many variations and modifications of a physiological measurement communications adapter within the scope of the claims that follow.
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An arm mountable portable patient monitoring device configured to receive physiological information from a plurality of sensors attached to a patient via wired connections for on-patient monitoring of parameter measurements and wireless transmission of parameter measurements to separate monitoring devices. The arm mountable portable patient monitoring device includes a housing, a strap, a display, a first sensor port positioned on a first side of the housing configured to face toward a hand of the patient when the housing is secured to the arm of the patient, second and third sensor ports configured to receive signals from additional sensor arrangements via a wired connections, one or more signal processing arrangements configured to cause to be displayed measurements of oxygen saturation and pulse rate, and a transmitter configured to wirelessly transmit information indicative of the measurements of oxygen saturation and pulse rate to a separate monitoring device.
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BACKGROUND OF THE INVENTION
The field of invention is adjustable guitar structures and their construction as well as methods to accurately intonate acoustic guitars.
The six-string acoustic guitar has survived many centuries without much alteration to its original design. Prior to the present invention, one very important aspect of acoustic guitars that has been overlooked is providing proper intonation of each string--which is defined as adjusting the saddle longitudinally with the string until all of the notes on the instrument are relatively in tune with each other. Traditional methods of acoustic guitar construction intonate the high and low E strings which are connected to the bridge with a straight non-adjusting saddle. The other four strings are either close to being intonated or, as in most cases, quite a bit out of intonation. Historically, discrepancies in intonation were simply accepted by the artist and the general public as it was not believed that perfect or proper intonation on an acoustic guitar was attainable. The artist accepted this fact by playing out of tune in various positions on the guitar, or developed a compensating playing technique to bend the strings to pitch while playing; which was difficult and/or impossible to do.
Especially in a studio setting, the acoustic guitar must play in tune with more precisely intonated instruments and the professional guitarist cannot have an acoustic guitar that is even slightly off in intonation.
If, for example, the weather or temperature changes, the guitar string gauge is changed, string action (height) is raised or lowered, the guitar is refretted, or a number of any other conditions change, the guitar must be re-intonated. This especially plagues professional musicians who frequently travel on tour giving concerts around the country in different climatic zones, which cause guitars to de-tune and require adjustability in intonation. Airplane travel, with the guitar being subjected to changes in altitude and pressures, exacerbates these problems. Accordingly, adjustability of intonation is desirable due to the many factors which seriously effect the acoustic guitar. Yet, most acoustic guitar companies still use the original non-adjustable single saddle. The fully adjustable acoustic guitar bridge claimed herein is the only system known to the inventors that allows for continuous fully adjustable intonation of each string without sacrificing the sound of the instrument. Thus, there has been a need for the improved construction of adjustable intonation apparatus and methods to properly intonate acoustic guitars.
Attempts to properly intonate acoustic guitars have been made without success. In the 1960's, attempts were made by Gibson® with the Dove® acoustic guitar by putting a so called Nashville Tune-O-Matic bridge® on the acoustic guitar. The Tune-O-Matic was designed for electric guitars and although it theoretically allowed the acoustic guitar to be intonated, the electric guitar metal bridge destroyed the acoustic tone and qualities of the acoustic guitar. Accordingly, these guitars were believed to have been discontinued, or have not been accepted in the market, at least by professional guitar players. In the 1970's, a compensated acoustic guitar bridge was developed which cut the saddle into two or three sections and intonated the guitar strings individually with two, three, or four strings on each saddle. This method however is not individually and continuously adjustable and thus has the major drawbacks listed above. It is important to note that traditional electric guitar bridges either have an adjustment screw running through the metal saddle, with the screw connected at both ends of the bridge (Gibson Tune-O-Matic), or springs loaded on the screw between the saddle and the bridge to help stabilize the saddle (as on a Stratocaster electric guitar). The above construction is not adaptable to acoustic guitars. On an acoustic guitar, if either the screw is connected at both ends of the bridge, or a spring is placed between the saddle and the screw, the saddle will be restricted in its vibration, thereby choking off or dampening the string vibration, resulting in lack of sustain (duration of the note's sound), no tone, or acoustic quality.
Other reasons why electric guitar bridges are not transferrable to acoustic guitars is that electric guitar bridges are constructed of metal which produces a bright tone with the electric guitar strings (wound steel as opposed to the acoustic guitar's wound phosphor bronze strings or nylon). The saddles on an electric guitar bridge are fixed (springs or the adjustment bolt connected at both ends of the bridge) since the pickups (guitar microphones) are located between the bridge and the neck and the electric guitar does not rely on an acoustic soundboard to project the sound. The electric guitar strings simply vibrate between two points and the vibrations are picked up by the electric guitar pickups.
The saddles for the acoustic guitar bridge cannot be made of metal (steel, brass, etc.). The acoustic guitar relies on the string vibrations to be transmitted from the saddles to the base of the bridge. The vibrations go from the bridge to the guitar top (soundboard) and on acoustic/electric guitars to the pickups; either internal under the bridge and/or connected against the soundboard to pickup the soundboard's vibrations. The saddle must be constructed of an acoustically resonant material (bone, phenolic, ivory, etc.) to be able to transmit the string vibrations to the base of the bridge. Metal saddles would dampen these vibrations and the acoustic guitar would produce a thin, brittle tone with very little or no sustain of the notes being played.
The claimed invention solves these problems. The saddle capture has a slight bit of slop or looseness in its threading with the adjustment bolt. Indeed, while round holes with clearance will work, the preferred hole is oval allowing maximum up and down freedom of movement. The saddle must have this small bit of freedom to vibrate in order to transmit the string vibrations into clear, full bodied, warm toned notes that will ring and sustain through the projection of the acoustic guitar's soundboard and/or internal pickups.
Another aspect of the present invention relates to making adjustments to the so-called Rule of 18. Standard guitars are manufactured using a mathematical formula called the Rule of 18 which is used to determine the position of the frets. A short explanation of the acoustic guitar is helpful to understanding this.
The acoustic guitar includes six strings tuned to E, A, D, G, B, and E from the low to high strings. Metal strips running perpendicular to the strings called frets 20, allow for other notes and chords to be played. (See FIGS. 1-4.) The positioning of the frets are determined by employing the Pythagorean Scale. The Pythagorean Scale is based upon the following consonant interval ratios: the fourth, the fifth, and the octave. As shown in FIG. 3, Pythagoras used a movable bridge 50 as a basis, to divide the string into two segments at these ratios. This is similar to the guitar player's finger pressing the guitar string down at selected fret locations between the bridge and the nut (FIG. 4).
To determine fret positions, guitar builders use a mathematical formula based from the work of Pythagoras called the Rule of 18 (the number used is actually 17.817). The guitar scale length is divided by 17.817. This is the distance from the nut (see FIG. 5) to the first fret. The remaining scale length is divided by 17.817 to determine the second fret location. This procedure is repeated for all of the fret locations up the guitar neck. For example, focusing on FIGS. 5A and 5B, in an acoustic guitar with a scale length of 25.5", the following calculations are appropriate: ##EQU1## The procedure and calculations continue until the required number of frets are located. Some altering of numbers is required to arrive at having the twelfth fret location exactly at the center of the scale length and the seventh fret producing a two-thirds ratio for the fifth interval, etc.
Unfortunately, this system is inherently deficient in that it does not result in perfect intonation. As one author stated: "Indeed, you can drive yourself batty trying to make the intonation perfect at every single fret. It'll simply never happen. Why? Remember what we said about the Rule of 18 and the fudging that goes on to make fret replacement come out right? That's why. Frets, by definition, are a bit of compromise, Roger Sadowsky observes. Even assuming you have your instrument professionally intonated and as perfect as it can be, your first three frets will always be a little sharp. The middle register--the 4th through the 10th frets-tends to be a little flat. The octave area tends to be accurate and the upper register tends to be either flat or sharp; your ear really can't tell the difference. That's normal for a perfectly intonated guitar." (See The Whole Guitar Book, "The Big Setup," Alan di Perna, p.17, Musician 1990.
While this prior art system is flawed, prior to this invention it was just an accepted fact that these are the best results that guitar makers have come up with.
SUMMARY OF THE INVENTION
The present invention is directed to improved structures and methods to accurately intonate acoustic guitars.
In the first aspect of the invention, an acoustic guitar is disclosed that allows the strings (nylon or steel) to be intonated accurately and easily whenever necessary by use of the claimed adjustable bridge. The bridge system employs a minimum of alternations to the traditional acoustic guitar bridge to retain the acoustic and tonal qualities of the instrument. The traditional appearance is less likely to receive resistance from most musicians, who are usually purists and traditionalists at heart. The recessed, rear-loaded cap screws utilize the forward and downward pull of the guitar strings to stabilize the saddles. A threaded saddle capture on each saddle provides stability, continuous threading capability, and the freedom to use various acoustically resonant materials (bone, phenolic, composites, etc., but not metal) for saddles.
Acoustically resonant material is material which will accept sound waves (due to string vibrations) delivered to it at one point and transmit those waves to another source (the base of the acoustic guitar bridge) with little or no degradation of the sound waves. Bone, phenolic, ivory, etc., are examples of acoustically resonant materials. Metal will transmit sound waves through itself but its mass and density will soak up and dampen the sound waves. These features eliminate the need for springs or multipoint fasteners which would have a negative effect on the acoustic guitar's tone and sustain. The claimed structure also allows for a single unthreaded connection to the guitar body avoiding single or double screw thread connections which are deleterious to tone. A 0.040" rosewood shim is employed over the internal bridge pickup. The vibration of the saddles on the shim is transmitted to the pickup regardless if the saddles are located directly over the pickup or not. The system has been tested and is compatible with most bridge pickup systems that are currently on the market.
In another aspect of the invention, it was discovered that the string, neck and fret design of a standard guitar, manufactured by using the standard of Rule of 18 was flawed and if a percentage, i.e., approximately 3/64" (on a scale length of 25.5"), or approximately 3.3%, was removed from the neck, perfect or close to perfect intonation was obtained due to correct fret placement and proper finger pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top view of a conventional acoustic guitar having a neck, a body, a resonant cavity or soundhole, and a bridge.
FIGS. 1A and 1B show two conventional methods of securing string to the bridge of an acoustic guitar.
FIG. 1C shows the conventional method of securing the string to the tuning keys of an acoustic guitar.
FIG. 2 shows an elevated view of the claimed fully adjustable acoustic bridge which is mounted on the guitar body.
FIG. 3 is an illustrative drawing to illustrate the Pythagoras Monochord (theoretical model), utilizing a movable bridge.
FIG. 4 shows a blown up and fragmented illustration of the relationship between the fingers, frets, saddle and bridge in the actual playing of a guitar, as compared to the theoretical model in FIG. 3.
FIG. 5A shows a pictorial of the neck of a conventional guitar to explain the Rule of the 18's.
FIG. 5B shows a pictorial of the claimed guitar illustrating compensation for, and explanation of the Rule of the 18's and Rule of the 3.3%. On a 25.5" scale length guitar, about 3/64" is removed from the neck.
FIG. 6 shows a top view and partial cross-section of the claimed bridge.
FIG. 6A is a section view through Section A--A of FIG. 6 of the saddle adjustment screw hole through the boss or ridge on the anterior portion of bridge. The hole does not contain threads and is preferably oval to limit side-to-side movement but allow up and down movement.
FIG. 6B a section view of the guitar string channel through the bridge taken along Section B--B of FIG. 6, showing the groove through which the string passes.
FIG. 7 is another section view of the bridge (for a nylon string acoustic guitar) with the electronic pickup embodiment, with all of the preferable parts shown, including the guitar string, saddle, capture, screw shim and internal bridge pickup.
FIG. 7A is a free body diagram of the forces exerted by the string and screw on the saddle and on the pickup.
FIG. 7B is a top view of the bridge generally shown in FIG. 7 with the electronic pickup.
FIG. 7C is a vertical view of the apparatus in FIG. 7B.
FIG. 8 is another sectional view of the bridge (for the steel string acoustic guitar) without pickup embodiment, with all of the preferable parts shown, including the guitar string, saddle, screw and shim.
FIG. 9 is an elevation drawing of the string saddle. The claimed bridge requires six individual saddle elements so that each string can be intonated separately.
FIG. 10 is an elevated perspective of the threaded saddle capture which is attached (preferably press-fitted) to the saddle.
FIGS. 11 and 12 are additional drawings of the saddle capture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the basic configuration of a conventional classic acoustic guitar 10 having a guitar body 12 having sides 13 and a top or soundboard 15 on which is mounted bridge 16. Guitar strings 22 stretch over the resonant cavity or soundhole 14 and on to the head stock 24 and tuning keys 26. A bridge 16 and a saddle 19 is mounted on the top (or on the soundboard) 15 of the guitar body 12. Upraised metal ridges called frets 20 are located at designated intervals on the handle perpendicular to the strings. A typical guitar has about twenty frets. As set forth in the background of the invention, the positioning of the frets was conventionally determined by the so-called Rule of the 18. As also indicated in the Background of the Invention, conventional wisdom blindly followed this rule and led to the conclusion that proper intonation was not possible. FIG. 1 also shows the ridge 17 called the "nut", which is typically made of bone (traditional) or plastic, ivory, brass, or graphite. The nut 17 is located at the end of the fingerboard 21 just before the headstock 24. It allows for the strings to be played open, (i.e., unincumbered) non-fretted notes. The nut 17 has six slots equally spaced apart, one for each string. The proper depth of the nut slot (for string) is that the string is 0.020" above the first fret (this is a common measurement among guitar makers), to allow the open note to ring true without buzzing on the first fret. A lower spec at the first fret would allow less pressure at the lower frets (first through fifth), and result in closer proper intonation at these frets; however, the open position would be unplayable due to excessive string buzzing upon the first fret.
FIG. 2 shows an elevated drawing of the adjustable bridge 18. The bridge utilizes individual saddles 20 which are adjustable in a direction longitudinal to the strings 22 and perpendicular to the neck 18. In the best mode, each saddle is located on a groove or trough 36. Each individual saddle has an attached threaded saddle capture 20a, which stabilizes and fortifies the connection between the saddles (which are typically made of non-metal or other soft material) and screws 38 which are threaded into the saddle captures. This is also shown in FIGS. 6, 7 and 8. The head of each screw is rotatably connected to transverse boss 34, which extends substantially perpendicular to the strings and substantially parallel to the groove and which forms part of the frame or housing 32. Turning each screw 38 causes the movement of each connected saddle in a direction longitudinal to the strings to accomplish proper intonation. Bridge frame or housing 32 has extensions 32a and 32b which add support and optimize the picking up of the vibration off the body and from the resonant cavity.
FIG. 3 is a theoretical illustration for purposes of understanding the conventional Rule of 18. The positioning of moveable bridge or fret 50 causes shortening or lengthening of the length of the string d (FIG. 3), changing the pitch of string 52. The positioning of the frets is determined by employing the Pythagorean theory with regard to moveable bridge 50 to develop the string into segments of the desired ratio. The human finger tries to approximate this in the playing of a guitar, as illustrated in FIG. 4. When the human finger depresses the string, contact is made with an adjacent fret changing the length d 1 of the resonant string. The frets normally do not touch the string until the string is depressed by the human finger when the guitar is played. This helps explain the present invention. The subject inventors appreciated that the application of the Pythagorean theory is premised on the string being under constant tension, which in fact is not the case when the guitar is actually being played and the string is under different tensions at different positions along the guitar neck when fretted by the human finger.
FIGS. 5(a) and 5(b) illustrate how the Rule of the 18 is applied to position the frets on the neck of a traditional guitar in contrast to the subject invention. FIG. 5(a) illustrates a traditional guitar neck. The first fret 51 is shown as being a distance away from the nut. Typically, the length of the string from the bridge to the nut is 25.5". The 12th fret 52 is also shown. The position of each fret is conventionally determined by the Rule of 18, as previously set out. Intermediate frets are not shown. As noted, the traditional thinking did not take into consideration the varying of the tension as the guitar player pushes on the string to make contact with different frets at different positions of the neck. Yet, as stated previously, the frequency of a stretched string under constant tension is inversely proportional to its length (fα1/2). This is what the Pythagorean monochord represents and the basis in which the Rule of 18 is determined (See FIGS. 3-5). What the prior art failed to appreciate is a variation of string tension produced at various fret locations. The string tension is not constant when fretted along the guitar neck. It requires more pressure at the lower fret locations (e.g., near the nut 17 in FIG. 1) than it does in the upper locations (towards the bridge 16). The Rule of 18 views the nut as a fret position, however, the nut is higher than the fret height to allow for the open string positions to be played. This inevitably results in lack of proper intonation--which leads to another aspect of the invention--what the inventors coined as the Rule of 3.3% compensation. In the best mode, the actual number is 3.2759675%. The calculations follow: For a neck with a scale length of 25.5" the nut to first fret distance is 1.430875" (by Rule of 18). 1.430875"×0.032759675 (3.3%)=0.046875" or 3/64". 1.430875"-0.046875"=1.3840". This is the proper distance between nut and first fret for accurate intonation. This compensation works regardless of string gauge.
The Rule of 3.3% compensation allows for any guitar with properly located frets and an adjustable intonatable bridge to achieve accurate intonation at all fret positions. This rule has the fret locations determined as previously described by the Rule of 18 with one alteration; once all of the fret positions are determined, go back to the nut and multiply 0.032759675 (3.3%) to the distance from the nut to the first fret. For a scale length of 25.5", the 3.3% compensation will be 3/64". In simple terms, cut 3/64" (3.3%) off of a guitar neck fingerboard at the nut end that already has its fret slots cut. The 3.3% compensation of the fingerboard compensates for the various string tensions along the neck, and for the increased string height at the nut. The Rule of 3.3% compensation has been tested and proven for all types of guitars: acoustic or electric, steel or nylon string. Research was done on the 25.5" scale since this is the most commonly preferred and produced scale length.
Turning now to the details of the bridge, FIG. 6A is a section view of a typical opening within which saddle adjustment screw 38 is inserted through a hole in the boss 34 on the bridge (Section A--A). The channel 39 is slightly oversized for the 4-40 socket head cap screw which is used in the best mode. The head of the screw rests on a circular shoulder 38a. The hole is stepped 40 to allow seating of the screw cap. The hole 39 has clearance and the screw that contacts it is preferably not threaded. While a round hole works an oval opening is better allowing for greater freedom of movement up and down than laterally. The clearance will allow the saddle to vibrate up and down and side to side in channel 36 as it does in a normal acoustic guitar bridge system. This non-restricted motion also allows an acoustic guitar with a bridge pickup to perform to its maximum potential in an amplified situation. Most acoustic/electric guitars employ some type of piezo crystal for amplification. A piezo crystal relies on pressure acting as a vibration sensor, where each vibration pulse produces a change in current. The saddles must be allowed freedom to vibrate to let the piezo pick up all of the vibrations. Unrestricted downward pressure of the saddle on the piezo is essential; however, back and forth (longitudinally--with string) is also required to allow for intonation. A free body diagram is shown in FIG. 7A which shows the forces on saddle 20 by string 22 and capture 20a. Vectors 24, 24a, 26 and 26a depict stresses caused by the string tension. Vectors 22 and 22a show saddle-to-bridge forces. Vectors 28 and 28a depict approximate forces caused by stop/play action. The saddle transmits the vibrations to the bridge and/or pickup.
FIG. 6B is a sectional view of the guitar string channel through the bridge (Section B--B). The string can be tied in traditional classical style (over the bridge) or knotted and sent directly through the channel. In this embodiment, a nylon string bridge is shown. The steel string bridge system is the same in design except that the steel string (with the ball end 40) is held by a bridge pin 42 located between the saddle channel and the screw channel. (See FIG. 8).
FIG. 7 is a sectional view of the bridge showing all of the desired parts for nylon string application with an electronic pickup. The guitar string 22 passes through the string channel (for the nylon string embodiment) or to the bridge pin (for the steel string embodiment; e.g., FIG. 8), making contact on the top of the saddle 20 and continuing up the neck 18 to the headstock 24. The saddle is stabilized by the forward and downward pull of the guitar string and the threaded capture 20a and screw 38 attachment. A force diagram is shown in FIG. 7A. In the best mode, 4-40 socket head cap screws 38 are used. The screws are threaded through the capture and allow the forward to backward adjustment (intonation) of the saddle by using a 3/32" allen wrench inserted from behind the bridge. In the best mode, the saddle rests upon a 0.040" rosewood shim, 60, which rests upon the guitar bridge pickup 62. The saddle 20 can rest upon the solid base of the bridge on acoustic guitars without a bridge pickup. The rosewood shim 60 should be slightly undersized from the channel it sits in to allow for freedom of movement and vibration. This will prevent the string vibration from being choked off or dampened and utilize the guitar pickup to its maximum potential.
FIG. 7b is a top view of the embodiment set out in FIG. 7. Individual saddle elements 20 support individual strings 22. As indicated previously, saddle capture 20a is in the best mode located off center. Screw 38 is threaded into off center capture 20a. This is also indicated in FIG. 7c which is a side view of the bridge shown in FIG. 7B. They are set out in the same drawing page so that both views can be looked at simultaneously by reader.
FIG. 8 illustrates another aspect of this invention, namely, utilizing a steel string and no pickup. The string ball end 40 is shown as well as bridge pin 42. The saddle is phenolic in the best mode.
FIG. 9 is an elevated drawing of the saddle 20. The claimed bridge requires six individual longitudinally adjustable saddles, or saddle elements, upon which each string rests so that each string can be intonated separately. The bottom of each saddle element must be straight and sit flush with the base of the bridge or rosewood shim. The top of the saddle has a radius edge 21 to provide minimal string contact, necessary for intonation and tone. Hole or opening 54 is located in the saddle to hold the threaded saddle capture 20a. Saddle material can be traditional bone or other composite materials. It cannot be steel or non-acoustically resonant material (see Background of Invention). Research on the claimed bridge indicates the best results attained with bone for the nylon string and phenolic for the steel string. Other composites such graphite, plastic, ivory, Corian®, can be used.
FIG. 10 is an elevated perspective of the threaded saddle capture 20a. The threaded saddle capture is located in an opening or hole through the saddle and provides saddle stabilization and reliability and ease of adjustment as the intonation adjustment screw (M4-40 SOC HD CAP SCR) is threaded through for intonation adjustment. In the best mode, collar 63 is provided. Extra material 64 is used to form an adjacent collar during the press fit operation. The capture is a machined steel, brass or hard material part that becomes a permanent fixture in the saddle when inserted in the hole and pressed in a vise. Experiments have show that while use of acoustically resonant material for saddles without a capture has worked for short periods of time, a capture is needed for reliable long-life operation. The capture is offset from the string location on the saddle. In other words, the screw is not in the center of the saddle. The string is over only the saddle material, thereby directly transmitting the string vibrations unobstructed by the screw, etc. This allows the string vibrations to transmit directly through the saddle material unaffected by the mass of the capture. FIGS. 11 and 12 are additional drawings of the saddle capture. FIG. 7 also shows the rosewood shim 60. In the best mode, a 0.040" thick rosewood shim is used between the saddle and the internal bridge pickup. Employing rosewood allows the saddle and string to vibrate as it would on an acoustic guitar without a bridge pickup. The shim must be slightly smaller than the bridge channel to permit it to freely vibrate. Rosewood also lets the vibration of the saddles on the shim to be transmitted to the pickup, regardless if the saddles are located directly over the pickup or not. This feature is necessary since the area over which the intonation of the six strings fall is larger than the width of most guitar bridge pickups.
In operation in the best mode, the claimed infinitely adjustable saddle is utilized as follows to accurately intonate a guitar: First, an open string is struck; in other words the string is struck and allowed to oscillate freely. The open string is then tuned to the "E" note using a tuner thereby setting the open string to the so called true pitch. Typical commercially available tuners can be used for this purpose.
The same string is then fretted at the 12th fret and also struck. In other words, the finger of the guitarist depresses the string so that it touches the 12th fret and the string is now only free to oscillate between the 12th fret and the bridge. This fretted note should be one octave higher that the open string note on the same string. A tuner once again is used to check whether the 12th fret note is the same note as the open string.
If a discrepancy is noted, the saddle element upon which that particular string rests is longitudinally adjusted utilizing an allen wrench to turn the screw thereby longitudinally adjusting the saddle element in relation to the string. As the screw is turned, the saddle is physically adjusted by virtue of the threaded connection between the screw and the capture.
Testing and continuous adjusting is repeated until the intonation of the threaded string matches the intonation of the open string. This method is repeated for all other stings. As can be seen, each string is individually and infinitely adjusted so that it can be properly intonated.
While multiple embodiments and applications of this invention have been shown and described, it should be apparent that many more modifications are possible without departing from the inventive concepts therein. Both product and process claims have been included, and it is understood that the substance of some of the claims can vary and still be within the scope of this invention. The invention, therefore, can be expanded and is not to be restricted except as defined in the appended claims and reasonable equivalence therefrom.
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A fully adjustable acoustic guitar bridge is claimed that allows the strings (nylon or steel) of an acoustic guitar to be separately and continuously intonated accurately and easily whenever necessary. The bridge system employs a minimum of alterations to the traditional non-adjustable acoustic guitar bridge to retain the acoustic qualities of the instrument. Recessed, rear-loaded cap screws utilize the forward pull of the guitar strings to stabilize the adjustable saddles. A threaded saddle capture on each saddle provides stability, continuous threading capability, and the freedom to use acoustically resonant materials (bone, phenolic, composites, etc.) for saddles. These features eliminate the need for springs or other fasteners, which would have a negative effect on the acoustic guitar's tone and sustain. A rosewood shim is employed on acoustic/electric guitars over the internal bridge pickup. The vibration of the saddles on the shim is transmitted to the pickup regardless if the saddles are located directly over the pickup or not. The system has been tested and is compatible with most bridge pickup systems that are currently on the market. The Rule of 3.3%, which cuts 3/64" off of a guitar neck fingerboard (for a neck with a scale length of 25.5") compensates for the various string tensions along the neck to allow for any guitar, with an adjustable bridge and properly located frets, to achieve accurate intonation at all fret positions.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/977,160, filed Apr. 9, 2014.
BACKGROUND OF THE INVENTION
[0002] This application relates to a method of preparing a ceramic fiber for a subsequent coating, wherein the fiber is treated from an energy source.
[0003] Ceramic, carbon and glass fibers are utilized in the formation of ceramic matrix composites (“CMC”) materials. CMC materials are finding applications in any number of high temperature uses. As an example, gas turbine engines may incorporate a number of components formed of CMC materials.
[0004] The CMC materials are formed from ceramic, carbon or glass fibers, such as silicon carbide (“SiC”) fibers. In the formation of CMC materials, the diameter of the fibers may be between 5 and 150 microns. In the process of making the CMC materials, it is often desirable to coat the SiC fibers with one or more coatings. These coatings could include boron nitride or other coatings, such as silicon nitride, silicon carbide, boron carbide, carbon, oxides or combinations thereof to improve the environmental durability of the underlying materials.
[0005] It is known that application of a plasma treatment to ceramic fibers can increase their strength and some other properties. However, such a pretreatment has not been proposed to better improve the coatability of the fibers.
SUMMARY OF THE INVENTION
[0006] In a featured embodiment, a method of coating a fiber for forming a ceramic matrix composite material comprises the steps of moving a fiber through an energy application station, and applying energy to the fiber, and providing an outer coating on the fiber.
[0007] In another embodiment according to the previous embodiment, the energy application station includes a plasma treatment.
[0008] In another embodiment according to any of the previous embodiments, the energy application station also includes a microwave application.
[0009] In another embodiment according to any of the previous embodiments, the energy application station includes a microwave application.
[0010] In another embodiment according to any of the previous embodiments, the fiber is a silicon-containing fiber.
[0011] In another embodiment according to any of the previous embodiments, the fiber has a diameter greater than or equal to 5 micron and less than or equal to 150 micron.
[0012] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided after a fiber moves through an energy application station.
[0013] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided while a fiber moves through an energy application station.
[0014] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided before a fiber moves through an energy application station.
[0015] In another embodiment according to any of the previous embodiments, the fiber having a diameter greater than or equal to 5 micron and less than or equal to 150 micron.
[0016] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided after a fiber moves through an energy application station.
[0017] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided while a fiber moves through an energy application station.
[0018] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided before a fiber moves through an energy application station.
[0019] In another embodiment according to any of the previous embodiments, the coating includes at least one of boron nitride, silicon nitride, silicon carbide, boron carbide, carbon, Si 3 N 4 , SiC, AlN, oxide coatings or combinations thereof.
[0020] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided after a fiber moves through an energy application station.
[0021] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided while a fiber moves through an energy application station.
[0022] In another embodiment according to any of the previous embodiments, an outer coating on the fiber is provided before a fiber moves through an energy application station.
[0023] In another embodiment according to any of the previous embodiments, the fiber is made into an intermediate product, and then into a final CMC component.
[0024] In another embodiment according to any of the previous embodiments, the final CMC component is for use in a gas turbine engine.
[0025] In another embodiment according to any of the previous embodiments, the coating includes at least one of boron nitride, silicon nitride, silicon carbide, boron carbide, carbon, Si 3 N 4 , SiC, AlN, oxide coatings or combinations thereof.
[0026] These and other features may be best understood from the following drawings and specification, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1A schematically shows one method of a treatment of a ceramic fiber.
[0028] FIG. 1B shows another embodiment.
[0029] FIG. 2 shows an intermediate product.
[0030] FIG. 3 schematically shows a final product.
[0031] FIG. 4A shows another method embodiment.
[0032] FIG. 4B shows yet another method embodiment.
DETAILED DESCRIPTION
[0033] As shown in FIG. 1A , a spool 80 may include a fiber 82 . The fiber may be a ceramic containing silicon, such as SiC, SiCO, SiCNO, SiBCN, Si 3 N 4 . Also, the fiber can be a ceramic without silicon, a carbon fiber, or an oxide fiber. Examples include boron carbide, carbon, aluminum oxide, mullite, zirconia, alumina-silicate glass and combinations thereof. The phase(s) of the fibers may be stoichiometric or non-stoichiometric. In addition, the fibers may be fully crystalline, fully amorphous or partially crystalline and partially amorphous.
[0034] Examples of such SiC fibers are available under the trade names Hi-Nicalon™ and Hi-Nicalon type S™. Such fibers may be available from Nippon Carbon Co, Ltd. (“NCK”) of Japan. Examples of ceramic oxide fibers are available under the trade name Nextel™ and may be procured from 3M™. The fiber 82 may be utilized to form CMC materials, and the fibers may be greater than or equal to 5 and less than or equal to 150 microns in diameter. Multiple fibers and fibers having a distribution of fiber diameters between 5 and 150 microns are also contemplated to benefit from this disclosure.
[0035] An energy application station or treatment 84 is shown applying energy to a pulled or drawn fiber. The fiber is then provided with a coating treatment 86 , such that a downstream fiber portion 88 is coated. The application of the energy treatment increases the coatability of the fiber.
[0036] The coating treatment 86 is shown schematically as is the energy application station 84 . The coating may be provided by a deposition process, or other appropriate coating processes including, but not limited to chemical vapor deposition, physical vapor deposition, dip coating, atomic layer deposition methods, spray coating, vacuum deposition or combinations thereof. Exemplary, but non limiting coatings may include boron nitride, silicon nitride, silicon carbide, boron carbide, carbon, Si 3 N 4 , SiC, AlN, oxide coatings or combinations thereof. The coatings themselves are known, however, the application of the energy treatment 84 increases the adherence and coatability to the fiber 82 .
[0037] As shown in FIG. 1B , a fiber 90 is pulled through an energy application station 92 that includes two stations 94 and 96 .
[0038] In various applications, the energy applied at station 84 (or stations 94 and 96 ) may include a plasma treatment or electromagnetic radiation, such as, but not limited to microwave, terahertz, radio, laser, ultraviolet, infrared or combinations thereof. The energy application will clean, functionalize, and create one or more reactive sites, such as unsaturated bonding, on the fiber surface that enhances the subsequent deposition of the coatings at station 86 .
[0039] In various applications, the energy application will selectively and beneficially interact with the coating material prior to deposition, resulting in a more desirable coating phase or structure. In one non-limiting example, the coating material can be a precursor compound such as a volatile organometallic compound. When in the vapor state, an exemplary electromagnetic radiation source such as microwave energy can selectively interact with bonds in the organometallic compound, causing them to decompose, change or convert to another bond type. This resulting modified organometallic compound may be more desirable in producing the preferred coating composition or structure. In one example, the organometallic compound contains Si bonded to one or more non-metals (O, C, H, N, etc). After interaction with the microwave energy, the bond(s) can break, leaving behind a reactive silicon atom with incomplete bond saturation, which would selectively interact with the fiber surface.
[0040] While it has been proposed to utilize plasma treatment on ceramic fibers, this has not been to prepare the fibers for coating.
[0041] The FIG. 1B embodiment may be utilized with one of the stations 94 being microwave application and the other station 96 being plasma application.
[0042] The plasma treatment itself may be as known. The same is true of the microwave or other energy applications. The parameters for each of the treatments may be determined experimentally once a particular application has been identified.
[0043] FIG. 2 shows an intermediate product 100 which may be made from a fiber such as fiber 88 . The intermediate product 100 may be a one, two or three dimensional product such as a fiber tow, pre-preg tape, woven cloths, knitted or braided or otherwise constructed volumes, such that a subsequent and final CMC product 130 (see FIG. 3 ) is formed. The intermediate product 100 may be subsequently utilized in a polymer infiltration and pyrolysis, a chemical vapor infiltration process and/or slurry cast melt information process to form the final CMC component 130 . The component 130 formed in this way may be for use in a gas turbine engine, in one example, and could be a turbine blade, vane, blade outer air seal, combustion liner, etc.
[0044] The FIG. 1 A/ 1 B embodiment is not the only order of application of coating and energy within the scope of application.
[0045] As shown in FIG. 4A , in an embodiment 200 , the coating treatment 204 is embedded into the energy treatment application 206 . In this manner, the deposited coating on the fiber 202 can interact with the energy source to provide a set of benefits to the coating and the adhesion of the fiber.
[0046] FIG. 4B shows an embodiment 210 wherein the coating treatment 204 is applied to the fiber 212 before it enters the energy treatment station 216 . In both the FIG. 4A and 4B embodiments, the coating material can be a precursor that can be converted to a more desirable phase in the final coating by the application of the energy.
[0047] Thus, if the energy application is considered a step (a) and the coating treatment considered a step (b), then the step (b) can occur after step (a), or the step (b) can occur during step (a), or the step (b) can occur before the step (a).
[0048] It should also be understood that while a single application of energy and coating is disclosed in this application, the coating and energy could be provided in an iterative manner. That is, there could be several coating and/or energy treatment stations.
[0049] Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
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A method of coating a fiber for forming a ceramic matrix composite material comprises the steps of moving a fiber through an energy application station, and applying energy to the fiber, and providing an outer coating on the fiber.
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BACKGROUND
[0001] This disclosure relates to supply chain financing, and more particularly to invoice agent coupling.
[0002] A buyer and seller of goods typically coordinate a delivery of goods by utilizing the services of a freight carrier. In some cases, the buyer relies on a third-party freight audit and payment (FAP) service provider for auditing freight charges and coordinating payments to the freight carrier. The buyer may also rely on a third party supply chain financing (SCF) service provider to confirm that goods or services provided by a supplier are accurately charged to the buyer, and may also rely on the SCF service to provide payments to the supplier. In some cases, the supplier may request early payment in the form of a short-term financing arrangement coordinated by the third party SCF service provider.
[0003] Generally, the SCF service provider requires an invoice with detailed payment information prior to coordinating the short-term financing arrangement. However, the buyer may not directly receive a freight invoice including detailed payment information from the freight carrier. Instead, the freight carrier may provide the freight invoice to the FAP service so that the buyer does not have to coordinate this activity. Generally, the FAP service presents the freight invoice to the buyer for approval, and thereafter the FAP service coordinates payment to the freight carrier. Also, the SCF and FAP services are not in data communication with each other. Thus, for the buyer to efficiently rely on both the third party FAP and SCF services, and for freight carrier to enter into a short-term financing arrangement coordinated by the SCF service provider, a process for coupling the third-party FAP and SCF services together for the FAP service to provide the detailed payment information directly to the SCF service is needed.
SUMMARY
[0004] In one exemplary embodiment, a method for invoice agent coupling includes the steps of receiving a service invoice generated by a primary service provider, receiving an authorization of payment of the service invoice, receiving a request for early payment authorization, and transmitting a services payment to the primary service provider.
[0005] In a further embodiment of the above, the transmitting step is performed prior to a predetermined maturity date.
[0006] In a further embodiment of any of the above, the request for early payment authorization is generated by a freight carrier.
[0007] In a further embodiment of any of the above, the service invoice is generated by a business payment agent, with the business payment agent being authorized to transmit the service invoice on behalf of a client of the primary service provider.
[0008] In another exemplary embodiment, a method for invoice agent coupling includes the steps of receiving a service invoice generated by a primary service provider, authorizing payment of the service invoice, transmitting the service invoice to a supply chain financing service provider, and transmitting a services payment to the primary service provider.
[0009] In a further embodiment of any of the above, the method includes the step of negotiating a payment agreement between the primary service provider and a client of the primary service provider prior to receiving the service invoice generated by the primary service provider.
[0010] In a further embodiment of any of the above, the method includes the step of accessing a supply chain financing portal provided by the supply chain financing service provider prior to of receiving the service invoice generated by the primary service provider.
[0011] In a further embodiment of any of the above, the method includes the step of processing a request for early payment authorization in response to transmitting the service invoice to the supply chain financing service provider. Further, the step of transmitting a services payment to the primary service provider is performed prior to a predetermined maturity date.
[0012] In a further embodiment of any of the above, the step of processing the request for early payment authorization is performed by the primary service provider.
[0013] In a further embodiment of any of the above, the method includes the step of negotiating a financing agreement between a financial institution and the primary service provider. Further, the services payment is provided by the financial institution.
[0014] In a further embodiment of any of the above, the financing agreement is guaranteed by a client of the primary service provider.
[0015] In a further embodiment of any of the above, the step of auditing the service invoice additionally includes receiving a shipping record, and comparing the shipping record and the service invoice.
[0016] In a further embodiment of any of the above, the method further includes the step of confirming receipt of an article associated with the shipping record.
[0017] These and other features disclosed herein can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic view of a prior art invoice system.
[0019] FIG. 2A is a flow chart of an auditing process for a coupled invoice system.
[0020] FIG. 2B is a flow chart of a supply chain financing process for the coupled invoice system of FIG. 2A .
[0021] FIG. 2C is a flow chart of the supply chain financing process of FIG. 2B .
DETAILED DESCRIPTION
[0022] FIG. 1 illustrates a schematic view of a prior art uncoupled invoice system 10 . The uncoupled invoice system 10 includes a standalone Freight Audit and Payment (FAP) system 11 and a standalone Supply Chain Financing (SCF) system 12 . The FAP system 11 includes an FAP service 14 provided by a third party FAP service provider. Generally, the FAP service is configured to audit the accuracy of a freight invoice issued by a freight carrier 16 to a freight client or buyer 18 for goods purchased from a supplier 20 . The buyer 18 may transmit a shipment invoice to the FAP service provider including the weight of the shipment. In another example, the supplier 20 transmits the shipment invoice to the FAP service provider. The FAP service 14 may also be configured to provide a payment to the freight carrier 16 in response to approval of the freight invoice by the buyer 18 .
[0023] The freight carrier 16 and the buyer 18 may each access the FAP service 14 through a FAP portal 22 provided by the FAP service provider, the freight carrier 16 or the buyer 18 . Generally, the freight carrier 16 submits a freight invoice electronically to the FAP service provider via the FAP portal 22 . However, the freight carrier 16 may also submit a freight invoice in paper form, to be later imported by the FAP service provider. The freight invoice includes detailed payment information. The detailed payment information generally includes a weight of the goods transported by the freight carrier 16 , a shipping route of the goods and a pre-negotiated shipping rate corresponding to the shipping route of the goods. The detailed payment information may also include payment terms. For example, the payment terms may require the buyer 18 to pay the freight carrier 16 within fifteen, thirty or sixty days of receipt of the freight invoice.
[0024] The FAP portal 22 includes a dashboard (not shown) configured to provide a convenient environment for the buyer 18 to review a summary of each freight invoice without reviewing the detailed payment information or other information identified in each freight invoice. Generally, the summary of each freight invoice includes the pre-defined shipping rate and the weight of the goods transported by the freight carrier 16 . Thus, the buyer 18 is not burdened by receiving and posting the freight invoices to the FAP portal 22 , nor does the buyer 18 have to provide payment terms and shipping rates for each freight invoice to the FAP service provider prior to the FAP service provider conducting an audit of the freight invoice.
[0025] The SCF system 12 includes a SCF service 24 provided by a third party SCF service provider. Generally, the SCF service 24 is configured to audit the accuracy of an invoice of goods or services provided by the supplier 20 and provide a payment to the supplier 20 after the buyer 18 approves the invoice of goods or services. The buyer 18 and the supplier 20 may each access the SCF service 24 through an SCF portal 26 provided by the SCF service provider, the buyer 18 or the supplier 20 . Generally, the buyer 18 provides an approved invoice of goods to the SCF service 24 , and the supplier 20 may review the approved invoice.
[0026] The supplier 20 may request an early payment authorization by accessing the SCF portal 26 . That is, the supplier 20 may request payment prior to a predetermined maturity date of the approved invoice. It should be understood that the predetermined maturity date is defined as the date on which the buyer 18 is contractually obligated to repay the amount due to the supplier 20 . The SCF service 24 is configured to access a short-term lending service 28 provided by a third party financial institution. The supplier 20 enters into a short-term financing arrangement whereby the supplier 20 receives payment from the financial institution, with the short-term loan being guaranteed by the buyer 18 . The buyer 18 reimburses the financial institution once the approved invoice reaches the predetermined maturity date. However, the supplier 20 receives payment on the predetermined maturity date when the supplier 20 does not request an early payment authorization. This short-term financing arrangement increases the overall cash flow and financial health of the supplier 20 and may also permit the buyer 18 to negotiate more favorable payment terms with the supplier 20 .
[0027] However, the FAP and SCF systems 11 , 12 are not coupled together or in data communication with each other. Thus, the buyer 18 must upload approved freight invoices to the SCF portal 26 , even though the FAP system 11 is specially configured to accept freight invoices from the freight carrier 16 and post a summary of the freight invoices to the buyer 18 for approval. Thus, the buyer 18 is burdened by receiving and sending the detailed payment information between the FAP and SCF systems 11 , 12 . Moreover, the freight carrier 16 does not have an efficient way of requesting an early payment authorization for freight invoices.
[0028] FIGS. 2A-2C illustrate a flow diagram for a coupled invoice system 130 according to one embodiment of the present disclosure. In this disclosure, like reference numerals designate like elements where appropriate and reference numerals with the addition of one-hundred or multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding original elements. As shown in FIG. 2A , the coupled invoice system 130 includes a freight auditing process 131 executed by an FAP server 114 (shown in FIG. 1 ). Generally, a freight carrier 116 provides a shipment of goods, and incurs one or more freight expenses, as shown at step 132 . The buyer 118 may engage an FAP service provider to provide freight auditing services. At step 134 , the freight carrier 116 transmits a pre-audit invoice to the FAP server 114 through a FAP portal 122 (shown in FIG. 1 ). It should be appreciated that auditing process 131 may be adapted to audit invoices for any service provided by a primary service provider. In another embodiment, the auditing process 131 may audit invoices provided to a client for advertisements and promotions. It should be appreciated that primary services provider refers to a service offered to the buyer 118 other than invoice auditing and supply chain financing services.
[0029] At step 136 , the FAP server 114 (shown in FIG. 1 ) conducts a pre-audit, by comparing each of the freight charges identified by the pre-audit invoice to a shipment invoice for the goods delivered by the freight carrier 116 to the buyer 118 . The FAP service provider may also manually perform a portion of the step 136 . The FAP service provider may compare the rate identified in the pre-audit invoice to one or more rate tables agreed to between the freight carrier 116 and the buyer 118 . The rate tables may be stored on a FAP server executing the FAP service 114 . In the event of any discrepancies, the FAP service provider notifies the freight carrier 116 to reissue a corrected pre-audit invoice at step 132 . Accordingly, the buyer 118 may avoid an incurrence of one or more erroneous freight charges. After the pre-audit invoice passes the pre-audit at step 136 , a post-audit invoice is generated and posted to the FAP portal 122 (shown in FIG. 1 ) at step 138 . Thereafter, a business unit (BU) of the buyer 118 accesses a dashboard (not shown) provided by the FAP portal 122 (shown in FIG. 1 ) to review a summary of the post-audit invoice, shown at step 138 .
[0030] The BU of the buyer 118 may approve or reject the post-audit invoice at step 140 . In some instances, the post-audit invoice may be compared to one or more business rules of the buyer 118 . In one example, the buyer 118 may object to the weight or shipping rate indicated on the freight invoice. In another example, the buyer 118 may object to one or more freight charges due to the untimely delivery of the goods to the buyer 118 . In yet another example, the buyer 118 may object to the shipping route used by the freight carrier 116 to deliver the goods to the buyer 118 . In yet another example, the buyer 118 may object to miscellaneous charges such as fuel or customs fees. If the BU of the buyer 118 rejects the post-audit invoice at step 140 , the invoice is returned to the pre-audit at step 136 , and the FAP service provider notifies the freight carrier 116 at step 132 to provide a corrected pre-audit invoice at step 134 .
[0031] Once the post-audit invoice is approved by the buyer 118 , an entry for the approved post-audit invoice is appended to an aging file at step 172 . The aging file includes an entry for each post-audit invoices and the predetermined maturity date associated with each of the post-audit invoices. One or more aging rules may be applied to the post-audit invoice to identify when a payment to the freight carrier 116 is due. Generally, the freight carrier 116 is paid by the buyer 118 when the post-audit invoice reaches the predetermined maturity date defined by the payment terms. Thereafter, the post-audit invoice is released to a funding report generated at step 174 to identify each post-audit invoice eligible for payment according to the generated at aging file at step 172 . At step 176 , the BU of the buyer 118 approves the funding report and authorizes the FAP service provider to process payments through an Automated Clearing House (ACH).
[0032] Referring to FIG. 2B , the coupled invoice system 130 includes a supply chain finance (SCF) process 146 . Generally, the SCF process 146 is executed by the SCF server 124 (shown in FIG. 1 ). The BU of the buyer 118 receives the post-audit invoice from the SCF service provider by way of the FAP portal 122 (shown in FIG. 1 ) and posts the information to the SCF portal 126 (shown in FIG. 1 ) at step 148 . However, this requires the buyer 118 to present more detailed information to the SCF service provider than is required for the BU of the buyer 118 to approve the post-audit invoice for payment. In another example, the buyer 118 provides the FAP entity with business unit status. In this arrangement, the FAP service provider may post the post-audit invoice and other detailed payment information directly to the SCF portal 126 , and the FAP service provider also has the legal authority to conduct business on behalf of the buyer 118 , including all steps in the SCF process 146 otherwise performed by the BU of the buyer 118 . In yet another example, the buyer 118 provides a business payment agent status to the FAP service provider by naming the FAP service provider as an additional party to an SCF contract binding the SCF service provider and the buyer 118 . Accordingly, the FAP service provider is authorized to upload the post-audit invoice and other remittance advice information directly to the SCF portal 126 and authorize the SCF service provider to make a payment to the freight carrier 116 according to the SCF contract.
[0033] At step 150 , the freight carrier 116 accesses the SCF portal 126 (shown in FIG. 1 ) and views the post-audit invoice. Thereafter, the freight carrier 116 may make a request for early payment authorization at step 152 . Accordingly, the freight carrier 116 has the option of receiving payment for freight charges prior to a maturity date previously agreed to by the buyer 118 and the freight carrier 116 . If the freight carrier 116 makes the request for early payment authorization, the SCF service provider coordinates a short-term financing arrangement between the freight carrier 116 and a third party financial institution or lender. In this arrangement, the buyer 118 may agree to guarantee a short-term loan made to the freight carrier 116 by the financial institution. Thus, the freight carrier 116 may leverage a credit rating of the buyer 118 to obtain more favorable financing terms for the short-term loan and may also increase the freight carriers 116 overall cash flow. The SCF server 124 (shown in FIG. 1 ) may generate a financing request and submit the financing request to a short-term lending service 128 provided by the financing institution. In another example, the SCF service provider manually coordinates the short-term financing arrangement.
[0034] Upon approval of the request for the early payment authorization, the lender issues a payment to the freight carrier 116 at step 154 . Once the freight invoice reaches the maturity date at step 156 and the buyer 118 approves the FAP service provider to process a payment at step 176 , the FAP service provider funds a buyer clearing account at step 158 . In this arrangement, the buyer clearing account belongs to the buyer 118 , but the FAP service provider administers the clearing account. Thereafter, the SCF service provider directs a payment to the financial institution at step 160 . Finally, at step 162 the financial institution receives a payment on the maturity date of the invoice to reimburse the financial institution for the short-term loan made to the freight carrier 116 .
[0035] Optionally, the freight carrier 116 may not submit a request for early payment authorization at step 152 . Referring to FIG. 2C , the freight invoice reaches the maturity date at step 182 . Thereafter, the SCF service provider funds the clearing account at step 184 . The SCF service provider then directs payment to the freight carrier 116 at step 186 . The freight carrier 116 receives payment on the maturity date of the freight invoice at step 188 .
[0036] The coupled invoice system 130 provides several benefits over the prior art uncoupled invoice system 10 . The FAP service provider is authorized to provide detailed payment information directly to the SCF service provider. Thus, the BU of the buyer 118 does not have to provide this detailed payment information each time a post-audit freight invoice is generated by the FAP service provider. Also, the freight carrier 116 may increase its overall cash flow by making a request for early payment authorization, prior to the freight invoice reaching the predetermined maturity date. The buyer 118 may also receive more favorable payment terms by agreeing to guarantee the short-term loan to the freight carrier 116 . Additionally, the freight carrier 116 receives notice of any disputed charges in advance of payment of the invoice by the buyer 118 , facilitating early issue resolution between the parties and allows the freight carrier 116 to request an early payment request earlier once the dispute is resolved.
[0037] Although the different embodiments have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the embodiments in combination with features or components from another one of the embodiments. It should also be appreciated that the coupled invoice system may be executed by a single computer system or multiple computer systems located at one or more geographical locations. Additionally, other service providers may benefit from the teachings. The coupled invoice system may benefit other auditing processes and other types of invoices.
[0038] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiments may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
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A method for invoice agent coupling includes, among other things, receiving a service invoice generated by a primary service provider and receiving an authorization of payment of the service invoice. Additional steps include receiving a request for early payment authorization, and transmitting a services payment to the primary service provider.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/895,411, filed on Mar. 16, 2007. The disclosure of the above application is incorporated herein by reference.
FIELD
The invention relates generally to a multiple speed transmission having a plurality of planetary gear sets and a plurality of torque transmitting devices and more particularly to a transmission having eight or more speeds, four planetary gear sets and a plurality of torque transmitting devices.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
A typical multiple speed transmission uses a combination of a plurality of torque transmitting mechanisms, planetary gear arrangements and fixed interconnections to achieve a plurality of gear ratios. The number and physical arrangement of the planetary gear sets, generally, are dictated by packaging, cost and desired speed ratios.
While current transmissions achieve their intended purpose, the need for new and improved transmission configurations which exhibit improved performance, especially from the standpoints of efficiency, responsiveness and smoothness and improved packaging, primarily reduced size and weight, is essentially constant. Accordingly, there is a need for an improved, cost-effective, compact multiple speed transmission.
SUMMARY
A transmission is provided having an input member, an output member, a plurality of planetary gear sets, and a plurality of torque-transmitting mechanisms. The plurality of planetary gear sets each have a sun gear member, a planetary carrier member, and a ring gear member.
In one aspect of the present invention, four of the gear sets are simple planetary gear sets.
In another aspect of the present invention, two of the plurality of torque transmitting mechanisms are brakes.
In another aspect of the present invention, three of the torque transmitting mechanisms are friction clutches.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1A is a schematic diagram of a transmission according to the principles of the present invention;
FIG. 1B is a chart showing feasible locations of the torque transmitting devices for the arrangement of the transmission shown in FIG. 1A ;
FIG. 1C is a schematic diagram of another arrangement of the transmission according to the principles of the present invention;
FIG. 1D is a chart showing feasible locations of the torque transmitting devices for the arrangement of the transmission shown in FIG. 1C ;
FIG. 2A is a schematic diagram of still another arrangement of the transmission according to the principles of the present invention;
FIG. 2B is a chart showing feasible locations of the torque transmitting devices for the arrangement of the transmission shown in FIG. 2A ;
FIG. 3A is a schematic diagram of still another arrangement of the transmission according to the principles of the present invention;
FIG. 3B is a chart showing feasible locations of the torque transmitting devices for the arrangement of the transmission shown in FIG. 3A ;
FIG. 4A is a schematic diagram of still another arrangement of the transmission according to the principles of the present invention;
FIG. 4B is a chart showing feasible locations of the torque transmitting devices for the arrangement of the transmission shown in FIG. 4A ;
FIG. 5A is a schematic diagram of still another arrangement of the transmission according to the principles of the present invention;
FIG. 5B is a chart showing feasible locations of the torque transmitting devices for the arrangement of the transmission shown in FIG. 5A ;
FIG. 6A is a schematic diagram of still another arrangement of the transmission according to the principles of the present invention;
FIG. 6B is a chart showing feasible locations of the torque transmitting devices for the arrangement of the transmission shown in FIG. 6A ;
FIG. 7A is a schematic diagram of still another arrangement of the transmission according to the principles of the present invention; and
FIG. 7B is a chart showing feasible locations of the torque transmitting devices for the arrangement of the transmission shown in FIG. 7A .
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
Referring now to FIG. 1A , an embodiment of a multi-speed or eight speed transmission is generally indicated by reference number 10 . The transmission 10 is illustrated as a rear-wheel drive or longitudinal transmission, though various other types of transmission configurations may be employed. The transmission 10 includes a transmission housing 11 , an input shaft or member 12 , and an output shaft or member 14 . The input member 12 is continuously connected to an engine (not shown) or to a turbine of a torque converter (not shown). The output member 14 is continuously connected with a final drive unit (not shown) or transfer case (not shown).
The transmission 10 includes a first planetary gear set 16 , a second planetary gear set 18 , a third planetary gear set 20 , and a fourth planetary gear set 22 . The planetary gear sets 16 , 18 , 20 and 22 are connected between the input member 12 and the output member 14 . In a preferred embodiment of the present invention, the planetary gear set 16 includes a sun gear member 24 , a ring gear member 26 , and a planet carrier member 28 that rotatably supports a set of planet or pinion gears 30 (only one of which is shown). The pinion gears 30 are configured to intermesh with the sun gear member 24 and the ring gear member 26 . The sun gear member 24 is connected for common rotation with a first shaft or intermediate member 32 and a second shaft or intermediate member 34 . It should be appreciated that the first intermediate member 32 is connected for common rotation with the second intermediate member 34 and that the intermediate members 32 and 34 may form one single shaft or multiple shafts through one or more members of the planetary gear sets, as seen throughout the several views. The ring gear member 26 is connected for common rotation with a third shaft or intermediate member 36 . The planet carrier member 28 is connected for common rotation with a fourth shaft or intermediate member 38 .
The planetary gear set 18 includes a sun gear member 42 , a ring gear member 44 , and a planet carrier member 46 that rotatably supports a set of planet or pinion gears 48 . The pinion gears 48 are configured to intermesh with the sun gear member 42 and the ring gear member 44 . The sun gear member 42 is connected for common rotation with the second intermediate member 34 . The ring gear member 44 is connected for common rotation with a fifth shaft or intermediate member 50 . The planet carrier member 46 is connected for common rotation with the input member 12 .
The planetary gear set 20 includes a sun gear member 52 , a ring gear member 54 , and a carrier member 56 that rotatably supports a set of planet or pinion gears 58 . The pinion gears 58 are configured to intermesh with the sun gear member 52 and the ring gear member 54 . The sun gear member 52 is connected for common rotation with the fifth shaft or intermediate member 50 and with a sixth shaft or intermediate member 51 . It should be appreciated that the fifth intermediate member 50 is connected for common rotation with the sixth intermediate member 51 and that the intermediate members 50 and 51 may form one single shaft or multiple shafts through one or more members of the planetary gear sets, as seen throughout the several views. The ring gear member 54 is connected for common rotation with a seventh shaft or intermediate member 60 . The planet carrier member 56 is connected for common rotation with an eighth shaft or intermediate member 62 . It should be appreciated that the eighth intermediate member 62 is connected for common rotation with the output member 14 and that the eighth intermediate members 62 and the output member 14 may form one single shaft or multiple shafts through one or more members of the planetary gear sets, as seen throughout the several views.
The planetary gear set 22 includes a sun gear member 72 , a ring gear member 74 , and a planet carrier member 76 that rotatably supports a set of planet or pinion gears 78 . The pinion gears 78 are configured to intermesh with the sun gear member 72 and the ring gear member 74 . The sun gear member 72 is connected for common rotation with a ninth shaft or intermediate member 64 and a tenth shaft or intermediate member 66 . It should be appreciated that the ninth intermediate member 64 is connected for common rotation with the tenth intermediate member 66 and that the intermediate members 64 and 66 may form one single shaft or multiple shafts through one or more members of the planetary gear sets, as seen throughout the several views. The ring gear member 74 is connected for common rotation with the fourth intermediate member 38 . The planet carrier member 76 is connected for common rotation with the output member 14 and with the eighth intermediate member 62 .
The transmission 10 includes a variety of torque-transmitting mechanisms or devices including a first intermediate clutch C 1 , a second intermediate clutch C 2 , a third intermediate clutch C 3 , a first brake B 1 and a second brake B 2 . The first intermediate clutch C 1 is selectively engagable to connect the input member 12 to the tenth intermediate member 66 . Alternatively, the first intermediate clutch C 1 may be connected to the input member 12 through the planet carrier member 46 , as seen throughout the several views. The second intermediate clutch C 2 is selectively engagable to connect the sixth intermediate member 51 to the ninth intermediate member 64 . The third intermediate clutch C 3 is selectively engagable to connect the seventh intermediate member 60 to the ninth intermediate member 64 . The brake B 1 is selectively engagable to connect the first intermediate member 32 to the transmission housing 11 to restrict rotation of the first intermediate member 32 relative to the transmission housing 11 . Finally, the brake B 2 is selectively engagable to connect the third intermediate member 36 to the transmission housing 11 to restrict rotation of the third intermediate member 36 relative to the transmission housing 11 .
The transmission 10 is capable of transmitting torque from the input member 12 to the output member 14 in at least eight forward torque ratios and one reverse torque ratio. Each of the forward torque ratios and the reverse torque ratio are attained by engagement of one or more of the torque-transmitting mechanisms (i.e. first intermediate clutch C 1 , second intermediate clutch C 2 , third intermediate clutch C 3 , brake B 1 and brake B 2 ). Those skilled in the art will readily understand that a different speed ratio is associated with each torque ratio. Thus, eight forward speed ratios may be attained by the transmission 10 .
The transmission housing 11 includes a first end wall 102 , a second end wall 104 , and a third wall 106 . The third wall 106 interconnects between the first and second end walls 102 and 104 to provide a space or cavity 108 in which planetary gear sets 16 , 18 , 20 , and 22 and the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are located. Further, the cavity 108 has a plurality of areas or Zones A, B, C, D, E, and F in which the plurality of torque transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 will be specifically positioned, in accordance with the preferred embodiments of the present invention.
As shown in FIG. 1A and throughout the several views, Zone A is defined by the area or space bounded: axially on the left by the first end wall 102 , on the right by planetary gear set 16 , radially inward by a reference line “L” which is a longitudinal line that is axially aligned with the input shaft 12 , and radially outward by a reference line “M” which is a longitudinal line that extends adjacent an outer diameter or outer periphery of the planetary gear sets 16 , 18 , 20 , and 22 . While reference line “M” is illustrated as a straight line throughout the several views, it should be appreciated that reference line “M” follows the outer periphery of the planetary gear sets 16 , 18 , 20 , and 22 , and accordingly may be stepped or non-linear depending on the location of the outer periphery of each of the planetary gear sets 16 , 18 , 20 , and 22 . Zone B is defined by the area bounded: axially on the left by planetary gear set 16 , axially on the right by the planetary gear set 18 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone C is defined by the area bounded: axially on the left by the planetary gear set 18 , axially on the right by the planetary gear set 20 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone D is defined by the area bounded: axially on the left by the planetary gear set 20 , axially on the right by the planetary gear set 22 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone E is defined by the area bounded: axially on the left by the planetary gear set 22 , axially on the right by the second end wall 104 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone F is defined by the area bounded: axially on the left by the first end wall 102 , axially on the right by the second end wall 104 , radially inward by reference line “M” and radially outward by the third wall 106 . As will be described and illustrated hereinafter, planetary gear sets 16 , 18 , 20 , and 22 will change positions within the transmission cavity 108 , however, the Zones described above will not change and will remain the same as shown throughout the Figures.
In the arrangement of the transmission 10 shown in FIG. 1A , the planetary gear sets 16 , 18 , 20 , and 22 are longitudinally arranged in the following order from left to right: 16 - 18 - 20 - 22 . Specifically, the planetary gear set 16 is disposed closest to the wall 102 , the planetary gear set 22 is disposed closest to the wall 104 , the planetary gear set 18 is adjacent the planetary gear set 16 , and the planetary gear set 20 is disposed between the planetary gear sets 18 and 22 . The torque-transmitting mechanisms are intentionally located within specific Zones in order to provide advantages in overall transmission size, packaging efficiency, and reduced manufacturing complexity. In the particular example shown in FIG. 1A , the torque-transmitting mechanism C 1 is disposed within Zone C, the torque-transmitting mechanisms C 2 and C 3 are disposed within Zone D, and the torque-transmitting mechanisms B 1 and B 2 are disposed within Zone F.
However, the present invention contemplates other embodiments where the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are disposed in the other Zones. The feasible locations of the torque-transmitting devices C 1 , C 2 , C 3 , B 1 , and B 2 relative to the Zones are illustrated in the chart shown in FIG. 1B . An “X” in the chart indicates that the present invention contemplates locating the particular torque-transmitting device in any of the referenced Zones.
With reference to FIG. 1C , an alternate embodiment of the multi-speed transmission is indicated by reference number 10 B. The transmission 10 B includes the planetary gear sets 16 , 18 , 20 , and 22 and the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 . The various components and connecting shafts that are identical with the transmission 10 in FIG. 1A have the same numerical designation.
The transmission 10 B includes the planetary gear sets 16 , 18 , 20 , and 22 longitudinally arranged identically to the arrangement shown in FIG. 1A . However, in the particular example shown in FIG. 1C , the torque-transmitting mechanisms C 1 and C 2 are disposed within Zone B. As in the previous embodiment, the torque-transmitting mechanism C 3 is disposed within Zone D and the torque-transmitting mechanisms B 1 and B 2 are disposed within Zone F.
Additionally, the present invention contemplates other embodiments of transmission 10 B where the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are disposed in the other Zones. The feasible locations of the torque-transmitting devices C 1 , C 2 , C 3 , B 1 , and B 2 relative to the Zones are illustrated in the chart shown in FIG. 1D . An “X” in the chart indicates that the present invention contemplates locating the particular torque-transmitting device in any of the referenced Zones.
Turning now to FIG. 2A , still another embodiment of the multi-speed transmission is indicated by reference number 200 . The transmission 200 includes the planetary gear sets 16 , 18 , 20 , and 22 and the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 . The various components and connecting shafts that are identical with the transmission 10 in FIG. 1A have the same numerical designation in FIG. 2A .
The transmission 200 includes the planetary gear sets 16 , 18 , 20 , and 22 longitudinally arranged in the following order from left to right: 18 - 20 - 16 - 22 . Specifically, the planetary gear set 18 is disposed closest to the wall 102 , the planetary gear set 22 is disposed closest to the wall 104 , the planetary gear set 20 is adjacent the planetary gear set 18 , and the planetary gear set 16 is disposed between the planetary gear sets 20 and 22 . The torque-transmitting mechanisms are intentionally located within specific Zones in order to provide advantages in overall transmission size, packaging efficiency, and reduced manufacturing complexity. In the particular example shown in FIG. 2A , the torque-transmitting mechanisms C 1 and C 2 are disposed within Zone A, the torque-transmitting mechanism C 3 is disposed within Zone C, and the torque-transmitting mechanisms B 1 and B 2 are disposed within Zone F.
However, the present invention contemplates other embodiments of the transmission 200 where the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are disposed in the other Zones. The feasible locations of the torque-transmitting devices C 1 , C 2 , C 3 , B 1 , and B 2 relative to the Zones are illustrated in the chart shown in FIG. 2B . An “X” in the chart indicates that the present invention contemplates locating the particular torque-transmitting device in any of the referenced Zones.
With reference to FIG. 3A , still another embodiment of the multi-speed transmission is indicated by reference number 300 . The transmission 300 includes the planetary gear sets 16 , 18 , 20 , and 22 and the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 . The various components and connecting shafts that are identical with the transmission 10 in FIG. 1A have the same numerical designation in FIG. 3A .
The transmission 300 includes the planetary gear sets 16 , 18 , 20 , and 22 longitudinally arranged identically to the arrangement shown in FIG. 2A . However, the input shaft 12 is arranged such that it crosses the boundary between Zones A and F. In the particular example shown in FIG. 3A , the torque-transmitting mechanisms C 1 and C 2 are disposed within Zone A, the torque-transmitting mechanism C 3 is disposed within Zone C, and the torque-transmitting mechanisms B 1 and B 2 are disposed within Zone F.
However, the present invention contemplates other embodiments of the transmission 300 where the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are disposed in the other Zones. The feasible locations of the torque-transmitting devices C 1 , C 2 , C 3 , B 1 , and B 2 relative to the Zones are illustrated in the chart shown in FIG. 3B . An “X” in the chart indicates that the present invention contemplates locating the particular torque-transmitting device in any of the referenced Zones.
With reference to FIG. 4A , still another embodiment of the multi-speed transmission is indicated by reference number 400 . The transmission 400 includes the planetary gear sets 16 , 18 , 20 , and 22 and the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 . The various components and connecting shafts that are identical with the transmission 10 in FIG. 1A have the same numerical designation in FIG. 4A .
The transmission 400 includes the planetary gear sets 16 , 18 , 20 , and 22 longitudinally arranged in the following order from left to right: 18 - 16 - 20 - 22 . Specifically, the planetary gear set 18 is disposed closest to the wall 102 , the planetary gear set 22 is disposed closest to the wall 104 , the planetary gear set 16 is adjacent the planetary gear set 18 , and the planetary gear set 20 is disposed between the planetary gear sets 16 and 22 . The torque-transmitting mechanisms are intentionally located within specific Zones in order to provide advantages in overall transmission size, packaging efficiency, and reduced manufacturing complexity. In the particular example shown in FIG. 4A , the torque-transmitting mechanisms C 1 and C 2 are disposed within Zone A, the torque-transmitting mechanism C 3 is disposed within Zone C, and the torque-transmitting mechanisms B 1 and B 2 are disposed within Zone F.
However, the present invention contemplates other embodiments of the transmission 400 where the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are disposed in the other Zones. The feasible locations of the torque-transmitting devices C 1 , C 2 , C 3 , B 1 , and B 2 relative to the Zones are illustrated in the chart shown in FIG. 4B . An “X” in the chart indicates that the present invention contemplates locating the particular torque-transmitting device in any of the referenced Zones.
With reference to FIG. 5A , still another embodiment of the multi-speed transmission is indicated by reference number 500 . The transmission 500 includes the planetary gear sets 16 , 18 , 20 , and 22 and the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 . The various components and connecting shafts that are identical with the transmission 10 in FIG. 1A have the same numerical designation in FIG. 5A .
The transmission 500 includes the planetary gear sets 16 , 18 , 20 , and 22 longitudinally arranged in the following order from left to right: 18 - 16 - 22 - 20 . Specifically, the planetary gear set 18 is disposed closest to the wall 102 , the planetary gear set 20 is disposed closest to the wall 104 , the planetary gear set 16 is adjacent the planetary gear set 18 , and the planetary gear set 22 is disposed between the planetary gear sets 16 and 20 . The torque-transmitting mechanisms are intentionally located within specific Zones in order to provide advantages in overall transmission size, packaging efficiency, and reduced manufacturing complexity. In the particular example shown in FIG. 5A , the torque-transmitting mechanisms C 1 and C 2 are disposed within Zone A, the torque-transmitting mechanism C 3 is disposed within Zone D, and the torque-transmitting mechanisms B 1 and B 2 are disposed within Zone F.
However, the present invention contemplates other embodiments of the transmission 500 where the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are disposed in the other Zones. The feasible locations of the torque-transmitting devices C 1 , C 2 , C 3 , B 1 , and B 2 relative to the Zones are illustrated in the chart shown in FIG. 5B . An “X” in the chart indicates that the present invention contemplates locating the particular torque-transmitting device in any of the referenced Zones.
With reference to FIG. 6A , still another embodiment of the multi-speed transmission is indicated by reference number 600 . The transmission 600 includes the planetary gear sets 16 , 18 , 20 , and 22 and the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 . The various components and connecting shafts that are identical with the transmission 10 in FIG. 1A have the same numerical designation in FIG. 6A .
The transmission 600 includes the planetary gear sets 16 , 18 , 20 , and 22 longitudinally arranged in the following order from left to right: 20 - 18 - 16 - 22 . Specifically, the planetary gear set 20 is disposed closest to the wall 102 , the planetary gear set 22 is disposed closest to the wall 104 , the planetary gear set 18 is adjacent the planetary gear set 20 , and the planetary gear set 16 is disposed between the planetary gear sets 18 and 22 . The torque-transmitting mechanisms are intentionally located within specific Zones in order to provide advantages in overall transmission size, packaging efficiency, and reduced manufacturing complexity. In the particular example shown in FIG. 6A , the torque-transmitting mechanisms C 1 , C 2 , B 1 , and B 2 are disposed within Zone F, and the torque-transmitting mechanism C 3 is disposed within Zone A.
However, the present invention contemplates other embodiments of the transmission 600 where the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are disposed in the other Zones. The feasible locations of the torque-transmitting devices C 1 , C 2 , C 3 , B 1 , and B 2 relative to the Zones are illustrated in the chart shown in FIG. 6B . An “X” in the chart indicates that the present invention contemplates locating the particular torque-transmitting device in any of the referenced Zones.
With reference to FIG. 7A , still another embodiment of the multi-speed transmission is indicated by reference number 700 . The transmission 700 includes the planetary gear sets 16 , 18 , 20 , and 22 and the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 . The various components and connecting shafts that are identical with the transmission 10 in FIG. 1A have the same numerical designation in FIG. 7A .
The transmission 700 includes the planetary gear sets 16 , 18 , 20 , and 22 longitudinally arranged in the following order from left to right: 20 - 22 - 18 - 16 . Specifically, the planetary gear set 20 is disposed closest to the wall 102 , the planetary gear set 16 is disposed closest to the wall 104 , the planetary gear set 22 is adjacent the planetary gear set 20 , and the planetary gear set 18 is disposed between the planetary gear sets 22 and 16 . The torque-transmitting mechanisms are intentionally located within specific Zones in order to provide advantages in overall transmission size, packaging efficiency, and reduced manufacturing complexity. In the particular example shown in FIG. 7A , the torque-transmitting mechanisms C 1 , C 2 , and C 3 are disposed within Zone B, the torque-transmitting mechanism B 1 is disposed within Zone F, and the torque-transmitting mechanism B 2 is disposed within Zone E.
However, the present invention contemplates other embodiments of the transmission 700 where the torque-transmitting mechanisms C 1 , C 2 , C 3 , B 1 , and B 2 are disposed in the other Zones. The feasible locations of the torque-transmitting devices C 1 , C 2 , C 3 , B 1 , and B 2 relative to the Zones are illustrated in the chart shown in FIG. 7B . An “X” in the chart indicates that the present invention contemplates locating the particular torque-transmitting device in any of the referenced Zones.
The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A transmission is provided having an input member, an output member, four planetary gear sets, a plurality of coupling members and a plurality of torque transmitting devices. Each of the planetary gear sets includes a sun gear member, a planet carrier member, and a ring gear member. The torque transmitting devices include clutches and brakes arranged within a transmission housing.
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