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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a mobile communications system, and in particular to a method for assigning a communication channel to a mobile terminal according to a carrier sensing scheme.
2. Description of the Related Art
Recently, to achieve effective use of available frequencies, a cellular communications system has employed such a channel assignment scheme that each cell station can assign one of all available channels to a mobile terminal even at the same frequency when it is determined that the degree of interference is sufficiently low at that frequency. Such a channel assignment scheme is called autonomous decentralized dynamic channel assignment.
In the case of personal communications system such as PHS (Personal Handy-phone System), TDMA/TDD (Time Division Multiple Access/Time Division Duplex) scheme has been employed. It is determined whether no interference occurs in a selected channel and, if no interference, then the selected channel is assigned to the mobile terminal which has requested a communication channel. On the other hand, at the mobile terminal, it is determined whether no interference occurs in the assigned channel and, if no interference, then communication is started at the assigned channel. Such a dynamic channel assignment method is called a carrier-sense channel assignment method. It should be noted that the cell station performs the carrier sensing operation, that is, detects interference level only at the timing of receiving.
An improved carrier sensing channel assignment method has been proposed in Japanese Patent Unexamined Publication No. 7-212821. According to the improved method, when searching for a communication channel, a cell station performs the carrier sensing operation not only at receiving timing but also at transmitting timing. If the interference levels at receiving and transmitting timing are lower than a predetermined threshold, the communication is started using the assigned channel. In other words, the cell station can detect interference levels in both up-link and down-link channels before starting the communication. Therefore, the probability of call loss is reduced, compared with the above method.
However, even the improved method cannot detect accurate CIR (carrier-interference ratio) at the mobile station because power reduction of radio propagation between the cell station and the mobile terminal is not taken into account. Therefore, to assign a communication channel to each mobile terminal located within the cell using the same channel assignment algorithm, it is necessary to set the interference threshold level of up-link channels to a relatively low level. When the interference threshold level is set low, there may be cases where the cell station erroneously determines that the interference of a selected channel occurs at the mobile terminal though the CIR of the selected channel is sufficiently high at the mobile terminal. In such cases, the number of available channels is reduced, resulting in increased probability of call loss.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a channel assignment method which can reduce the probability of call loss.
Another object of the present invention is to provide a channel assignment method which can improve use of frequencies by allocating communication channels with reliability.
According to the present invention, a communication channel is dynamically assigned to a mobile station in each base station of TDMA/TDD (Time Division Multiple Access/Time Division Duplex) communications system. When receiving a control signal from the mobile station, an interference detection criterion is determined depending on a signal strength of the control signal. After selecting a channel from a plurality of predetermined channels, it is determined whether interference occurs in a selected transmitting time slot relative to the interference detection criterion in a selected channel, and further determined whether interference occurs in a selected receiving time slot relative to a predetermined interference detection criterion in the selected channel. The selected channel is assigned as a communication channel to the mobile station when it is determined that no interference occurs in the selected transmitting and receiving time slots.
According to the present invention, it is determined whether interference occurs in a selected transmitting time slot using the interference detection criterion which varies depending on the control signal received from the mobile station. And when it is determined that no interference occurs in the selected transmitting and receiving time slots, the selected channel is assigned to the mobile station. Therefore, there is little probability that the mobile station detects interference when receiving, resulting in improved channel connection probability and reduced call loss probability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a cellular communications system employing an embodiment of a channel assignment method according to the present invention;
FIG. 2 is a flowchart showing the embodiment according to the present invention;
FIG. 3 is diagram showing an interference detection criteria table for explanation of interference detection criteria conversion in the embodiment; and
FIG. 4 is a time chart showing TDMA/TDD format at the cell station for explanation of carrier sensing timing in the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a PHS system has a plurality of cell stations each forming a micro-cell and each cell station (CS) 10 can communicate with a personal station (PS) 30 located in the micro-cell 20 thereof.
The cell station 10 is comprised of a radio transceiver 101 and a channel controller 102 which performs channel control according to TDMA/TDD scheme. When receiving a radio signal from the personal station 30, the radio transceiver 101 outputs demodulated data and the corresponding signal level to the channel controller 102. The cell station 10 is further comprised of a processor 103 which controls the operations of the cell station 10 including the carrier sensing dynamic channel assignment. The processor 103 performs the carrier sensing dynamic channel assignment using a priority table 104 and an interference detection criteria table 105 as will be described later. Further, the processor 103 performs the operation control by running control programs including the carrier sensing dynamic channel assignment which are previously stored in a memory (not shown).
The priority table 104 stores a priority value for each channel so as to search for channels in order of decreasing priority. The priority table 104 is updated each time channel assignment is performed as will be described later.
As shown in FIG. 2, the interference detection criteria table 105 contains the relationship between received signal levels and interference detection criteria so as to search for an interference detection criterion L TH corresponding to a received signal level. The higher the received signal level, the higher the interference detection criterion L TH . More specifically, when the received signal level falls into a range from 10 dB to 20 dB, the interference detection criterion L TH is set to a lower criterion level 10 dBμV. When the received signal level increases to a range from 40 dB to 50 dB, the interference detection criterion L TH also increases to a higher criterion level 40 dBμV. Therefore, the interference determination can be properly performed depending on the received signal level.
Referring to FIG. 3, the personal station 30 transmits a link channel establishment request signal to the cell station 10 using the up-link control channel when registering its location, calling, called, and performing band-over between cell stations (step S201). When receiving the link channel establishment request signal, the processor 103 of the cell station 10 converts the received signal level of the up-link control channel to the corresponding interference detection criterion L TH by referring to the interference detection criteria table 105 (step S202). The interference detection criterion L TH is stored onto a memory (not shown).
Subsequently, the processor 103 selects one of available frequency channels to perform the carrier sensing operation by referring to the priority table 104 (step S203). More specifically, the processor 103 searches the priority table 104 for an available channel having the highest priority at that time.
When such a channel is selected, the selected channel CH is subjected to the carrier sensing at transmitting and receiving timing. The respective received signal levels at receiving and transmitting timing are stored as interference levels IL UP and IL DOWN onto the memory (step S204). As will be described later, the carrier sensing is performed over consecutive four frames at the transmitting and receiving timing (see FIG. 4).
Thereafter, the processor 103 compares the interference level IL DOWN of the transmitting timing to the interference detection criterion L TH obtained in the step S202 to determine whether IL DOWN is smaller than L TH (step S205). If IL DOWN is smaller than L TH during four consecutive frames (YES in step S205), then the processor 103 further compares the interference level IL UP of the receiving timing to interference level L STD1 to determine whether IL UP is smaller than L STD1 (step S206). The interference level L STD1 of 26 dBμV is provided by Japanese standards RCR-STD28.
When IL DOWN is not smaller than L TH during at least one frame (NO in step S205) or when IL UP is not smaller than L STD1 during at least one frame (NO in step S206), the processor 103 decreases the priority of the selected channel CH (step S207) and the control goes back to the step S203 where another channel is selected referring to the priority table 104. In this manner, the steps S203-S207 are repeatedly performed while searching the priority table 104 until an acceptable channel is found.
If IL UP is smaller than L STD1 during four consecutive frames (YES in step S206), then the selected channel CH is allowed to be assigned to the personal station 30. More specifically, the cell station 10 transmits a link channel assignment signal to the personal station 30 using down-link control channel (step S208).
When receiving the link channel assignment signal, the personal station 30 is set to the assigned channel CH and performs the carrier sensing in the assigned channel CH at receiving timing (step S209). The received signal level at receiving timing is stored as interference level IL H-DOWN onto a memory. The carrier sensing is performed over consecutive four frames at receiving timing.
Thereafter, the interference level IL H-DOWN is compared to interference level L STD2 to determine whether IL H-DOWN is smaller than L STD2 over consecutive four frames (step S210). The interference level L STD2 of 26 dBμV is provided by Japanese standards RCR-STD28.
When IL H-DOWN is not smaller than L STD2 during at least one frame (NO in step S210), the control goes back to the step S201 where the personal station 30 transmits a link channel establishment request signal to the cell station 10 again.
If IL H-DOWN is smaller than L STD2 during four consecutive frames (YES in step S210), then the personal station 30 starts communicating with the cell station 10 using the assigned channel CH (step S211).
At the cell station 10, when the communication is started, the processor 103 increases the priority of the assigned channel in the priority table 104 (step S212).
Referring to FIG. 4, in the case where time slots T3 and R3 are used for transmitting and receiving timing of the cell station 10, respectively, the carrier sensing is performed at the timing of time slot T3 to detect the interference level IL DOWN for consecutive four frames and at the timing of time slot R3 to detect the interference level IL UP for consecutive four frames.
The detected interference levels IL DOWN1 -IL DOWN4 and IL UP1 -IL UP4 are used to determine whether the selected channel is adequate for communication as described in steps S205 and S206 of FIG. 3. More specifically, if all the transmitting-timing interference levels IL DOWN1 -IL DOWN4 are smaller than L TH (YES in step S205), then the processor 103 further compares each of the receiving-timing interference levels IL UP1 -IL UP4 to interference level L STD1 of 26 dBμV (step S206). If all the receiving-timing interference levels IL UP1 -IL UP4 are smaller than L STD1 (YES in step S206), then the selected channel CH is allowed to be assigned to the personal station 30. Contrarily, if at least one of IL DOWN1 -IL DOWN4 is not smaller than L TH (NO in step S205) or when at least one of IL UP1 -IL UP4 is not smaller than L STD1 (NO in step S206), the processor 103 decreases the priority of the selected channel CH (step S207) and the control goes back to the step S203.
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A communication channel is dynamically assigned to a mobile station in autonomous decentralized channel assignment in TDMA/TDD communications system. An interference detection criterion is determined depending on a signal strength of a call request signal. It is determined whether interference occurs in a transmitting time slot relative to the interference detection criterion in a selected channel, and further determined whether interference occurs in a receiving time slot relative to a predetermined interference detection criterion in the selected channel. When it is determined that no interference occurs in the selected transmitting and receiving time slots, the selected channel is assigned to the mobile station.
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FIELD OF THE INVENTION
This invention relates generally to a longitudinally extendible front end for an automotive vehicle and, more particularly, to a locking structure for the telescopically extendible rails to transfer impact forces to the frame of the vehicle.
BACKGROUND OF THE INVENTION
The front end structure of an automotive vehicle is designed to provide visual appeal to the vehicle owner while functioning as an energy absorbing structure during frontal and offset crashes. The size, shape and construction of the front end structure contribute to the ability of the front end structure to attenuate the crash pulse and restrict intrusions into the operator's cabin of the vehicle. It is important to design a front end structure to absorb crash energy through the most effective structural components, which is a front rail system. To that extent, a significant amount of effort by vehicle engineers is devoted to designing the front rails to crush in a controlled manner while absorbing a maximum amount of energy. If additional energy absorption is required, adding length to the front rails is the next logical engineering consideration. Even though longer front rails are desirable for efficient energy management, this option is usually commercially unacceptable to the vehicle customer because resulting structure is considered to be visually unattractive, increases the vehicle overall length and reduces vehicle parking maneuverability.
One of the goals in the design of vehicle frame structure is to provide better engagement and absorption of energy during a collision. The major components in absorbing energy in frontal as well as rear impacts are the rails. Furthermore, in a side collision if the vehicle has a softer front end it can help mitigate the injuries to occupants in both vehicles. If there is an apparatus to absorb more energy and prolong the time to crush the rails, the crash pulse and intrusion can be reduced significantly. With a longer front end structure on a vehicle, there is potential to achieve this goal. A secondary aspect to extending the front end structure is to localize less severe crash damage into a few local parts that are easily repairable or replaceable. A significant problem, however, is providing the extendible front end is to do so without changing other critical design aspects, such as styling and dimensions of a vehicle, that are critical to both the manufacturer and the customer.
Alternative engineering design can provide larger bumpers, deployable bumper airbags, and rails with pyrotechnique methods etc., which can have styling and packaging issues or require sensors to activate and can lead to high repair costs in the case of a false deployment of the known prior art systems. For these reasons, such alternative systems have not met with commercial acceptance. Accordingly, attempts have been made to provide a selectively extendible bumper structure that is operable to move the bumper from an aesthetically pleasing position to an extended position that positions the bumper at a significant distance from the retracted position. Such extendible bumper structures have been associated with a speed sensor such that the bumper extends automatically in response to the attainment of a preselected speed criteria.
One such extendible bumper structure can be found in U.S. Pat. No. 6,773,044, issued on Aug. 10, 2004, to John E. Schambre, et al, in which the front bumper is supported on telescopically extendible rails that move the front bumper forwardly when the vehicle reaches a predetermined speed. Drive cables and a worm gear assembly drive a ball screw cam into a locking mechanism inside the movable rail pieces. The locking links are driven outwardly by the ball screw cam to extend through slots aligned in the fixed and movable rail pieces so that crash forces can be transferred from the movable rail piece to the fixed rail piece during an impact.
The extendable rails disclosed in the Schambre patent are driven by a cable mechanism and a drive motor located inside the bumper. Accordingly, this bumper beam needs to be designed to have enough package space to house these components. Providing the space to house these components is an added design requirement for the bumper. The locking mechanism is one of the most critical components to manage energy during a frontal impact. The material that is removed in the fixed and movable rails to make slots for the locking links is significant. Locking links as disclosed in the Schambre patent need to be very strong and the resulting slot area becomes considerably large. As a result, the rail pieces become locally weaker at the slots and would have a tendency to bend during collision, especially when an offset impact is incurred.
Another extendible bumper structure is found in U.S. Pat. No. 6,709,035, issued to Chandra Namuduri on Mar. 23, 2004. The Namuduri extendable rail pieces are assembled inside a secondary casing which is mounted inside the base frame rail defining three sheet metal parts with closed cross sections at the front of the bumper when the rails are in a retracted position. The extendable rail travels inside the middle (secondary) rail casing which is rigidly attached to the outer frame rail. The actuating mechanism works with a lead screw that connects to a drive motor and a nut. The nut is connected to the inside end of the movable rail piece through a self-locking mechanism that works with a plurality of small spheres sliding on a tapered bushing. These spheres tightly constraint the extendable rail and the secondary casing during an impact.
The Namuduri bumper energy absorber for supporting the bumper structure relative to a vehicle includes an inner tube, an outer tube, a lead screw, a nut and a motor. Rotation of the lead screw by the rotor causes translation of the nut along the lead screw for driving at least a portion of the bumper structure between extended and retracted positions. When the extendable rail is moving outward and inward, respectively, a sensing and controller system is used to control the position of the two moving rail pieces. The degree of extension can be controlled by various parameters via sensors, including gear position, vehicle speed, obstacle range, approach rate and hard braking. With respect to crash energy management and efficiency of the system, having three tubes in the retracted position is not desirable and also add unnecessary weight and cost of manufacturing. The positioning of the motor mechanism installed inside the rails take up a considerable length and would not crush due to the many metal pieces in the motor, drive and the constraint mechanism. Furthermore, the movable rails need to be of a considerable size to adsorb a significant amount of energy during impact. Hence, the resulting complete mechanism becomes larger than a current front end and may not be suitable for vehicle design, especially for small vehicles.
U.S. Pat. No. 5,967,573, issued on Oct. 19, 1999, and related U.S. Pat. No. 6,302,458 issued on Oct. 16, 2001, and U.S. Pat. No. 6,401,565 issued on Jun. 11, 2002, all of which are issued to Jenne-Tai Wang, et al., disclose an extendible front bumper structure that actuates upon attainment of a pre-established speed criteria through a rack and pinion mechanism. The extendible rail structure is locked against the fixed rail structure by a plurality of small spheres that slide on a tapered bushing. These spheres deform the outer tube to absorb energy upon impact. U.S. Pat. No. 6,834,898, granted on Dec. 28, 2004, to Jenne-Tai Wang, et al, discloses similar structure having increased stiffness by mounting the actuator inside the tubular frame rail member. U.S. Pat. No. 6,976,565, granted to Paul Meernik et al, on Dec. 20, 2005, discloses a spring-loaded apparatus for absorbing energy in an extendible bumper apparatus as disclosed in the above-identified Wang patents.
Another configuration for an extendible bumper system can be found in U.S. Pat. No. 6,976,718, issued to Isumu Nakanishi on Dec. 20, 2005, in which an electric motor drives a threaded actuator rod to extend the front bumper from a retracted position to an extended position. The bumper apparatus incorporates an electromagnetic lock mechanism and a deformable, energy absorbing shaft to absorb impact forces encountered by the bumper apparatus.
It would be desirable to provide an extendible bumper for an automotive vehicle that incorporates a locking mechanism to transfer any crash forces encountered by the extended bumper to the frame of the vehicle. Such an extendible rail system would provide a rail extension apparatus and a control for extending the rails to improve crash energy management without affecting the visual appeal of the vehicle when stopped or at low speeds. The extendible rail system would be applicable to front or rear bumpers on an automotive vehicle.
SUMMARY OF THE INVENTION
It is an object of this invention to overcome the aforementioned disadvantages of the known prior art by providing an extendible bumper apparatus that incorporates wedge members that transfer crash forces to the frame of the vehicle.
It is another object of this invention to provide a tab mechanism that projects outwardly from the actuating mechanism for extending the telescopic rails supporting the extendible bumper to engage the wedge members transferring crash forces to the frame of the vehicle.
It is yet another object of this invention to provide a reliable and robust rail/bumper extension system that can work independently and does not depend on expensive sensing technology to be operable to deploy when a crash is encountered.
It is a feature of this invention to provide an extendable rail mechanism that provides an increase in crushable rail length.
It is an advantage of this invention that the extendible rail mechanism increases the energy absorption capability of the crushable rail structure of an automotive frame.
It is another advantage of this invention that the extendible rail structure retracts at low vehicle speeds for vehicle appearance and easy parking.
It is another feature of this invention to provide a semi-active deployment system for an extendible rail mechanism in which the extendible rail activates and extends based on minimal input signals.
It is still another advantage of this invention that the actuators added to provide an extendible rail mechanism do not adversely impact the crush capability of the vehicle frame rail system on which the extendible rail mechanism is mounted.
It is yet another advantage of this invention that the crash characteristic of the bumper is not adversely affected when the extendable rail mechanism is retracted and contained within the existing vehicle frame rail.
It is still another feature of this invention that the extendible rail is formed with a rectangular dog-bone shape so that the extensible rail will crush during an oblique crash in a manner similar to the base rail system.
It is still another advantage of this invention that the extendable rail can absorb energy in either the fully retracted or fully extended position.
It is yet another feature of this invention that the retracted extensible rail does not impose any significant restraints on the ability of the base frame rail apparatus to absorb crash energy.
It is a further advantage of this invention that the additional length of the extended rail apparatus will add energy absorption capability to the base rail apparatus of the vehicle.
It is a further feature of this invention that a positive interlock feature is enabled when the rail is fully extended to transfer crash energy into the base frame rail mechanism.
It is still a further feature of this invention that the interlock mechanism self-releases when disengaging to allow the extended rail to return to its at rest and retracted position.
It is yet a further feature of this invention that the extendible rail mechanism includes a guide and support system for minimizing sliding friction to minimize the effort needed to effect rail extension.
It is another feature of this invention that an electric motor provides the energy required for moving the extension rail with the bumper attached thereto, but is not part of the self-locking feature except for being operatively connected thereto for driving the tabs into engagement with the wedge members for self-locking the extensible rail mechanism.
It is yet a further advantage of this invention that the actuation motor can be used to provide both position and load feedback to confirm and continuously monitor the position of the extendible rail deployment, thereby providing a means of diagnostics to ensure the system is functional and ready to absorb energy when needed.
It is still another advantage of this invention that the interaction of the projectable tabs and the engaged wedge members provides a locking mechanism for the extendible bumper apparatus to transfer crash forces to the base frame of the vehicle.
It is still another feature of this invention that the tabs project through small slots formed in the extensible rail when the rail has been fully extended.
It is yet another feature of this invention that the actuator includes a conical member for driving the tabs outwardly into engagement with the wedge members when the extensible rail reaches the end of its extensible movement.
It is a further object of this invention to provide an extensible rail system incorporating a self-locking mechanism that is durable in construction, inexpensive of manufacture, carefree of maintenance, facile in assemblage, and simple and effective in use.
These and other objects, features and advantages are accomplished according to the instant invention by providing an extendible rail and bumper apparatus that is mountable within the existing base frame lower rails of an automotive frame to provide an improved crash force absorbing bumper apparatus for deployment on either the front or rear bumpers of an automobile. The extendible rail member is mounted for telescopic movement through slidable guide members. A front plate is formed with wedge members positioned next to the extendible rail member. The actuation mechanism includes an electric motor that rotates a threaded rod having a conical member mounted thereon for translational movement thereon. The conical member engages a pair of outwardly projectable tabs that are driven outwardly into engagement with the wedge members when the extendible rail is fully extended. If required to absorb impact energy, the outwardly projected tabs push the wedge members into engagement with the front plate to transfer the energy into the base frame rail apparatus of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of this invention will become apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a perspective view of an extendible rail mechanism according to the principles of the instant invention, mounted in the base lower frame rail of an automotive vehicle, the extendible rail member being shown in a retracted position;
FIG. 2 is a perspective view of an extendible rail mechanism similar to that of FIG. 1 , but showing the extendible rail member in an extended position;
FIG. 3 is a partial perspective view of the bumper mounted on the extendible rail mechanism with the extendible rail being retracted into the fixed rail member;
FIG. 4 is a perspective detail view of the actuation mechanism, including the electric motor, threaded rod, base plate for the extendible rail and the outwardly projectable tabs alignable with the wedge members when the extendible rail is fully extended, as is depicted herein;
FIG. 5 is a partial cross-sectional view of the extendible rail mechanism showing the base plate of the extendible rail and the front plate taken at the point the extendible rail reaches full extension but immediately before the tabs are driven outwardly into alignment with the wedge members;
FIG. 6 is an elevational view of the extendible rail mechanism corresponding to the position of the base member as depicted in FIG. 5 ;
FIG. 7 is a partial cross-sectional view of the extendible rail mechanism showing the base plate of the extendible rail and the front plate taken at the point the extendible rail reaches full extension and after the tabs are driven outwardly by the conical actuator into alignment with the wedge members; and
FIG. 8 is an elevational view of the extendible rail mechanism corresponding to the position of the base member as depicted in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-8 , an extendible rail and bumper apparatus incorporating the principle of the instant invention can best be seen. The extendible rail apparatus 10 is mounted in the base lower frame rails F of an automotive vehicle. The extendible rail apparatus 10 can be packaged within a typical existing front rail cavity without significant changes or obstructing packaging and attachment points to other front end components such as radiator, cross members etc. The extendible rail apparatus 10 is preferably constructed as a module that is firmly secured to the fixed front rail end by a back plate 12 and a front plate 22 . Each laterally spaced lower front rail F of the automobile will be provided with a separate module 10 with the forwardly projecting ends of the movable rail member 20 being connected to the bumper system B so that the bumper B extends and retracts with the movable rail members 20 .
The modular extendible rail apparatus 10 is supported within the lower frame rail F by a back plate 12 and a forwardly positioned front plate 22 on which are mounted a pair of laterally spaced slide support members 15 . A movable rail member 20 is housed within the lower frame rail F and slidably supported on the slide support members 15 for movement in a fore-and-aft direction. The movable rail member 20 has a pair of glide members 25 that are attached to the respective lateral sides of the movable rail member 20 and slidably supported within the support members 15 . In this configuration, the movable rail member 20 is linearly movable between a retracted position, as seen in FIG. 1 where the movable rail 20 lies between the back and front plates 12 , 22 , and an extended position, as shown in FIG. 2 where a substantial portion of the movable rail member 20 is located forwardly of the front plate 22 .
Movement of the movable rail member 20 is powered through an electric motor 27 that is mounted behind the back plate 12 and operatively coupled to the electrical system of the automobile and operatively controlled through a control mechanism described in greater detail below. The motor 27 is connected to a threaded rod 29 , as is best seen in FIG. 4 , through a worm gear mechanism and extends forwardly from the motor 27 through the back plate 12 into engagement with an actuator mechanism 30 . As will be described in greater detail below, the operation of the electric motor 27 drives the rotation of the threaded rod 29 to move the actuation mechanism 30 forwardly or rearwardly, depending on the direction of rotation of the threaded rod 29 .
The back plate 12 and the motor 27 are placed in front of a spacer reinforcement bracket S that is part of the design of the lower frame rail F. The motor 27 is mounted generally perpendicularly to the fixed lower frame rail F and the longitudinally extending slide support rails 15 and does not hinder the crush zone of the lower frame rail F. When the movable rail 20 is moved into the extended position, the movable rail is locked into engagement with the lower frame rails F through the actuation mechanism 30 , as will be described below, and provides an additional crush zone forwardly of the lower frame rail F to provide the capability of absorbing additional energy from an impact.
The actuation mechanism 30 is best seen in FIGS. 5-8 and is formed with a drive plate 32 that is secured to the rearward portion of the movable rail member 20 . A conical drive member 35 is threadably mounted on the threaded rod 29 for translational movement along the rod 29 when the rod 29 is rotated by the electric motor 27 . The conical drive member 35 includes a shaft portion 36 that is slidably received through an opening in the drive plate 32 and terminates in a conical cam member 37 positioned forwardly of the drive plate 32 . The conical cam member 37 is too large to move rearwardly through the opening in the drive plate 32 and forms an apex at the forwardmost point thereof. A spring 38 is mounted on the shaft portion 36 rearwardly of the drive plate 32 and is retained in position on the shaft portion 36 by a keeper nut 39 affixed to the rearward end of the shaft portion 36 . The spring 38 exerts a biasing force on the keeper nut 39 to urge the keeper nut 39 rearwardly and, thus, force the conical cam member 37 against the drive plate 32 .
The drive plate 32 has mounted on a forward side thereof a pair of vertically spaced locking members 40 that are retained on the drive plate 32 by respective fasteners 42 positioned within slots 43 formed in the locking members 40 to allow vertical movement of the locking members 40 relative to the drive plate 32 . Each locking member 40 is formed with a pair of tabs 45 that correspond to openings formed in the top and bottom surfaces, respectively, of the movable rail member 20 . A biasing spring 48 , located between the tabs 45 on each respective locking member 40 , is trapped between the corresponding top or bottom surface of the movable rail member 20 and each of the locking members 40 . The biasing spring 48 urges the locking members 40 inwardly toward engagement with the conical cam member 37 .
The front plate 22 has an appropriately shaped opening therethrough for the passage of the movable rail member 20 and the glide members 25 . The top and bottom portions of the opening through the front plate 22 have a gap between the front plate 22 and the movable rail member 20 , which gap is filled with a wedge member 50 positioned at the top and bottom of the front plate 22 . The corresponding surface of the front plate 22 is sloped inwardly toward the rear to mate with the correspondingly sloped surface of the wedge member 50 . Thus, when the wedge member 50 is attempted to be moved rearwardly relative to the front plate 22 , the mating sloped surfaces of the wedge member 50 and the front plate 22 prevent such movement.
The translational movement of the conical drive member 35 effected by the rotating threaded rod 29 pushes the drive plate 32 , and therefore the movable rail member 20 , in the direction of movement induced into the conical drive member 35 . When the drive member 35 is moving forwardly, the spring 38 keeps the conical cam member 37 against the drive plate 32 and forces the movable rail member 20 forwardly. Similarly, when the conical drive member 35 is moving rearwardly, the cam member 37 pushes against the drive plate 32 to pull the movable rail member 20 rearwardly. The forward movement of the movable rail member 20 is limited by a stop member 26 affixed to the glide member 25 to engage limits on the slide support member 15 and halt the continued forward movement of the glide member 25 . When the forward movement of the movable rail member 20 is stopped, the continued rotation of the threaded rod 29 pushes the conical drive member 35 forwardly relative to the drive plate 32 , compressing the spring 38 between the keeper nut 39 and the back wall of the drive plate 32 , as can be seen in a comparison of FIGS. 5 and 7 .
The forward progression of the conical cam member 37 drives the respective locking members 40 outwardly due to the biased engagement of the locking members 40 with the cam member 37 , as is depicted in FIG. 7 . This outward movement of the locking members 40 extends the tabs 45 through the corresponding slots in the movable rail member 20 and places the tabs 45 in alignment with the wedge members 50 . Thus, if the bumper B incurs an impact that pushes the movable rail member 20 rearwardly, the tabs 45 engage the wedge member and lock the extendible rail apparatus 10 in an extended position to provide an additional crush zone and an efficient transfer of the energy imparted into the movable rail member 20 into the fixed lower frame rails F through the wedge members 50 engaged with the front plate 22 .
When the movable rail 20 extends forwardly and stops the locking tabs 45 are driven outward by the tapered cam 37 and extend through small slots on the movable rail member 20 . This happens when the slots on the movable rail member 20 are moved forwardly to be positioned in front of the front plate 22 and wedge members 50 . During an impact, two wedge members 50 (top and bottom) on each front plate 22 are driven between the movable rail member 20 and the front plate 22 to secure the fixed lower frame rail F and the extended rail member 20 when a load is applied to the retractable rail member 20 through the bumper B. This interengagement between the wedge members 50 and the front plate 22 allows the retractable rail member 20 to crush and transfer the load to the rest of the frame structure of the automobile before and during the collapse of the movable rail member 20 .
To retract the movable rail member 20 , the motor 27 drives the screw rod 29 in the opposite direction, which first pulls the conical cam member 37 rearwardly into the drive plate 32 . This movement of the cam member 37 allows the locking members 40 to retract inwardly due to the biasing force imparted by the springs 48 keeping the locking members 40 in engagement with the conical cam member 37 . As a result, the tabs 45 are retracted through the slots in the movable rail member 20 to allow the movable rail member 20 to retract into the fixed lower flame rail F. The extended rail member 20 is now free to retract rearwardly inside into the fixed rail F.
The extendible rail apparatus 10 incorporating the principles of the instant invention is much simpler and easy to implement than is known in the art. The extendible rail apparatus 10 does not demand any significant structural changes to the existing current automotive frame design for packaging. Also, the locking members 40 do not require large openings in the extendable rails for implementation. The actuation mechanism 30 provides an effective constraint mechanism since the locking members 40 do not depend on the strength of locking forks that come out through the slots on the moving rails. The operation of the instant invention depends on friction based wedge members 50 that are driven by small tabs 45 through small slots. These tabs 45 do not transfer the impact load but instead drive the wedge members to constraint the already extended movable rail member to the stationary lower rail frames and transfer loads thereto.
The actuation mechanism 30 also does not adversely use up the valuable crush zone already available in the front rail for the mounting and packaging of the drive motor 27 and the actuation mechanism. The extendible rail apparatus 10 also does not have three layers of sheet metal parts in the retracted mode which compromises the capability of the lower frame rails to dissipate impact energy. The drive motor 27 is mounted perpendicular to the axis of the lower frame rail F and can be disengaged during the collapse of the lower frame rail F. The modular extendible rail apparatus 10 incorporating the instant invention provides a pre-assembled module that can be inserted into a slightly modified lower front rail F and does not obstruct the collapse of existing crush zones during a frontal crash. The internal parts of the actuation mechanism 30 can be designed to crush using low cost plastics and mild steel components.
In operation, the retracted movable rail member 20 can be extended when the vehicle reaches a threshold criteria, such as a preset speed of operation. A speed sensor, which is already available in vehicles, signals the control mechanism that the threshold criteria has been reached and the electric motor 27 is activated to cause rotation of the threaded rod 29 operatively connected thereto. As the rod 29 rotates the conical drive member 35 moves along the rod 29 pushing the drive plate 32 and the movable rail 20 to which the drive plate 32 is connected forwardly through the spring 38 . When the forward movement of the movable rail member 20 is halted through the stop member 26 , the drive member 35 moves forwardly relative to the drive plate 32 , compressing the spring 38 and sliding the cam member 37 forwardly to drive the engaged locking members 40 vertically. The cam member 37 causes the locking tabs 45 to project through aligned slots in the movable rail member 20 to become aligned with the wedge members 50 located between the movable rail member 20 and the front plate 22 connected to the fixed lower frame rail F.
Since the extendible rail apparatus 10 activates when the vehicle reaches a threshold speed, no pre-crash sensors are needed. The extended movable rail member 20 increases the front impact crush zone and, thereby mitigates the adverse effects on the occupants of the vehicle, as long as one or both rails are engaged during a collision. The collisions that engage one or both rails include full, offset, and angular in both frontal and rear crashes. The movable rail member can also provide a softer impact on a target vehicle in a side impact collision and, hence, leads to a more compatible vehicle for the real world crashes.
Assuming that no impact has occurred, the lowering of the operating speed of the vehicle again activates the electric motor 27 to rotate the threaded rod 29 in the opposing direction than that use to extend the movable rail member 20 . The rearward movement of the cam member allows the springs 48 to retract the locking tabs 45 back through the slots in the movable rail member 20 , while the drive member 35 continues to move rearwardly along the threaded rod 29 with the cam member 37 pulling the drive plate 32 and the attached movable rail member 20 rearwardly to the retracted position.
It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention.
For example, although the description of the preferred embodiment above relates to a front bumper configuration, the instant invention can be equally applied to rear bumper structures on automotive vehicles, thus providing a front or back or front and back telescopic bumper assemblies 10 . Furthermore, the instant invention can be retrofitted to an existing automotive frame structure or incorporated into new automotive frame design.
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An extendible rail and bumper apparatus is mountable within the base frame lower rails of an automotive frame to provide an improved crash force absorbing bumper apparatus for deployment on either the front or rear bumpers of an automobile. The extendible rail member is mounted for telescopic movement through slidable guide members. A front plate is formed with wedge members positioned next to the extendible rail member. The actuation mechanism includes an electric motor that rotates a threaded rod having a conical member mounted thereon for translational movement thereon. The conical member engages a pair of outwardly projectable tabs that are driven outwardly into engagement with the wedge members when the extendible rail is fully extended. If required to absorb impact energy, the outwardly projected tabs push the wedge members into engagement with the front plate to transfer the energy into the base frame rail apparatus of the vehicle.
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Continuation-in-part (CIP) of prior application No. 60/618,025, filed Oct. 12, 2004.
FIELD OF THE INVENTION
The present invention relates generally to a pneumatic wave generation for pools and more particularly to pneumatic wave generation systems that generate waves in pools as small as a back yard pool.
BACKGROUND OF THE INVENTION
Wave generation systems are the featured amusement at many amusement parks and aquatic theme parks throughout the world. In such applications various mechanical and pneumatic devices and apparatus have been utilized to engage and displace water at one end of the pool to create a surface wave pattern. A conventional wave generation system may be housed at a deep end of the pool with multiple caisson chambers. A ventilation system is provided within each caisson above the surface of the water therein. A source of forced air capable of effecting aspiration by applying compressed air to the surface above the water surface in the chamber is applied by conduit system. When the caissons are actuated with pressurized air the water level therein is driven down out of a lower caisson passage way and into the pool thereby creating the intended wave disturbance.
U.S. Pat. No. 4,812,077 to Raike discloses a wave generation system of the type mentioned above. Another patent to Raike, U.S. Pat. No. 6,729,799 also describes the above type of wave generation system. In these systems, a pneumatic system including a motor driven fan that communicates selectively with duct lines to caissons through a pair of two position air directed valve assemblies. Selective actuation of the two position air directional valve assemblies between the caisson chambers allow the waves to be generated in many alternately wave shapes and patterns augmenting the utility of the installation and its amusement value to users. Waves produced in water theme parks typically operate two to three hundred hours per month. The system put forth in the two patents to Raike is well designed for a large amusement park.
However, the objective of this invention is to create a smaller pool size, usually around twenty four feet wide to eighty feet long and having a volume of water around 27,000 gallons for use in the residence, apartment, condominiums complexes and is intended for only occasional use. The 24 feet in width was chosen because that in the minimum width pool to produce a true sinusoidal was of one meter in height. One meter in height wave are ideal for acceptable raft riding and will break into a roller wave and advance to the zero water depth. Eighty feet pool length has been shown to be a good short length and slope to provide and safe and enjoyable board surfing in a shot wave pool. The inventor believes the twenty four feet by eighty feet pool represents the minimum size for a small pool with satisfactory waves with a safe and acceptable bottom slope. To achieve this objective of the pool for residential uses, pneumatic compressor and control power must run on 120 volts ac, the typical house current.
Another objective of this system is to create waves of various patterns. This is done in the commercial systems by having two or more caissons that are pressurized alternately. For the smaller pool one can use two caissons which are energized alternately or in a given sequence to produce waves in various patterns. Instead of using a valve, usually positioned above the caisson, to pressurize and depressurize the caisson in the inventor's system, the high pressure blower has a valve built within the blower assembly, a duct selector that allows for pressurizing and decompressing the duct and therefore the caisson. Supplemental air release is provided on the duct with a valve assembly at the end of the duct.
What allows the above objective to be achieved is the duct used to energize the caisson is perforated with openings along the upper half of the duct. In the conventional system shown in U.S. Pat. No. 4,812,077 to Raike, above referenced, the large volume of pressurized air necessary to rapidly charge the caisson is injected into the caisson by a nozzle positioned above the water level. The pressurized air, thus, is not evenly distributed over the surface of the water within the caisson and its focused entry into the water tends to cause turbulence as the water level is pressured downward. Undesirable turbulence degrades the quality of the generated wave and represents a system loss of pneumatic efficiency that is likewise undesirable. Thus, the need exists for a wave generator that can equally distribute and disperse pressurized air over the surface of the water within a caisson so as to result in minimal losses from turbulence and maximum pneumatic efficiency.
In the inventor's system, the pressurized air is introduced into the caisson via a duct that is perforated with openings on the top half of the duct. This duct allows air evenly distributed throughout the caisson and eliminates turbulence. By preventing turbulence the pneumatic system becomes more efficient. Due to the increase in efficiency, less air is need to move the same amount of water which allows for reducing the construction height of the caisson above water level thereby reducing the volume of space to be energized with pressurized air. This not only cuts down on the construction cost but also makes the pool much more economic when used. The decrease in the volume of air need because of the increase in pneumatic efficiency makes a small wave pool for residential use possible. The lesser volume of air necessary decrease the blower size and the caisson size thus lowering the cost of installation. This along with the lowering of cost to operate due to the smaller blower make the wave pool economical for a residential operation.
One of the major problems in adapting the existing wave generators like the one in U.S. Pat. No. 4,812,077 to Raike to a smaller scale is that the housings in which the caissons are deployed are relatively large and raise above the pools deck at the deep end. As a result, steps must be incorporated into the pool deck in order to allow for the users to transverse the perimeter of the pool. The size of the caisson housing in a conventional wave generator is a function of the relatively large air displacement requirements by the state of the art due to the turbulence caused by the injection of air and bends in the ducts. Since the cycle time of charging each caisson with pressurized air and discharging the generated wave from one caisson and exhausting the caisson is significantly short on the order of 2 seconds or less, a relatively large and excessive volume of pressurized air must be quickly injected into the caisson in order to correspondingly effectively quick movement of the water level downward. This also makes the air compressor much larger and uneconomical to purchase or use for a small installation. It is thus the objective of the invention to reduce the amount of air required to charge a caisson in a wave generating system. Such a reduction in volume of air would reduce the size of the caisson air chamber allowing for reduction of the vertical height and the lowering of the cost to build said pools. Additionally the reduction of the volume of air required to charge the wave generation caisson would enhance the system efficiently and allow the use of a smaller energy efficient fan system. In the conventional wave generation system, the large volume of pressurized air necessary to rapidly charge the caisson is injected into the caisson by a nozzle positioned above the water level causing turbulence as explained above. This turbulence lessens the efficiency of the system and necessitates a large volume of air to produce the wave. Thus, an objective of the system is to produce a wave generator that can equally distribute and dispense pressurized air over the surface of the water within the caisson so that the resulting minimal loss from turbulence and maximum pneumatic efficiency. Further, in order to supply the excessive quantity of pressurized air into the caisson, current system employs a high capacity fan system which distributes the air to the caisson by an extensive system of large conduits or ducts. Such fans are expensive and noisy in operation and have high power utilization rates resulting in undesirable increase in the cost of operating the wave generation system. Thus, the objective of the invention is to create a wave generator that produces a quieter, low powered fan unit that efficiently distributes pressurized air into the caisson through an efficient, bend free conduit system. The feature that allows this to be done is a duct system used to energize the caisson is perforated with openings along the upper half of the duct. The duct allows air to evenly distribute throughout the caisson and eliminates turbulence and maximizes efficiency. This permits less air to be needed and allows for reduced construction height of the caisson above the water level thereby reducing the volume and space to be energized with air pressure. This lesser air pressure, of course, means that a smaller far more efficient fan unit can be used.
SUMMARY OF THE INVENTION
The invention is a wave generation system for bodies of water such as pools. At the deep end of the pool there is a set of air tight caissons. These caissons have an open bottom and allow the water of the pool to flow within. Pressurized air from a high pressure blower is introduced into these caissons via a duct. The duct, which passes through the caissons, is perforated on its top to allow the pressurized air from the blower to distribute itself evenly over the surface of the water. The air fills the caisson forcing the water out the open bottom of the caisson and into the pool causing the wave. These waves can be used as in a normal wave pool or used to power waves in a river type ride.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a wave pool with the invention installed.
FIG. 2 is a cutaway side view of the wave pool of FIG. 1 .
FIG. 3 is a side view of the blower and the blower valve and a portion of the first caisson.
FIG. 3A is a side view of the blower valve.
FIG. 4 is a side view of a portion of the duct.
FIG. 5 is a cutaway view of the duct along line 5 - 5 of FIG. 4 .
FIG. 6 is a perspective view of the pressure relief valve.
FIG. 7 is a top view of another embodiment of a wave pool with a river around the pool.
FIG. 7A is a cutaway side view of the wave pool of FIG. 7 .
FIG. 7B is a cutaway view of the wave pool of FIG. 7 along line 7 B- 7 B of FIG. 7A .
FIG. 8 is a top view of another embodiment of a wave pool with a longer fan shaped river around the pool.
FIG. 9 shows the blower and caisson area of another embodiment of the wave pool and a pattern of wave that can be created by this configuration of ducts and blowers.
FIG. 10 shows the same configuration of blowers, ducts and caissons as FIG. 9 and a different pattern of wave from FIG. 9 that can be created by this configuration of ducts and blowers.
FIG. 11 shows a top view of a circular wave pool.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show the present invention, a pneumatic wave generator for a small installation. FIG. 1 shows a pool and the wave generation system comprising of a hydraulic system and pneumatic system. The pool 12 includes a deep portion 14 having substantially a square configuration and shallow portion 16 longitudinally opposite the deep portion 14 . The pool 12 includes a bottom 18 with the greatest depth at the deep portion 14 and a shallow portion 16 that slopes upward to a zero depth.
In the preferred embodiment the pool would in its minimum size be twenty four feet by eighty feet. The twenty four feet wide is the minimum width for a wave pool to create a true sinusoidal wave of one meter in height. The one meter high wave are the size ideal for raft riding and will break into a roller wave and advance to zero depth. The eighty feet length is the minimum length for the slop of the bottom of the pool to allow the wave to go to zero depth that allows board surfing safely.
FIG. 1 shows the caissons 20 . This FIG. 1 shows five caissons 20 , which is the number ideal for a small installation, however, this number can vary from installation to installation. FIG. 2 , a cutaway view of the pool 12 shows that the caissons 20 are basically cubical in structure. The caissons 20 extend above the water level of the pool 12 and extend down to the bottom 18 of the pool with the front wall 22 having a submerged passageway 24 near the bottom 18 the pool 12 . The water from the pool 12 can flow through this submerged passageway 24 partially filling the caisson 20 .
FIGS. 1 and 2 also shows ducts 26 and 28 running through the caissons 20 above the water line. These carry air from the high pressure blower 30 into the caisson 20 . The high pressure air forced into the caisson 20 forces the water in the caisson 20 downward and causes it to pass out through the submerged passageway 24 . This water that passes through the submerged passageway 24 forms the wave upon the pool 12 . At the ends of the ducts 26 and 28 is a pressure release valve 32 . This pressure release valve 32 is shown in FIG. 6 . This pressure release valve 32 exhausts air from the caisson 20 . When the pressure release valve 32 is opened, air from the caisson 20 flows into the ducts 26 and 28 again and is exhausted by the pressure valve 32 .
Some of the air is also exhausted through the blower valve 34 shown in FIGS. 3 and 3A . Blower valve 34 connects the high pressure blower 30 alternately to the ducts 26 and 28 as shown in FIGS. 3 and 3A . FIG. 3 is a side view that shows the blower valve 34 hooking the high pressure blower to the ducts 26 and 28 . FIG. 3A is a top view of blower valve 34 . In FIG. 3A blower valve's inlet 36 is attached to the high pressure blower 30 . Blower valve's outlet 38 shifts between attaching to duct 26 and duct 28 . In FIG. 3A the blower valve's outlet 38 is attached to duct 26 and duct 28 is open.
When duct 28 is opened it means that air will be exhausted from the caissons 20 which duct 28 services. When the blower's valve's outlet 38 is attached to duct 26 it means that air is being forced into the caissons 20 which duct 26 services. The blower valve 34 moves between the two ducts 26 and 28 very rapidly. The timing is generally one to one and one-half seconds for the air to be injected into the caissons 20 and then one to one and one-half seconds to allow the air to exit. This leaves very little time to fill the large caissons 20 with air and push the water into the wave form. Therefore, the high speed blower 30 must be able to produce large volumes of high pressure air. As I pointed out above, inventor's new system with perforated straight ducts 28 and 26 , increases the efficiency of the pneumatic system by approximately 25 percent. This means the size of the caissons 20 can be cut down by at least 25 percent and it also means that the high pressure blower 30 has to move 25 percent less air. Thus, a smaller size high pressure blower 30 can be used which will reduce the cost of the installation and operation. Also, the caissons 20 themselves can be reduced in size also reducing a manufacturing cost. In the traditional wave generating system shown in U.S. Pat. No. 4,812,077 the air is allowed to escape through the same opening in which the air is injected. In applicant's system, the air in the caissons 20 escapes through the openings 40 in the perforated ducts 26 and 28 . The numerous openings 40 in the perforated ducks 26 and 28 create a much larger open area than the opening through which the air is injected and exhausted in U.S. Pat. No. 4,812,077. Thus, the air will more easily escape in this new system. This is further enhanced by the inventor, not only allowing the air to escape at the blower valve, but also placing on the duct 26 and 28 a pressure release valve 32 witch each cycle is opened to allow the air to escape. This better system of exhausting the air causes the pneumatic system to be much more efficient. The added efficiency, of course, lowers the size of the high pressure blower 30 necessary and also requires the high pressure blower 30 to use less effort and thus last longer. It also allows for the caissons 20 to be reduced in size, thus cutting down on the manufacturing cost and the higher efficiency means that there will be less power needed to produce the wave and thus the operating expenses would be less.
The shape of the ducts 26 and 28 is shown in FIGS. 4 and 5 . The ducts 26 and 28 are basically long, round pipes that run through the caissons 20 above the water level. FIGS. 4 and 5 show that these pipes have openings 40 in the top to allow the air to escape into the caissons 20 when the high pressure blower 30 is pumping air into the duct 26 and 28 and when the high pressure blower 30 ceases to pump air into the duct 26 and 28 and the blower valve 34 opens and the pressure release valve 32 opens, and air from the caissons 20 then rushes through these openings 40 and out the pressure release valve 32 and the blower valve 34 . The openings 40 in the ducts 26 and 28 are placed at the top of the ducts 26 and 28 so that the air, when pumped through the duct 26 and 28 , and escapes out these openings 40 , will make contact with the ceiling of the caisson 20 and spread down thus causing the air to spread out over the full surface of the water within the caisson 20 . This improves the pneumatic efficiency and allows for less air to be used. The openings 40 can actually be placed anywhere on the ducts 26 and 28 , however, as I pointed out above, although it would work and create the waves it is less efficient than placing the openings 40 on the top of the duct 26 and 28 .
FIG. 6 shows the pressure release valve 32 . Each duct 26 and 28 as shown in FIG. 1 has a pressure release valve 32 . The pressure release valve 32 , as shown in FIG. 6 , is cylindrical and contains a butterfly valve flap 42 . When air is being injected into the ducts 26 and 28 by the high pressure blower 30 , the butterfly flap 42 is closed not allowing the air to escape out the pressure release valve 32 . When the high pressure blower 30 ceases to inject air into the duct 26 and 28 , the butterfly valve flap 42 opens and allows the air to escape out the pressure release valve 32 . As I stated above, the pressure release valve 32 and the blower valve 34 opens the duct 26 or 28 at the same time to allow the air to escape out. Unlike the previous state of the art, the ducts 26 and 28 have both ends of it that can open to allow the air to escape whereas the previous art had only one opening to allow the air to escape. This double opening allows the system to be more pneumatically efficient. The pressure relief valve 32 and the blower valve are all controlled by an electronic control system. This system can be hooked up to the pressure relief valves 32 and the blower valves 34 by wires of by radio waves.
FIG. 3 shows the high pressure blower 30 . In the preferred embodiment the high pressure blower 30 is placed at the side of the pool, below the water line such that it exhausts into the ducts 26 and 28 just above the water line. By placing the high pressure blower 30 in this configuration, the deck area 44 at the deep portion 14 of the pool 12 does not raise significantly above the water level. This configuration has been sought by the industry. In the prior art the housing in which the caissons are deployed are relatively large and raise above the deck at the deep end the pool an undesirable height. As a result, steps must be incorporated into the pool deck in order to allow the user to transverse the perimeter of the pool. In addition, the high housing of the caissons at the deep end of the pool may interfere with the placement of the competitive starting box in the pool, and thereby defeat or inhibit the capacity of the pool to serve as a venue for competitive swimming meets. Finally, high caisson housing is esthetically displeasing. Wave generators providing essential functional utility, yet having a lower vertical height compatible with providing a uniform deck area surrounding the pool is accordingly desired by the industry.
The high pressure blower 30 can be run by an electrical motor or an internal combustion engine. The internal combustion engine can be run from natural gas, propane or gasoline.
The wave generator for this system has been basically designed for a small system.
FIG. 7 shows a pool 50 for a commercial establishment that has ten caissons 52 . The caissons 52 also in this pool 50 are driven just like the previous pool 12 from a high pressure blower 30 at the side that distributes the air in two ducts 54 and 56 , one of which has openings in each caisson 52 . The blower valve 34 and high pressure blower 30 are similar to the five caisson pool 12 except the ten caissons 52 are for a larger establishment. FIG. 7 is also unique because it not only shows a wave pool 50 but also a river 58 that flows around the pool 50 , with a deck 60 in the middle of the pool 50 that allows individuals to either enter the river 58 or the wave pool 50 . FIG. 7 a is a cut-away view of FIG. 7 showing the water line. FIG. 7 b shows the water line for the wave pool 50 and the river 58 . The wave pool 50 is similar to the wave pool 12 cross section shown in FIG. 2 and it stops at the deck area 60 at zero depth. However, further out past the deck area 60 another area of water for the river 58 is created. Thus and individual cannot only ride the waves but also ride through the river 58 in his tube or raft. FIG. 7 cut along line 7 b - b or FIG. 7 a shows a cut-away view of the system showing that the river runs 58 on both sides of the wave pool 50 . FIGS. 7 a and 7 b shows the bottom construction of this pool.
FIG. 8 shows another configuration for a wave pool 62 . This configuration has a much more extensive deck 64 and a much larger river 66 . That too is operated with ten caissons 52 and the duct 54 and 56 similar to the wave pool 12 and 50 of FIG. 1 and FIG. 7 . However, in this one the wave pool 62 and the river 66 are outstretched in a fan shape. The deck 64 area is greatly enhanced so that individuals will have a longer ride on the river 66 . The wave pool 62 area fans out just as in FIG. 1 .
FIGS. 9 and 10 show another configuration for ducts 162 , 164 , 166 , and 168 and the caissons 78 . In this system a high pressure blower 30 could be placed at each end of the wave pool 68 and the set of caissons 78 . The high pressure blower 30 still pressurizes two ducts 162 and 164 or 166 and 168 that run across all ten of the caissons 78 . The ducts 162 , 164 , 166 , and 168 have the perforated tops in every fourth caisson 78 rather than in every other caisson 20 and 52 as in the previous configurations. The another high pressure blower 80 also has two ducts 74 and 76 out of it and it too has the perforations on the duct in every fourth caisson 78 . Thus, there are four ducts 162 , 164 , 166 , and 168 to every caisson 78 ; however, only one of those ducts 162 , 164 , 166 , or 168 is perforated in each caisson.
Configuring the caissons 78 in this way, one can produce several different wave patterns. Two of these wave patterns are shown in FIGS. 9 and 10 . In FIG. 9 when the first high pressure blower fills ducts 162 and the second high pressure blower fills duct 166 at the same time and ducts 164 of first high pressure blower and duct 168 of second high pressure blower are exhausted at the same time, one begins to produce the wave patterns 100 of FIG. 9 . Then duct 164 of first high pressure blower is pressurized while duct 162 is exhausted and duct 168 of second high pressure blower is pressurized while duct 166 is exhausted further creating the wave pattern 100 of FIG. 9 .
FIG. 10 is created by pressurizing duct 162 of high pressure blower 160 and duct 168 of high pressure blower 170 while exhausting duct 164 of high pressure blower 160 and duct 166 of high pressure blower 170 . Then duct 164 of high pressure blower 160 is pressurized and duct 166 of high pressure blower 170 is pressurized while duct 162 of high pressure blower 160 and duct 168 of high pressure blower 170 exhausted. This will create the wave pattern 102 of FIG. 10 .
FIG. 11 shows you that a circular wave pool 90 can also be built. In this configuration there are 12 caissons 92 . However, one could use less or more caissons. Each of the caissons 92 contains at least one duct 94 that is perforated. The caisson 92 construction and the way in which the waves are created are exactly the same in this configuration as in the previous configurations. The air from the high pressure blower 98 is forced into the ducts 94 and it escapes into the caisson 92 out of the perforations in the top of the ducts 94 . This distributes the air over the water evenly and thus creates high pneumatic efficiency. The air, of course, presses the water downward and the water escapes through the submerged passageway not shown in the example creating the wave. In the configuration shown in FIG. 11 the wave generation system has a horizontal high pressure blower 98 with three outlets 103 . Those three outlets 103 deliver air by a non-perforated duct to the blower valve 104 . The blower valve 104 is like the previous embodiment in that it is designed to alternately pressurize two ducts 94 . The two ducts 94 extend from the high pressure blower 98 in opposite directions in the circular configuration. Each duct 94 runs through three caissons 92 chambers and has perforations in the first and third caissons 92 for which it runs through. Using this configuration there is one perforated duct 94 in each caisson 92 . There are many different configurations that could be used in this system. The high pressure blower 98 could have only one outlet to a blower valve as in the previous example that alternately pressurizes two different ducts. These ducts would extend fully around the circular configuration with alternate caissons having perforation. In this configuration there still would be one perforated duct per caisson. The configuration could also have more than three different fan exhausts with ducts running to the caissons. The basic design consideration is that there would be at least one perforated duct in each caisson so that the waves can be produced. In the configuration of FIG. 11 the pressure relief valves 110 are placed in the walls of the caisson in some of the caissons 92 . These pressure relief valves 110 work the same as in the previously embodiments. When the blower valve 104 shuts off the flow of air to the caissons the pressure relief valve 110 opens and exhausts the air from the caisson 98 . In the caisson that are adjacent to the blower valve 104 there are no pressure relief valves 110 . When the blower valve 104 moves from one duct 94 to the other duct 94 it opens up the first duct 94 so that the air can pass back through the perforation and escape out the blower valve 104 . As in the previous embodiment the blower valve 104 and the pressure relief valve 110 are hooked to an electronic control system that control there actions.
Changes and modifications in the specifically described embodiments can be carried out without departing from the scope of the invention which is intended to be limited only by the scope of the appending claims.
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The device is a wave generation system for bodies of water such as pools. At the deep end of the pool there is a set of air tight caissons. These caissons have an open bottom and allow the water of the pool to flow within. Pressurized air from a high pressure blower is introduced into these caissons via a duct. The duct, which passes through the caissons, is perforated on its top to allow the pressurized air from the blower to distribute itself evenly over the surface of the water. The air fills the caisson forcing the water out the open bottom of the caisson and into the pool causing the wave. These waves can be used as in a normal wave pool or used to power a river type ride.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This Application claims rights under 35 USC §119(e) from U.S. Application Ser. No. 61/527,159 filed Aug. 25, 2011, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
Embodiments are generally related to direction finding systems. Embodiments are also related to a method and system for determining north in target locator systems. Embodiments are additionally related to a single receiver GPS pointing vector sensing system.
BACKGROUND OF THE INVENTION
GPS (Global Positioning System) navigation systems include a constellation of satellites each of which provides a coded signal which may be picked up by radio receivers on the surface of the earth. Separate coded signals from a set of satellites may be processed by a receiver system for use in determining location as defined by latitude, and longitude based on the code carried by the signals. The operation of GPS systems in determining location based on coded signals received from satellites reflects the conventional functioning of such systems.
However, it has been found that the signals generated by GPS satellites may be used in other ways and in particular the carrier phase of the signals may be used in certain surveying applications. For example, a pair of stationary antenna/receiver combinations may be located at the ends of a baseline (whose length is required to be determined) and, based on the observed relative phase of the GPS carrier signal from satellites at known positions, determine the orientation of the antenna pair relative to an earth reference.
Current GPS orientation techniques require two position measurements either accomplished using two antennas and two receivers as typical in surveying applications or requiring precise movement of a single antenna/receiver pair to two different relative positions. These approaches typically require significant separation (>1 meter) between measurements in order to mitigate position inaccuracy between measurements making for large, bulky equipment.
Digital magnetic compasses are currently used in handheld target systems to determine orientation relative to north. These devices may be easily influenced by local fields due to geological formations, metal vehicles and even equipment worn by the user. There is generally no indication when these devices are compromised leading to incorrect targeting solutions. GPS solutions are generally discounted as they can be influenced by multipath effects or jamming.
A need therefore exists for compact GPS, non-magnetic sensing of azimuth direction for target systems.
BRIEF SUMMARY
The following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiment and is not intended to be a full description. A full appreciation of the various aspects of the embodiments disclosed herein can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
It is, therefore, one aspect of the disclosed embodiments to provide for direction finding systems.
It is another aspect of the disclosed embodiments to a method and system for determining north in target locator systems.
It is yet another aspect of the disclosed embodiments to provide for a single receiver GPS pointing vector sensing system.
It is another aspect of the present invention to provide a GPS system for determining north in a target locator system with two antennas includes two stationary GPS antennas separated by less than half a wavelength. A single receiver is also included, and is used to determine the pointing vector of the system.
It is yet another aspect of the disclosed embodiments to provide a GPS system in which the outputs of two antennas are scaled with time varying gains and summed in order to generate a carrier phase modulation that is dependent on satellite orientation.
It is yet another aspect of the disclosed embodiments to provide a GPS system that includes a three axis gyroscope that allows determination of the pointing vector while in motion.
The aforementioned aspects and other objectives and advantages can now be achieved as described herein. A system and method of determining a pointing vector using two GPS antennas and a single GPS receiver is disclosed. Two stationary GPS antennas, with a separation preferably less than half of a wavelength (˜100 mm) may use a single receiver to determine the pointing vector of the system. Incorporation of a three axis angular rate measurement allows pointing determination during system rotation. The present invention provides the ability to sense multipath and jamming, potentially alerting the user that the measurement may not be reliable.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the disclosed embodiments and, together with the detailed description of the invention, serve to explain the principles of the disclosed embodiments.
FIG. 1 illustrates a schematic diagram of a GPS system showing an orientation of two antennas with respect to a satellite, in accordance with the disclose embodiments;
FIG. 2 illustrates a schematic diagram of the system depicted in FIG. 1 with the antenna configuration rotated 90 degrees relative to the satellite, in accordance with the disclosed embodiments;
FIG. 3 illustrates a block diagram an of first antenna being scaled by a sinusoidal waveform, in accordance with the disclosed embodiments;
FIG. 4 illustrates a graph of carrier amplitude relative to antenna output as a function of alpha, in accordance with the disclosed embodiments;
FIG. 5 illustrates a graph of carrier phase relative to antenna output as a function of alpha, in accordance with the disclosed embodiments;
FIG. 6 illustrates a block diagram of the processor depicted in FIG. 3 utilized for determining a pointing vector directly from measurements of a carrier phase, in accordance with the disclosed embodiments; and
FIG. 7 illustrates a graph of the scale from predicted amplitude to measured amplitude, in accordance with the disclosed embodiments.
DETAILED DESCRIPTION
The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
Referring to FIG. 1 , a schematic diagram of a GPS system 100 showing an orientation of first and second antennas 102 and 104 with respect to a satellite. The orientation can be for example, the satellite and the first and second antennas 102 and 104 are in same plane. The transmission direction 106 of the satellite is indicated with the dotted arrow. The first antenna 102 and second antenna 104 have their phase centers 108 aligned to the vector indicated with the solid arrow. The carrier signal 110 is illustrated by the sine wave. The carrier signal 110 has a phase of zero at the first antenna 102 .
The phase at the second antenna 104 can also be calculated. The GPS carrier frequency is nominally 1.57542 GHz corresponding to with a wavelength of 190.3 millimeters. If the first and second antennas 102 and 104 are separated by fifty four millimeters, the phase 112 on the carrier wave 110 on the second antenna 104 relative to the first antenna 102 is calculated as
−380*54/190.3=−102 degrees
The Doppler shift in carrier frequency caused by the motion of the satellite has an insignificant impact on this phase difference.
Referring to FIG. 2 the antenna configuration of FIG. 1 is rotated ninety degrees relative to the satellite. The first and second antennas 102 and 104 receive the same, carrier phase resulting in a zero degree phase difference. This illustrates the dependency on phase difference with orientation on the horizontal plane.
Extending this relationship to three dimensions, the phase difference observed between the two antennas for each of the satellites in degrees for this example can be determined as
Phase difference=102*cos θ,
where θ is the angle between the vector defined by the phase centers 108 and the vector pointing to the transmission direction 106 of the satellite.
The angle between the two unit vectors can be determined using the following relationship:
cos(θ n )= Z n ·Z b =x b x n +y b y n +z b z n Equation (1)
where Z n is the unit vector pointing to the nth satellite and Z b is the unknown unit vector connecting the two antenna phase centers in the coordinate system defined for Z n . θ n is the angle between these vectors for the nth satellite.
From FIGS. 1 and 2 , the measured carrier phase delta between the two antennas can be expressed as:
α n ( t )β Cos(θ n )=β( x b x n ( t )+ y b y n ( t )+ z b z n ( t ))+ n n ( t ) Equation (2)
where β is the maximum phase difference determined by the antenna separation of hundred and two degrees.
The vector to the satellite defined by x n , y n , Z n are indicated as time varying as the satellites are in motion. There is an additive noise term n n that represents the noise on the carrier phase measurement from the GPS receiver. Note that there are three unknowns in the equation (2), xb, yb and zb. In a noise free measurement, these values may be determined from three satellite measurements to satisfy the three equations, three unknown criteria for the unique solution. In the presence of noise, the three unknowns can be solved by taking many measurements, either using more than three satellites or using many measurements through time. The GPS position solution requires a minimum of four satellites and generally, more than four satellites are available adding more measurements to the least squares fit. The problem is amenable to recursive least square solution for a static system or may be incorporated into a Kalman estimator for a dynamic system with the addition of inertial sensors to predict rotation of the x b , y b and z b vector components.
The state equations used for such an estimator can be constructed from the previous equation as
[ α m 1 α m 2 ⋮ α mn ] = β [ x 1 y 1 z 1 x 2 y 2 z 2 ⋮ ⋮ ⋮ x n y n z n ] [ x b y b z b ] Equation ( 3 )
where the measurement is α m1 =α 1 +n 1
One embodiment of this disclosure is the method used to sense the satellite dependent carrier phase shift at the two receiving antennas using a single receiver. In this embodiment, the antenna outputs are scaled by time varying gains and summed in order to generate a carrier phase modulation that is dependent on satellite orientation.
Referring to FIG. 3 , the first antenna 102 being scaled by a sinusoidal waveform 118 with a minimum amplitude of zero and peak amplitude of one is shown by utilizing a scaler 114 , typically implemented with a variable gain amplifier or variable attenuator. The apparatus 300 can be utilized for determining a pointing vector 130 . The second antenna 104 is scaled by another sinusoidal waveform 120 with identical frequency but one eighty degrees out of phase by utilizing another scaler 116 . The scaled antenna outputs 121 and 119 are summed and fed into a GPS receiver 124 antenna input by utilizing a summer 122 . While scaling with a sinusoid over a range of zero to one is used in this example, other waveforms and amplitudes may be used to the same effect. The sinusoid offers the greatest amplitude swing with the smallest resultant jerk, minimizing potential issues in receiver carrier tracking loop.
The GPS receiver 124 processes the summed antenna signal 123 using standard GPS receiver software to generate a satellite almanac 132 that allows prediction of satellite position, provide raw carrier phase measurements 134 and determine the GPS receiver location 136 . These standard data outputs are input to a processor 126 along with the measured modulation 120 and the measured inertial rotation rates 127 provided by the inertial measurement system for example three axis gyroscope 128 . The raw carrier phase measurements include a measure of the phase modulation induced by the time varying summation of the two antenna signals. The processor 126 determines the pointing vector 130 based on the signals from GPS receiver 124 and three axis gyroscope 128 .
The carrier signals measured from first and second antennas 102 and 104 are scaled and expressed as in equations (4) and (5), the variable a representing the gain, which varies from 0.0 to 1.0 in sinusoidal manner, applied to first antenna 102 output. In these equations, the maximum phase shift between these antennas, β, is relative to first antenna 102 .
s 1n =α sin(ω c t ) Equation (4)
s 2n =(1−α)sin(ω c t +γ) Equation (5)
γ=β cos(θ n ) Equation (6)
The second antenna output can be equivalently expressed as:
s 2n =(1−α)cos(γ)sin(ω c t )+(1−α)sin(γ)cos(ω c t ) Equation (7)
The sum of the two weighted antenna outputs
a n =s 1n +s 2n =a sin(ω c t )+ b cos(ω c t ) Equation (8)
a =α+(1−α)cos(β cos(θ n )) Equation (9)
b =(1−α)sin(β cos(θ n )) Equation (10)
a n =√( a 2 +b 2 )sin(ω c t+a tan( b/a )) Equation (11)
FIG. 4 illustrate a graph 400 showing the variation of the carrier amplitude as a function of alpha parametric with gamma, while FIG. 5 illustrate a graph 500 showing the variation of carrier phase as a function of alpha parametric with gamma. The operating point selected for the example was a maximum phase delta of 102 degree (1.78 radians), resulting in a periodic amplitude loss on the carrier varying from 1.0× to 0.62×. The optimum operating point is a trade between maximizing the resultant phase modulation versus the impact of the amplitude modulation on the ability of the receiver to track lower signal levels. It may also be desirable to use lower gammas (smaller antenna separation) so that the phase response shown in FIG. 5 stays somewhat linear in order to preserve the sinusoidal modulation shape. The selected gamma of 1.78 radians has a slight non-linearity in phase response as it varies from 0 to 1.78 radians.
The variation of carrier amplitude as a function of alpha parametric with gamma depicted as 416 , 402 , 404 , 406 , 408 , 410 , 412 and 414 for relative carrier phase delta values 0, 0.5236, 1.0472, 1.5708, 1.78, 2.0944, 2.618 and 3.1416 radians respectively are shown in FIG. 4 . Also the variation of carrier phase as a function of alpha parametric with gamma depicted as 502 , 504 , 506 , 508 , 510 , 512 514 and 516 for relative carrier phase delta values 0, 0.5236, 1.0472, 1.5708, 1.78, 2.0944, 2.618 and 3.1416 radians respectively are shown in FIG. 5 .
Referring to FIG. 6 , a block diagram of the processor 126 depicted in FIG. 3 , utilized for determining the pointing vector 130 directly from a carrier phase measurement 134 is shown. The satellite almanac 132 and receiver position 603 are given as input to the compute satellite position module 602 . The compute satellite position module 602 determines the time varying range to each satellite and the time varying unit vectors pointing to each satellite in the local East-North-Up (ENU) reference frame. The range is expressed in terms of phase based on the wavelength and represented as Doppler phase rate 607 . The time varying unit vectors are represented as satellite ENU unit vectors 605 . The carrier phase measurement 134 is subtracted from the Doppler phase rate 607 by utilizing a subtrator 604 . The resultant phase measurement 611 includes a residual phase rate and low frequency phase variation as well as the desired phase modulation. A rolling average equal to the period of the carrier phase modulation is computed and subtracted from the phase measurement in order to remove the residual phase errors and preserve phase modulation information. For the case when a one Hertz modulation signal is used, a rolling one second average signal 613 obtained from a one second average module 610 , is subtracted from the resultant phase measurement 611 by utilizing a subtrator 606 . This eliminates low frequency variation and converts any residual phase rate into a constant offset. The antenna modulation signal 120 is given as input to a pointing vector estimator 608 . The pointing vector estimator 608 may be a Kalman estimator. The gyroscope input is integrated to create a Direction Cosine Matrix (DCM) corresponding to the rotation of the system since the previous estimator iteration. This is used by the estimator to predict the pointing vector 130 for the next estimator iteration.
A Kalman estimator is provided here as the preferred implementation for the pointing vector estimator 608 , other estimator implementations are possible. The state for the estimator is defined as:
X ^ k = [ x b k y b ( k ) z b ( k ) ] Equation ( 12 )
where x b , y b and z b is the pointing vector of the system. The state prediction for the next update is given by
{circumflex over (X)} k,k-1 =F{circumflex over (X)} k-1 Equation (13)
where F is a DCM calculated representing system motion relative to the previous estimator iteration.
Earth referenced unit vectors for satellites 1 through n are calculated from the satellite almanac 132 provided by the GPS receiver 124 :
U = [ x 1 y 1 z 1 x 2 y 2 z 2 ⋮ ⋮ ⋮ x n y n z n ] Equation ( 14 )
For a 1 Hz phase modulation, the gain on antenna 1 , α, is defined as
α k =0.5 sin(2 πt k )+0.5 Equation (15)
The measurement prediction is the predicted carrier phase in expressed in meters as determined by:
γ ^ k = β * U * X ^ k , k - 1 Equation ( 16 ) a = α k + ( 1 - α k ) cos ( γ ^ k ) Equation ( 17 ) b = - ( 1 - α k ) sin ( γ ^ k ) Equation ( 18 ) θ ^ k , k - 1 = λ [ atan ( b a ) + γ ^ k 2 ] 2 π Equation ( 19 )
where λ is the carrier wavelength, α is the modulation used for the antenna gain and β is determined by the antenna separation. γ k and θ k,k-1 , a and b are n×1 vectors. The a tan arguments are evaluated element by element rather than as a matrix divide.
The linearized measurement prediction is determined from:
{circumflex over (θ)}′ k,k-1 =H{circumflex over (X)} k,k-1 Equation (20)
H=dU (α k −0.5) Equation (21)
where d is the distance between centers of the two antennas.
The kalman estimator then uses the standard set of equations:
P k,k-1 =F k P k-1 +Q Equation (22)
where Q is zero for stationary operation. For dynamic operation, Q must be set based con the rotational motion anticipated.
y k =θ m − k,k-1 Equation (23)
S k =H k P k,k-1 H k T +R Equation (24)
R is a diagonal matrix with the values in the diagonal set to the set to the variance of the carrier phase noise, high pass filtered with a 1 Hz cutoff frequency.
K k =P k,k-1 H k T S k −1 Equation (25)
{circumflex over (X)} k ={circumflex over (X)} k,k-1 +K k y k Equation (26)
P k =( I−K k H k ) P k,k-1 Equation (27)
The magnitude of the predicted carrier phase modulation and the measured carrier phase modulation ideally match at steady state. The magnitude of the difference between measurement and prediction can be used as a measure of the accuracy of the solution. Satellite signals with significant difference between prediction and measurement are likely impacted by multipath or jamming signals and can be selectively dropped from the solution until a minimum accuracy as determined by the remaining difference has been achieved.
It will be appreciated that variations of the above disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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A system and method of determining a pointing vector using two GPS antennas and a single GPS receiver is disclosed. Two stationary GPS antennas, with a separation preferably less than half of a wavelength (˜100 mm) may use a single receiver to determine the pointing vector of the system. Incorporation of a three axis angular rate measurement allows pointing determination during system rotation. Incorporation of three axis gyroscope system allows pointing determination while in motion. The system provides the ability to sense multipath and jamming. Also the system can potentially eliminate the impact and certainly alert the user that the measurement may not be reliable.
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BACKGROUND OF THE DISCLOSURE
1. Field of the Invention
The present invention relates to a liquid developer for use in developing electrostatic latent images in electrophotography, electrostatic printing etc.
2. Description of the Prior Art
The composition of the conventional liquid developer for electrophotography is such that the pigment particles and the additives such as resin etc which have such actions as to control the polarity of the pigment particles and give dispersibility in the carrier liquid or provide the fixability to a toner are dispersed in a highly insulating carrier liquid and in said carrier liquid the said pigment particles absorb the resins to form a toner. For instance, as a polarity controlling agent or a dispersing agent of the pigment particles such as carbon black, there are used vegetable oils such as linseed oil, soya bean oil and resins such as alkyl resin, polystyrene and acrylic resins, and these are mixed with the pigment to be kneaded and pulverized finely and then are dispersed in a carrier liquid e.g. a highly insulating organic solvent such as paraffin hydrocarbons to produce a liquid developer.
As a method for determining the polarity of the toner particle, in addition to a method in which the surface of the pigment particles is covered with a polarity controlling resin as described above, another method in which the charged condition is controlled by dissolving a surface active agent in a carrier liquid and causing it to be absorbed by the toner particle is known. The surface active agents used for such purpose are numerous and examples thereof are the metallic soaps such as cobalt naphthenate, manganese naphthenate and the alkyl benzene sulphonates such as calcium, sodium, barium and the like dodecylbenzene sulphonates and the phospholipids such as lecithin, cephalin, etc, but the method and effect of their use cannot be said to be always uniform, and because they are of low electric resistance when they are dissolved in a carrier liquid to use it to the degree at which although the electric resistance is lowered yet not to damage the electrostatic latent image which had been formed on the photosensitive body, the quantity of the surface active agent is subject to a strict limitation. Due to the above there is such a defect that sufficient quantity to give adequate electric charge to the toner particles cannot be added.
Also, those known materials which hitherto have been dissolved in a carrier liquid to impart a negative electric charge to the toner particles are not so numerous, and only lecithin, alkyl benzene calcium sulphonate, polyamide resin etc are known.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a liquid developer for electrophotography having negatively charged toner with no such defect as mentioned above.
It is another object of the present invention to provide a liquid developer for electrophotography wherein a negatively charging electric charge controlling agent which has a good solubility in a carrier liquid and does not lower the electric resistance of said carrier liquid is dissolved.
Still another object of the present invention is to provide a liquid developer for electrophotography which has a good storage stability and which provides a distinct and fogless image.
That is, the inventor of the present invention has made experiments relating to the effects of the electric charge control on the toner particles melting various polymers and copolymers in carrier liquids and found out that the below mentioned copolymers have strong effects on controlling the toner particles being charged negatively.
The present invention resides in a liquid developer for electrophotography characterized by being a liquid developer for electrophotography wherein toner particles are dispersed in a highly insulating carrier liquid and in the said carrier liquid is melted a copolymer comprising at least one kind of monomer selected from among the monomers shown by the below mentioned general formula (1) and at least one kind of monomer selected from among the monomers shown by the general formula (2) so as to cause the said toner particles to be charged negatively.
Further, the present invention resides in a liquid developer for electrophotography characterized by being a liquid developer for electrophotography wherein toner particles are dispersed in a highly insulating carrier liquid and in the said carrier liquid is melted a copolymer comprising at least one kind of monomer selected from among the monomers shown by the below mentioned general formula (1), at least one kind of monomer selected from among the monomers shown by the general formula (2) and at least one kind of monomer selected from among the monomers shown by the general formula (3) so as to cause the said toner particles to be charged negatively. ##EQU2##
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As the carrier liquid to be used in the present invention those which hitherto have been used for the electrophotography are usable, and use of the organic solvents having the volume resistance of 10 9 Ω-cm or above and the dielectric constant of 3 or less is preferable.
For instance, paraffinic hydrocarbons, isoparaffinic hydrocarbons, alicyclic hydrocarbons, halogenated hydrocarbons, and the like, and specifically n-heptane, cyclohexane, dipentene, kerosene, mineral spirit, tetralin, perchloroethylene, trichlorotrifluoroethane and the like can be used.
Next, as the toner particles to be dispersed in the carrier liquid the finely pulverized pigment or kneaded mixture of adhesive resin and pigment is used.
As pigments such as Mogul A, Elftex 5, Elf Vulcan XC (trademarks for products of Cabot Corp.), Statex (trademark of a product of Columbia Carbon Co.), Carbon Black XC-550 (trademark of a product of Asahi Carbon Co.), Carbon Black No. 44, Carbon Black No. 100 (trademarks of products of Mitsubishi Kasei Co.), Benzidine Yellow GNN, Benzidine Orange Scarlet KR, Fast Red, Brilliant Carmine 6B, Sky Blue, Cyanine Blue FG, Phthalocyanine Green LL (trademarks of products of Sanyo Coloring Yatter Co.), Victoria Blue, Aizen Spilon Black, Aizen Spilon Orange, Aizen Spilon Red (trademarks of products of Hodogaya Kagaku Co.), Oil Blue, Vari Fast Blue, Spirit Black, Alkali Blue (trademarks of products of Orient Kasei Co.), Aniline Black (a product of ICI Co.), Cyanine Blue NSG, Farst Rose 836, Benzidine Yellow 471 (all of them are trademarks of products of Dainichi Seika Co.) etc. are used, but the pigments are used for the purpose of coloring the toner particles so that it is clear that all the pigments hitherto have been used for toner are usable.
And as the binder resins used mixing with the above mentioned coloring powders mainly for providing fixability, dispersibility and transcribability to the toner particles those resins which hitherto have been used for toners can also be used, and specifically use of the following resins is preferable. For instance such as polyvinyl chloride, polyvinylidene chloride, vinyl chloride-vinylidene chloride copolymer, chlorinated polypropylene, vinyl chloride-vinyl acetate copolymer, vinyl chloride-vinyl acetate-maleic anhydride copolymer, rubber hydrochloride, cyclized rubber, wax rubber, ethylcellulose, nitrocellulose, polyacrylic ester, linseed oil modified alkyd resin, polyvinyl acetate, polyamide resin, cumarone resin, dammar resin, colophonium modified phenol resin, ketone resin, maleic acid resin, polystyrene, low molecular polyethylene, colophonium, copal, ester, phenol modified pentaerythritol ester etc. are usable.
The copolymers which controls negatively the above mentioned toner particles used for the present invention are synthesized in a manner as described below.
That is, at least one member selected from the monomers of the afore-mentioned general formula (1) and at least one member selected from the monomers of the general formula (2), and, if necessary, at least one member selected from the monomers of the general formula (3) are subjected to solution polymerization or bulk polymerization in an atmosphere of nitrogen gas and in the presence of a polymerization initiator such as azoisobutyronitrile, benzoyl peroxide etc.
The specific examples of the monomers shown by the general formula (1) are such as vinyl laurate, vinyl oleate, vinyl stearate, dodecyl acrylate, octyl acrylate, stearyl acrylate, tridecyl acrylate, hexadecyl acrylate, dodecyl methacrylate, heptadecyl methacrylate, stearyl methacrylate, lauryl vinyl ether, n-octyl vinyl ether, tridecyl vinyl ether etc.
The specific examples of the monomers shown by the general formula (2) are such as sodium vinyl sulphonate, sodium allyl sulphonate, sodium methallyl sulphonate, sodium P-styrene sulphonate, calcium vinyl sulphonate, calcium allyl sulphonate, calcium methallyl sulphonate, calcium P-styrene sulphonate, barium P-styrene sulphonate, magnesium P-styrene sulphonate, strontium P-styrene sulphonate, potassium vinyl sulphonate, potassium allyl sulphonate, potassium methallyl sulphonate, potassium P-styrene sulphonate, ammonium vinyl sulphonate, ammonium allyl sulphonate, ammonium metallyl sulphonate, ammonium P-styrene sulphonate etc.
And the specific examples of the monomers shown by the general formula (3) are such as aminostyrene, allylamine, allyl methylamine, N-methylamino ethyl acrylate, N-ethylaminoethyl acrylate, N-methyl aminoethyl methacrylate, N-vinyl dimethyl amine, N,N-dimethylamino ethyl acrylate, N,N-diethyl aminoethyl acrylate, N,N-dimethylaminoethyl methacrylate, N,N-dimethylaminoethyl methacrylate, N-vinyl pyridine, 2-vinyl-5-methyl pyridine etc.
The copolymers obtained from the monomers of the above mentioned general formulae (1), (2) and (3) have the characteristics of good solubility in carrier liquids, excellency in the chemical stability and negatively control the toner particle electric charge. In the copolymer the monomer of the general formula (1) is considered to increase the solubility in carrier liquids, and when used with the number of atoms of carbon in the alkyl group being on the order of 8 - 20 it will show favorable solubility in the carrier liquid.
And the monomer of the general formula (2) is considered to affect on the control of electric charge and it has been found out that the copolymers consisting of the monomers of the general formulae (1) and (2) show good solubility in carrier liquids, and negatively control the electric charge of the toner particles. Further it has been found out that if the monomers of the general formulas (1) and (2) be combined with a monomer shown by the general formula (3) the resultant copolymer increases further the effect to control the toner particle electric charge negatively.
The ratio of monomers of the general formulas (1), (2) and (3) which constitute a copolymer can be changed variously in use depending on the monomers to be selected, nevertheless it is necessary that the monomer of the general formula (1) has to be contained in mole ratio of the degree not to reduce the solubility of the copolymer in a carrier liquid.
Also, even a small quantity of the monomer of the general formula (2) has an effect in controlling the electric charge of the toner particles negatively, and it may be increased to the extent that the solubility in a carrier liquid is not lost.
Furthermore, when the monomer of the general formula (3) is used, even a small quantity of the monomer of the general formula (2) shows a very strong controlling effect on the negative charge. A small quantity of the general formula (3) also shows a considerable effect and it can be used in the mole ratio of the degree not to reduce the solubility of the copolymer in a carrier liquid.
Next, the quantity to be added of the copolymer of the present invention is small and if a small quantity is dissolved in 1 l of carrier liquid it takes effect e.g. if added and melted 0.015 g or more it shows sufficient effect. Also, the property to reduce the electric resistance of the carrier liquid is low so that a fair amount of it can be melted in a carrier liquid in use, and can be used within the allowable range of the lowering of electric resistance of the carrier liquid without bringing about deterioration in the performance of liquid developer. However, the range of 0.015 g to 10 g per 1 l of carrier liquid is preferable as it is economical and causes no reduction in the electric resistance.
A description will be given below specifically with reference to the preferred embodiments of the present invention, however, these embodiments are for the purpose of aiding to understand the present invention and is not intended in any way to limit the present invention.
EXAMPLE 1
300 ml of dioxane, 42 g of stearyl methacrylate and 2.5 g of 2,2'-azobis (isobutyronitrile) were poured into a 4-neck 500 ml flask and after sufficiently replacing the air in the flask with nitrogen gas and while heating up to 40° - 50°C, a solution of 18 g of P-styrene sodium sulphonate in 50 ml of water was dropped and raised the liquid temperature up to 70° - 80°C, then after stirring for approximately 7 hours it was allowed to stand to cool down. Next the reaction liquid was concentrated under reduced pressure and refined twice by means of reprecipitation method using 20% hydrous methanol, and when the precipitates was dried, a light brown tacky material was obtained. When this material was analyzed by means of infrared absorption spectrum, it was confirmed that the material was a copolymer consisting of stearyl methacrylate and sodium p-styrene sulphonate.
Next, a mixture consisting of 60 g of carbon black, 150 g of wax rubber, 100 g of cumarone resin and 800 g of Isopar-H (trademark of a product of Esso Co.) was dispersed for 2 hours in a sand mill and 20 g of the resultanting dispersion and 0.9 g of the above mentioned copolymer were sufficiently dispersed in 800 g of Isopar-H and there was obtained a liquid developer.
On the other hand, on an alminium foil 0.05 mm thick was coated and dried a dispersion liquid consisting of 100 g of microcrystal cadmium sulfide, 10 g of 50% toluene solution of vinyl chloride-vinyl acetate copolymer and 80 g of toluene with the thickness of 40μ when dried.
On the top was sticked a polyester film of the thickness of 38μ by means of cold setting epoxy resin bonding agent to form a three layer photosensitive body.
To the said photosensitive body was applied +7 KV corona discharge, then simultaneously with the image exposure applied an AC corona electric charge, and further by exposing the whole surface uniformly formed an electrostatic latent image which was developed using the above mentioned liquid developer obtaining a good positive image. Placing a sheet of transfer paper on top of the said image +6 KV electric discharge was applied from the rear face and when the transfer paper was taken off most of the picture on the photosensitive body was transferred to the said transfer paper. The transferred picture was distinct with high density and fixed perfectly. When development was performed using a liquid developer II having composition of the above mentioned liquid developer but not containing the copolymer consisting of sodium methacryl sulphonate and octyl methacrylate, the developed picture was very bad with much fog and the density of picture was low.
Also, similarly, development was made using a liquid developer III prepared by using just the same amount of sodium clodecylbenzene sulphonate instead of the stearyl methacrylate-sodium p-styrene sulphonate copolymer in the above.
The data obtained in the above by comparing the picture density and fog density relative to the liquid developer prepared time and after allowing it to stand for one month is given below.
______________________________________ Developer prepared After standing time one month Picture PictureLiquid developer density Fog density density Fog density______________________________________Example 1 1.04 0.02 1.04 0.02Liquid developer 0.5 0.05 0.4 0.05-2Liquid developer 0.8 0.04 0.5 0.05-3______________________________________
The above data shows that the liquid developer of the present invention provides high picture density, less fog and excellent conservation stability.
EXAMPLE 2
Example 1 was repeated using lauryl methacrylate instead of stearyl methacrylate and further using sodium methallylsulphonate instead of sodium P-styrenesulphonate and there was obtained colorless tacky copolymer.
Next, the mixture of 50 g of carbon black, 200 g of curomane resin, 100 g of cyclized rubber and 800 g of Isopar-H ((trademark of a product of Esso Co.) was dispersed in a sand mill, and 20 g of the resultant dispersion liquid and 1 g of the above mentioned lauryl methacrylate-methallyl sodium sulphonate copolymer were dispersed sufficiently in 800 g of Isopar-H to produce a liquid developer.
On the other hand, a mixture of 100 g of microcrystal zinc oxide, 20 g of styrene butadiene copolymer 50% toluene solution, 40 g of n-butyl methacrylate 50% toluene solution, 120 g of toluene, and 4 ml of Rose Bengale 1% methanol solution was dispersed for 6 hours in a sand mill, then it was coated on the paper which had been subjected to undercoating treatment and dried up so that the thickness of dried coating are became 20μ to obtain electrophotographic photosensitive paper. To the said photosensitive paper was applied -6 KV corona electric charge, then an enlarged image was projected from a microfilm of a negative to form an electrostatic latent image, and by soaking it in the above mentioned liquid developer a black positive image was obtained. Picture density was high and showed excellent fixability. In the case wherein the copolymer consisting of lauryl methacrylate and sodium methallyl sulphonate was not contained in the above mentioned liquid developer, the developed picture had very low picture density with much fog and the picture had a touch of solarization.
EXAMPLE 3
A mixture of 50 g of copper phthalocyamine blue, 200 g of cumarone resin, 100 g of cyclized rubber, 25 g of low molecular polyethylene, and 800 g of Isopar-H (trademark of a product of Esso Co.) was kneaded for 2 hours in a sand mill, and 20 g of the resultant dispersed material and 1 g of the copolymer of stearyl methacrylate and sodium P-styrene sulphonate used in Example 1 were dispersed in 800 g of Isopar-H to obtain a liquid developer.
On the other hand, melts consisting of high purity amorphous selenium and powder tellurium in the ratio of 9 : 1 was evaporated up to 50μ in thickness on a nickel plated brass plate to obtain a photosensitive plate. To the photosensitive plate was applied plus 6 KV corona electric charge and image exposure was made by means of a film having positive image so as to form an electrostatic latent image and then was developed using the above mentioned liquid developer, and when transferred to a transfer paper a clean positive picture was obtained and fixability was also perfect.
Picture density of said picture was 1.2 and fog density was 0.01.
The picture density and fog density of the reproduced body obtained in the same manner using a liquid developer which did not contain the copolymer were 0.45 and 0.05, respectively.
EXAMPLES 4 -15
Liquid developers were prepared in the same manner as in Example 1 by forming copolymers by means of the combination of monomers as shown in the table mentioned below and transcription was made. Almost the same results as Example 1 were obtained.
__________________________________________________________________________ AddedMonomer of Monomer of Mol ratio quantity of PictureExamplegeneral formula (1) general formula (2) (1) : (2) copolymer density (g/l)__________________________________________________________________________CH.sub.3 CH.sub.3| |4 CH.sub.2 =C CH.sub.2 =C 2 : 1 2 g 0.9|COOC.sub.8 H.sub.17 SO.sub.3 NH.sub.4 CH.sub.3 |H CH.sub.2 =C| || CH.sub.2 SO.sub.35 CH.sub.2 =C ∠Ca 1.5 : 1 0.8 g 1.1| CH.sub.2 SO.sub.3| |COOC.sub.17 H.sub.35 CH.sub.2 =C | CH.sub.3H CH.sub.3| |6 CH.sub.2 =C CH.sub.2 =C 2 : 1 0.8 g 1.05| |C.sub.8 H.sub.17 CH.sub.2 SO.sub.3 KCH.sub.3 H| |7 CH.sub.2 =C CH.sub.2 =C 1.5 : 1 0.8 g 1.0|C.sub.12 H.sub.25 SO.sub.3 NaH CH.sub.3| |8 CH.sub.2 =C CH.sub.2 =C 1.5 : 1 2 g 0.85| |C.sub.17 H.sub.35 CH.sub.2 SO.sub.3 NH.sub.4CH.sub.3 H| |9 CH.sub.2 =C CH.sub.2 =C 2 : 1 0.8 g 1.15| |OC.sub.8 H.sub.17 CH.sub.2 SO.sub.3 NaH CH.sub.3| |10 CH.sub.2 =C CH.sub.2 =C 1.5 : 1 0.8 g 1.04|OC.sub.12 H.sub.25 SO.sub.3 NaH H| |11 CH.sub.2 =C CH.sub.2 =C 1.5 : 1 0.8 g 1.0| |OC.sub.17 H.sub.35 SO.sub.3 Na HCH.sub.3 CH.sub.2 =C| || SO.sub.3CH.sub.2 =C12 | ∠Ba 1.5 : 1 0.8 g 1.12|COOC.sub.17 H.sub.35 CH.sub.2 =C--SO.sub.3 H HH CH.sub.2 =CSO.sub.3||13 CH.sub.3 =C ∠Mg 2 : 1 0.8 g 1.2||COOC.sub.8 H.sub.17 CH.sub.2 =CSO.sub.2 H CH.sub.3 |CH.sub.3 CH.sub.2 = CSO.sub.3||14 CH.sub.3 =C ∠Sr 1.5 : 1 0.8 g 1.0||COOC.sub.12 H.sub.25 CH.sub.2 =CSO.sub.3 | CH.sub.3CH.sub.3 H| |15 CH.sub.2 =C CH.sub.2 =C 1.5 : 1 0.8 g 1.2|C.sub.17 H.sub.35 SO.sub.3 K__________________________________________________________________________
EXAMPLE 16
300 ml of dioxane, 2 g of stearyl methacrylate, 28 g of diethyl aminoethyl methacrylate, 2.5 g of 2',2-azobis (isobutyronitrile) were poured into a 4-neck 500 ml flask. After sufficiently replacing the air in the flask with nitrogen gas, and while heating up to 40° - 50°C, solution of 18 g of sodium P-styrene sulphonate in 50 ml of water was dropped. After the dropping, the liquid temperature was raised up to 70° - 80°C and then after stirring for approximately 7 hours it was allowed to stand to cool down.
Concentration of the reaction liquid was made under reduced pressure and performed reprecipitation refining twice using 20% hydrous methanol and when the precipitates were dried up, light brown material was obtained. As a result of infrared absorption spectrum analysis of said material, it was confirmed that the material was a copolymer consisting of stearyl methacrylate, diethyl aminoethyl methacrylate and sodium P-styrene sulphonate.
Next, in order to make a liquid developer using the above mentioned copolymer, a mixture of 60 g of carbon black, 150 g of wax rubber, 100 g of cumarone resin, 800 g of Isopar-H (trademark of a product of ESSO Co.) was dispersed for 2 hours in a sand mill, and 20 g of the resultant dispersion material and 0.03 g of said copolymer were dispersed in 800 g of Isopar-H to obtain liquid developer.
Using said liquid developer transcription according to electrophotography was performed in a similar manner as described in Example 1.
Also in the above, for the sake of comparison a liquid developer was produced using the same amount of lecithin in place of the said copolymer and transcription was done in similar manner.
The data obtained in the above by comparing the picture density and fog density relative to the liquid developer prepared time and after allowing it to stand for one month is given below.
______________________________________ After allowing to Prepared time stand one month Picture PictureLiquid developer density Fog density density Fog density______________________________________Example 16 1.2 0.01 1.15 0.01Comparative 1.0 0.02 0.9 0.03developer______________________________________
EXAMPLE 17
A copolymer was prepared as in the case of Example 16 by using 38 g of stearyl methacrylate, 17.3 g of diethyl aminoethyl methacrylate and 14 g of sodium methallyl sulphonate.
Next, a mixture of 50 g of carbon black, 200 g of cumarone resin, 100 g of cyclized rubber, 800 g of Isopar-H (trademark of a product of Esso Co.) was dispersed for 2 hours in a sand mill, and then 20 g of the resultant dispersion material and 0.5 g of the above mentioned copolymer were sufficiently mixed and dispersed in 800 g of Isopar-H to obtain a liquid developer.
On the other hand, a melts consisting of high purity amorphous selenium and pulverulent tellurium in the ratio 9:1 was evaporated on a nickel plated brass plate up to 50μ in thickness to prepare a photosensitive plate. To the said photosensitive plate was applied plus 6 KV corona electric charge, and by means of film having a positive image, the image was exposed to form an electrostatic latent image which was developed using the said liquid developer, and when transferred onto a transfer paper, a clear positive picture was obtained.
The picture density of this picture was 1.2 and fog density was 0.01.
EXAMPLE 18
A polymer was synthesized in a similar manner as in the case of Example 16 using lauryl methacrylate, dimethyl aminoethyl methacrylate and sodium methallyl sulphonate.
Next, a mixture of 50 g of copper phthalocyamine blue, 200 g of cumarone resin, 100 g of cyclized rubber, 25 g of low molecular polyethylene, and 800 g of Isopar-H (trademark of a product of Esso Co.) was dispersed for 2 hours in a sand mill, and then 20 g of the resultant dispersion material and 0.08 g of the above mentioned reaction product were dispersed in 800 g of Isopar-H to obtain a liquid developer.
On the other hand, a mixture of 100 g of microcrystal zinc oxide, 200 g of styrene-butadiene copolymer 50% toluene solution, 40 g of n-butyl methacrylate 50% toluene solution, 120 g of toluene, and 4 ml of Rose Bengale 1% methanol solution was dispersed for 6 hours in a ball mill, and then it was coated on a paper which had underwent undercoating treatment and dried up so that the thickness of the dried up coating became 20μ to produce a photosensitive paper for electrophotography. To the said photosensitive paper was applied -6 KV corona electric charge, then an enlarged image was projected from a negative microfilm to form an electrostatic latent image which was soaked in the above mentioned liquid developer obtaining a clear black positive picture. Picture density of it was 1.0 and fog density was 0.01. Also, for the purpose of comparison a liquid developer which did not contain the above mentioned copolymer was prepared and development was made in the similar manner only to obtain a picture having low picture density and much fog.
EXAMPLE 19
Copolymers were produced by combination of the monomer listed in the table mentioned below in the similar manner as described in example 16, and then preparing liquid developers performed transcription. As a result almost the same effects as in the case of Example 16 were obtained.
__________________________________________________________________________Monomer of Monomer of Monomer of Mol AddedEx.- general general general ratio quan- Pictureampleformula (1) formula (2) formula (3) (1):(2) tity density :(3) (g/l)__________________________________________________________________________CH.sub.3 CH.sub.3 H| | |19 CH.sub.2 =C CH.sub.2 =C CH.sub.2 =C 2:1:1 0.03 1.1|COOC.sub.8 H.sub.17 SO.sub.3 Na CH.sub.3 CH.sub.3H | |20 CH.sub.2 =C CH.sub.2 =C CH.sub.2 =C 1.5:1:1 0.5 g 1.0| | |COOC.sub.17 H.sub.35 CH.sub.2 SO.sub.3 NH.sub.4 COO(CH.sub.2)--N(C.sub.2 H.sub.5).sub.2 HH H |21 CH.sub.2 =C CH.sub.2 =C CH.sub.2 =C 2:1:1 0.05 1.1| |C.sub.8 H.sub.17 CH.sub.2 SO.sub.3 NaH CH.sub.2 H| | |22 CH.sub.2 =C CH.sub.2 =C CH.sub.2 =C 1.5:1:1 0.03 1.15| |C.sub.17 H.sub.35 (CH.sub.2).sub.4 N(CH.sub.3).sub.2 SO.sub.3 N.sub.aCH.sub.3 H H| | |23 CH.sub.2 =C CH.sub.2 =C CH.sub.2 =C 1.5:1:1 0.05 1.05| |C.sub.12 H.sub.25 SO.sub.3 N.sub.a H CH.sub.3CH.sub.3 | || CH.sub.2 =C || | |24 CH.sub.2 =C CH.sub. 2 SO.sub.3 CH.sub.2 =C 2:1:1 0.05 1.15|| ∠Ca|OC.sub.8 H.sub.17 CH.sub.2 SO.sub.3 | C.sub.2 H.sub.5 CH.sub.2 =C (CH.sub.2).sub.2 N∠ | CH.sub.3 HH CH.sub.3 CH.sub.3| | |25 CH.sub.2 =C CH.sub.2 =C CH.sub.2 =C 1.5:1:1 0.05 1.2| | |C.sub.4 H.sub.9OC.sub.12 H.sub.25 CH.sub.2 SO.sub.3 K COOCH.sub.2 N∠ C.sub.4 H.sub.9H H H| CH.sub.2 =C |26 CH.sub.2 =C | CH.sub.2 =C 1.5:1:1 0.05 1.1| SO.sub.3 |CH.sub.3OC.sub.17 H.sub.35 ∠Mg COO(CH.sub.2).sub.2 N∠ SO.sub.3 H | CH.sub.2 =C HCH.sub.3 H CH.sub.3| || CH.sub.2 =CSO.sub.3 |27 CH.sub.2 =C ∠B.sub.a CH.sub.2 =C 1.5:1:1 0.03 1.2| |COOC.sub.12 H.sub.25 CH.sub.2 =CSO.sub.3 | | H CH.sub.2 N(C.sub.2 H.sub.5).sub. 2H CH.sub.3 CH.sub.3| | |28 CH.sub.2 =C CH.sub.2 =C CH.sub.2 =C 2:1:1 0.03 1.12| |COOC.sub.8 H.sub.17 COOCH.sub.2 N(CH.sub.3).sub.2 SO.sub.3 N.sub.aCH.sub.3 CH.sub.3 CH.sub.3| | |29 CH.sub.2 =C CH.sub.2 =C CH.sub.2 =C 1.5:1:1 0.5 g 1.0| | |CH.sub.3OC.sub.12 H.sub.25 SO.sub.3 NH.sub.4 COO(CH.sub.2).sub.4 N∠ C.sub.2 H.sub.5H H HCH.sub.2 =C | CH.sub.2 =C30 | CH.sub.2 =C |CH.sub.3 2:1:1 0.05 1.1C.sub.8 H.sub.17 | | SO.sub.3 K CH.sub.2 N∠ C.sub.4 H.sub.9__________________________________________________________________________
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A liquid developer for electrophotography and a process for developing latent images using the liquid developer. The liquid developer comprises a highly insulating carrier liquid, a toner particle dispersed therein, and a copolymer produced from at least one member selected from the monomers of the formula (1) and at least one member selected from the monomers of the formula (2) or a copolymer produced from at least one member selected from the monomers of the formula (1), at least one member selected from the monomers of the formula (2) and at least one member selected from the monomers of the formula (3). ##EQU1##
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application No. PCT/DE2004/002287, filed 15 Oct. 2004, which claims priority of German Application No. 103 58 203.7, filed 12 Dec. 2003, and each of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a unit for use in automatic container return systems. More particularly, the invention relates to a unit for use in an automatic returnable container return system of the type including a conveyor device for horizontal transport of the returnable containers in the direction of the longitudinal axis of the returnable containers, and for rotation of the containers around their longitudinal axes.
BACKGROUND OF THE INVENTION
One unit of this type is known from EP 1 167 247 B 1. It comprises at least two essentially cylindrical conveyor rollers that are aligned parallel to one another, longitudinally in the direction of conveyance of the articles. The conveyor rollers are capable of rotating around their longitudinal axes, and each conveyor roller comprises an integrated conveyor belt that rotates around the said roller. The top run of each conveyor belt is essentially aligned on the circumferential surface of the conveyor rollers, which in the region of the top run of the conveyor belts is recessed. To enable the longitudinal transport of the containers, the conveyor rollers are tilted toward one another such that the two top runs of the conveyor belts form a V-shaped channel, in which the container lies. Containers are transported longitudinally until they reach an identification unit, which is designed to scan data on the container, for example a barcode on its outer surface. The identification unit is ordinarily positioned above the path of conveyance or to its side. Because the circumferential surfaces of the containers lie in random positions once the containers have been loaded into the unit, the barcode may not lie within the scanning range of the identification unit. In such cases it is necessary to rotate the container. This is accomplished by means of a unidirectional rotation of the conveyor rollers, which causes the conveyor belts integrated into said rollers also to rotate. Once the distinguishing markings on the container have been scanned, the conveyor rollers reassume a position in which the top runs of the conveyor belts form a V-shaped channel. By actuating the conveyor belts, the container is then advanced in a longitudinal direction for further processing or is conveyed in a reverse direction if it is identified as a container that cannot be accepted by the system.
Another unit of this type is disclosed in EP 1 081 661 A 2. This unit comprises two conveyors that are essentially identical in design; these are comprised of conveyor elements and are tilted toward one another so as to form a V-shaped channel. Between the transport elements, slots are provided extending transversely to the longitudinal direction of conveyance. Beneath the two conveyors, rotational discs are arranged, extending over at least a portion of the length of the conveyors, in which discs can be raised so that they protrude through the slots in the transport elements. When this function is activated, a container lying on the conveyors is lifted off the conveyors by the rotating discs. The container then rests on the rotating discs and can be placed in rotation via the unidirectional actuation of the rotating discs. As in the above case, this allows an obscured identifying mark on the container, such as a barcode, to be scanned by an identification unit.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is to provide a conveyor unit for use in automatic container return systems. This object is attained according to the invention with a unit for use in an automatic container return system of the type including a conveyor device for horizontal transport of the returnable containers in the direction of the longitudinal axis of the returnable containers, and for rotation of the containers around their longitudinal axes, the unit including a conveyor device having a circulating conveyor chain. A support element provided on the conveyor chain, and conveyor members provided on the support elements. The conveyor members are rotatable around an axis extending longitudinally in the direction of conveyance.
With the present invention, the conveyor members in the conveyor chain produce both the translational motion and the rotational motion of the container. Thus additional components required for rotating the container can be omitted.
In one advantageous embodiment of the invention, the support element for the conveyor members is a taut cable or belt. A taut cable or belt is a very simply implemented support element, on which the conveyor members can be lined up like beads on a chain. A support element of this type offers the additional advantage of simultaneously serving as the rotational axis for the conveyor members.
In a further advantageous embodiment of the invention, the support element for the conveyor members is a link chain with recesses in links, and which recesses extend transversely to the direction of conveyance, whereby the conveyor members are disk-shaped and are rotatably mounted in the recesses on individual shafts which extend longitudinally in the direction of conveyance and which are supported in the respective links. In this case it is advantageous for each link in the link chain to have two recesses arranged side by side, extending transversely to the longitudinal direction of conveyance, and with one conveyor member being arranged in each recess. In this manner, the cost of two separate conveyor chains can be eliminated.
If the conveyor chains of the device are arranged side by side, the inventive apparatus can also be used without great expense as a conveying device for conveying boxes, packages, and the like. When the conveyor chains are moved in a longitudinal direction, the boxes, packages, and similar articles are transported in a longitudinal direction, and when the conveyor members are rotated, such articles are moved in a transverse direction. Sorting gates or sorting areas for boxes, packages, and similar articles can be constructed on the basis of this principle.
Below, the invention will be described in greater detail with reference to two exemplary embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a unit according to a first embodiment of the present invention;
FIG. 2 is a front elevation of this unit of FIG. 1 ;
FIG. 3 is a perspective representation of a unit according to a second embodiment of the invention;
FIG. 4 is a side elevation of this unit of FIG. 3 , in reduced dimensions; and
FIG. 5 is a front elevation of this unit of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
The inventive embodiment of the unit shown in FIG. 1 includes a base frame 1 that is U-shaped in cross-section, on an outer panel of which two electric motors 2 , 3 are mounted. A drive shaft 4 of the electric motor 2 projects through the base frame 1 and supports a chain drive sprocket 5 , which has two circumferential grooves 5 . 1 which are essentially semicircular in cross-section and are configured to hold two conveyor chains 6 , 7 . An identical sprocket wheel 8 is rotatably mounted at the other end of the base frame 1 in its side panels. For this sprocket wheel 8 , a tensioning device 9 is provided, which is not further depicted in the drawing.
The conveyor chains 6 , 7 include individual conveyor members 10 . Each conveyor chain 6 , 7 includes a steel cable 10 . 4 as a support element, which is shown in FIG. 2 , on which the conveyor members 10 are lined up. Each conveyor member 10 has a cylindrical circumferential surface 10 . 1 and, on its end surfaces, in a male-female manner, a semicircular head 10 . 2 and a semicircular shell 10 . 3 . On the basis of this configuration, the conveyor members 10 engage in one another in the conveyor chain 6 , 7 , and can also take on the curvature of the sprocket wheels 5 , 8 .
The conveyor chains 6 , 7 rotate on the sprocket wheels 5 , 8 and thus have a top run 11 and a bottom return run 12 , such as an upper side and a lower side, respectively. The top runs 11 are guided at their edges by two support rollers 13 , 14 , which are rotatably mounted on the base frame 1 .
Beneath the top run 11 of the conveyor chains 6 , 7 a pressure roller 15 is arranged centrally relative to the conveyor chains 6 , 7 , extending longitudinally in the direction of conveyance. The pressure roller 15 includes a rotary drive, which includes a toothed belt wheel 16 that rests on a drive shaft 19 of the electric motor 3 , a toothed belt 17 , and a toothed belt wheel 18 that rests on the axle of the pressure roller 15 . The circumferential surface of the pressure roller 15 bears against the cylindrical surfaces 10 . 1 of the conveyor members 10 arranged above it.
When the electric motor 2 is activated for the purpose of driving the sprocket wheel 5 , a bottle 20 lying on the conveyor chains 6 , 7 is conveyed longitudinally along the conveyor chains 6 , 7 . Once the bottle 20 reaches a position above the pressure roller 15 , the electric motor 2 can be stopped in this position, for example by use of a photoelectric sensor or some other type of sensor. If at this point the pressure roller 15 is placed in rotation by the electric motor 3 and the toothed belt drive 16 , 17 , 18 , the resulting friction will cause the abutting conveyor members 10 to rotate around the steel cables, each of which forms an axis of rotation. The bottle 20 lying on these conveyor members 10 will then begin to rotate in the same direction as the pressure roller 15 . This rotational motion of the bottle 20 will bring an identifying marking on the bottle 20 , such as a barcode, into the scanning range of a sensor, for example a barcode reader, so that distinguishing characteristics specific to the bottle can be read into the system. If the identification unit should determine that the bottle is returnable, it is further advanced in the previous longitudinal direction. If the bottle 20 is a container of the type which cannot be accepted by the system, it can be returned, for example, to an input area, by reversing the drive of the conveyor chains 6 , 7 .
To minimize the friction between the conveyor members 10 and the pressure roller 15 during the translational actuation of the conveyor chains 6 , 7 , either the pressure roller 15 can be pivoted downward, away from the conveyor members 10 , or the pressure roller 15 can be equipped with releases arranged longitudinally along the lines of contact with the conveyor members 10 . In this case it is necessary, once the rotational motion has been completed, to realign the releases underneath the conveyor members 10 . For this purpose, a positioning sensor for the pressure roller 15 can be provided.
If the friction between the pressure roller 15 and the conveyor members 10 during the translational actuation of the conveyor chains 6 , 7 is to be disregarded, then the rotational drive can also be activated. In this case, the bottle 20 will move in a helical fashion.
If, rather than just two conveyor chains 6 , 7 as in the above exemplary embodiment, multiple conveyor chains are to be aligned side by side, the unit can also be used as sorting gates or in sorting areas for boxes, packages, or similar articles. In this case the boxes, packages, and the like are transported longitudinally along the conveyor chains with their translational actuation, and with the rotational actuation of the conveyor members 10 such articles are transported transversely relative to the longitudinal extension of the conveyor chains.
In FIG. 3 through 5 a further exemplary embodiment of the invention is illustrated. The reference figures used in the above-described exemplary embodiment are used here again to identify identical or equivalent components.
This unit also includes base frame 1 with U-shaped cross-section, on the side panel of which electric motor 2 for translational motion and electric motor 3 for rotational motion of the conveyor assembly are mounted. Two sprocket wheels 5 rest on the drive shaft 4 of the electric motor 2 , each lying adjacent to the side walls of the base frame 1 on the inside. Identical, but not actuated, sprocket wheels 8 are mounted at the opposite end of the unit on the side walls of the base frame 1 .
A link chain 21 including links 22 that are connected to one another in an articulated fashion runs over the sprocket wheels 5 , 8 . Each of the articulated joints between the links 22 is designed with female joint elements 23 and male joint elements 24 at their side ends, with these two joint elements 23 , 24 being connected to one another by means of a link pin 25 that projects to the side. These link pins 25 lie within the tooth spaces of the sprocket wheels 5 , 8 , so that a secure transmission of force via the motor shaft 4 and the actuated sprocket wheels 5 to the link chain 21 is ensured. The non-driven sprocket wheels 8 which can in turn be acted upon by a tensioning device 9 which is partially illustrated, allowing the adjustment of the tension in the link chain 21 . The top run of the link chain 21 is guided over its link pins 25 in lateral guides 13 , 14 that are U-shaped in cross-section.
The link chain 21 forms a support element for disc-shaped conveyor members 10 that are arranged extending transversely to the longitudinal direction of conveyance. To accommodate these conveyor members 10 , each link 22 in the link chain 21 comprises two recesses 26 arranged side by side and arranged extending transversely to the longitudinal direction of conveyance. The conveyor members 10 are rotatably mounted in the recesses 22 . In addition, shafts are provided, aligned in the longitudinal direction of conveyance, which extend through the conveyor members 10 and are mounted in cross supports 28 on each of the links 22 .
With the side-by-side arrangement of the conveyor members 10 in link chain 21 , as with the preceding exemplary embodiment, two conveyor chains 6 , 7 are created, on whose conveyor members 10 a bottle 20 being transported is laterally supported.
For the rotary actuation of the conveyor members 10 a pressure roller 15 is provided. The positioning, construction, and actuation of this pressure roller 15 are as described in reference to the first exemplary embodiment.
This unit, too, enables the helical movement of a bottle 20 with the simultaneous activation of the translational and rotational drives.
For details on the mode of operation of the unit according to the second exemplary embodiment, please refer to the first exemplary embodiment, as the operating principles are identical. The unit illustrated in FIG. 3 through 5 can also be used as sorting gates or in a sorting area for boxes, packages or similar articles.
While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and 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 or limits of the claims appended hereto.
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Unit for automated container recovery machines, such as for receiving returnable bottles and cans, includes a conveyor device for transporting the returnable containers horizontally in the direction of their longitudinal axes and for rotating the containers about their longitudinal axes. The aim is to provide an additional unit of this type. To achieve this, the conveyor device includes one or more continuous conveyer chains which are adjacent to one another and include support elements and conveyor members which are situated on the support elements. The conveyor members can be rotated about an axis that extends in the longitudinal direction of the conveyor device.
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FIELD
The present invention relates to containers for holding, storing and dispensing liquids, such as sauce, dressing or other items.
BACKGROUND
Food items served with sauces or other condiments (such as ketchup, mustard, dressings, or the like) for dipping are common (generically, the foregoing referred to herein as condiments). Typically, the condiment is provided in a small round plastic container which may or may not have a lid. A problem with such a container is that it is not convenient or efficient to remove excess condiment on the container rim after the food item is dipped therein, resulting in excess condiment remaining on the food item. Also, round containers are difficult to grasp when a user's fingers may be slippery from condiment, grease, or the like which may accumulate during eating.
It would be desirable to have a condiment container which would provide a more effective and efficient means to remove excess condiment on a dipped food item. It would also be desirable to have a condiment container which could be easily grasped in a user's fingers even if the fingers are slippery.
SUMMARY
Generally described, the present invention provides in a first exemplary embodiment a container for holding and storing sauces and other liquids, comprising a base having a generally flat base bottom, a generally frusto-conical wall extending upward from the bottom and having a rim, the wall having a first section, a second section opposing the first section, the first section having a height greater than the second section, a third section, and a fourth section opposing the third section, the third and fourth sections each having an inwardly curved gripping section, the gripping section having at least one gripping surface a lip extending substantially around the rim of the wall.
The wall first section has at least one and preferably a plurality of fluid retention devices for retaining fluid when a food item is wiped across the retention devices. The retention devices can be ribs, grooves, bumps, other protrusions, combinations and mixtures of the foregoing or the like.
The container may have a lid adapted to snap fit over the lip, the lid having a generally flat lid bottom, a lid wall extending upward from the lid bottom, the lid wall having a first section and a second section, the first section having a height greater than the second section, a seal portion comprising a first flange extending generally outward and generally perpendicular to the lid wall and a second flange extending generally downward from the first flange, the seal portion being adapted to mate with the lid and form a seal therewith, whereby the lid wall first section is generally aligned with the base wall first section.
The gripping section may include a plurality of retention devices to facilitate gripping. The retention devices can be grooves, ribs, bumps, combinations of the foregoing or the like.
The container is preferably constructed to allow a number of containers to nest and stack to minimize storage space. The lid is similarly constructed. When the lid is attached to the container a number of lid-container units can be stacked to permit storage of pre-filled containers.
Other features of the present invention will become apparent upon reading the following detailed description of embodiments of the invention, when taken in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated in the drawings in which like reference characters designate the same or similar parts throughout the figures of which:
FIG. 1 is a perspective view of a container base according to one exemplary embodiment of the present invention.
FIG. 2 is a bottom plan view of the base of FIG. 1 .
FIG. 3 is a side elevation view of the base of FIG. 1 .
FIG. 4 is a top plan view of the base of FIG. 1 .
FIG. 5 is a perspective view of a lid according to one exemplary embodiment of the present invention.
FIG. 6 is a perspective view of the base of FIG. 1 and the lid of FIG. 5 in which the lid is in position over the base.
FIG. 7 is a perspective view of the lid attached to the base.
FIG. 8 is a perspective view of a first alternative embodiment of a base, including a plurality of retention devices.
FIG. 9 is a perspective view of a second alternative of a lid including a tab.
FIG. 10 is a perspective view of a container base with condiment showing a food item being wiped across the lip and retention devices.
DETAILED DESCRIPTION
FIGS. 1-7 show one exemplary embodiment of a container 10 having a base 20 and a lid 22 . FIGS. 1-4 show the details of the base 20 , which generally has a bottom 24 , a wall 28 and a rim forming a lip 30 .
The wall 28 has a first section 32 , second section 34 , third section 36 and fourth section 38 . The first and second sections 32 , 34 oppose each other and the first section 32 has a height greater than that of the second section 34 so that the lip 30 is angled with respect to the base 20 . The wall 28 may flare outward in a generally frusto-conical shape. The general relationship between the diameter of the base 20 and the lip 30 is such that a container is created which, when placed on a flat surface, is generally resistant to tipping when a condiment is placed therein.
The third and fourth sections 36 , 38 oppose each other and each has a recessed area which serves as a gripping area 40 . Each recessed gripping area 40 may curve inward slightly so that a user can grip the gripping areas 40 with a thumb and opposing finger. Each gripping area 40 may optionally have one or more gripping surfaces 42 , which may take the form of protrusions, grooves, recesses, ribs, ridges, steps, bumps, spikes, domes, fingers, nibs, and combinations of the foregoing. The gripping area 40 may extend to the base 20 (as shown in FIG. 1 ) or may extend only toward the base 20 . If the former, the gripping area 40 may optionally create a curved notched out area 44 in the base 20 .
The lip 30 may extend outward from the wall 28 . Alternatively, the lip 30 may have a flange which extends both outward and inward.
Turning to FIG. 5 , the lid 22 includes a bottom 60 and a sidewall 62 . The sidewall 62 has a first section 64 that is greater in height than a second section 66 . A rim 68 has a seal 70 comprising a first flange 72 and a second flange 74 , the seal 70 being adapted to mate over the lip 30 by a friction or snap fit to seal the container base 10 , as shown in FIGS. 6-7 . The seal 70 can be one which is removable and resealable, or, the seal 70 can be a seal which is formed so that in use, a container 10 filled with condiment has the lid 22 and seal 70 formed to provide a seal which can be unsealed only once (such as a milk jug cap seal). In such an embodiment the seal 70 may have a weakened or frangible area which a user can separate or remove by pulling on a tab 90 (see FIG. 9 and as described hereinbelow).
The container 10 may be made of any suitable material, such as, but not limited to, polymer plastic, stainless steel, aluminum, paper/cellulose, wood, recycled or recyclable material, edible materials, mixtures and combinations of the foregoing or the like and may be formed by any suitable manufacturing process, such as, but not limited to, vacuum forming, blow molding, or the like.
The lid bottom 60 can be marked with a pen, pencil or marker with the contents, or can have a sticker adhered to or a stamp placed on the bottom 60 as advertising.
In one use, a server can place a quantity of liquid, such as a condiment 78 (e.g., ketchup or mustard), sauce (e.g., barbeque) or dressing (e.g., ranch, blue cheese) (the foregoing referred to generically as “condiment(s)”, but is intended to include such items as can be contained in the container), in the base 20 and attach the lid 22 to the base 20 to prevent spilling. The container 10 can be served with various food items suitable for dipping, such as, but not limited to, chicken wings, vegetable sticks, fried cheese sticks, spring rolls or the like. The user can then remove the lid 22 and dip the food item into the condiment and wipe the excess condiment on the lip 30 , such as proximate the wall first section 32 . As the food item is raked across the lip 30 the excess condiment is retained by the lip 30 and flows down the wall 28 and back into the container base 20 . The angle and diameter of the wall first section 32 is such that the condiment is retained in the base 20 .
A user can pick the base 20 up and hold it between his or her fingers, using the gripping areas 40 to hold the base 20 . The gripping surfaces 42 help to maintain the user's grip, particularly when the user's fingers may be slippery, wet or greasy or have excess condiment on them.
In a first alternative embodiment, shown in FIG. 8 , the base 20 can have at least one, and preferably a plurality of fluid retention devices 80 , such as, but not limited to, protrusions, grooves, recesses, ridges, steps, bumps, spikes, domes, fingers, nibs, combinations and mixtures of the foregoing or the like formed as part of the wall 28 , such as part of the first section 34 (it being understood that other portions of the wall can include such retention devices 80 ). The condiment retention device 80 helps to retain excess 79 condiment 78 (see FIG. 10 ) when the user wipes the food item across the lip 30 and the wall 32 .
The base 20 can be nestably stacked with multiple bases 20 to minimize the area needed for storage. Similarly, the lid 22 can be nestably stacked with a plurality of other lids 22 . The base bottom 24 and lid bottom 60 are generally the same diameter so that multiple containers 10 (in which the lid 22 is fitted on the base 20 ) with or without condiments, can be stacked. In this manner, a set of different condiments can be conveniently carried from kitchen to table by stacking several containers 10 on top of each other without fear of spilling or inadvertently mixing the contents. Containers 10 can be filled with condiments, sealed, and stacked and stored, such as in a refrigerator, until used.
The lid 22 can optionally have a tab 90 (as shown in FIG. 9 ) to aid in removal of the lid 22 .
In one exemplary embodiment, the container base 20 can be a 2, 3 or 4 ounce capacity size. It is to be understood that the size and proportions can be adapted for different uses. Similarly, the angle of the wall 28 can be modified as the use requires. For example, the container 10 can be adapted for use as a paint container such that a user can hold the container in one hand and dip a small brush in to reservoir of paint, wiping the excess paint off using the lip 30 or the retention devices 80 (see FIG. 8 ).
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.
As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. “Exemplary” means “an example of” and is not intended to convey an indication of a preferred or ideal embodiment. “Such as” is not used in a restrictive sense, but for explanatory purposes.
It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope or spirit. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following inventive concepts.
It should further be noted that any patents, applications and publications referred to herein are incorporated by reference in their entirety.
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A container for holding a dipping condiment or sauce and allowing a user to wipe a food item to remove excess condiment or sauce. The container has a base and a side wall having one portion higher than an opposing portion, the wall including at least one ridge, groove or other fluid retention device. The wall also includes a pair of opposing inwardly curved gripping surfaces for facilitating gripping by a user's fingers, the gripping surfaces including ribs or grooves. The container may also include a lid which snap fits onto the lip of the container.
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RELATED APPLICATIONS
[0001] This application is a continuation of copending U.S. application Ser. No. 11/542,072, which was filed on Oct. 3, 2006, which is a continuation of U.S. application Ser. No. 10/789,357, which was filed on Feb. 27, 2004, which is a continuation of U.S. application Ser. No. 09/693,548, which was filed on Oct. 19, 2000, now U.S. Pat. No. 6,712,486, which claims the benefit of U.S. Provisional Patent Application Nos. 60/160,480, which was filed on Oct. 19, 1999 and 60/200,351, which was filed on Apr. 27, 2000. The entirety of each of these related applications is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is in the field of light emitting diode (LED) lighting devices and more particularly in the field of an LED lighting module having heat transfer properties that improve the efficiency and performance of LEDs.
[0004] 2. Description of the Related Art
[0005] Light emitting diodes (LEDs) are currently used for a variety of applications. The compactness, efficiency and long life of LEDs is particularly desirable and makes LEDs well suited for many applications. However, a limitation of LEDs is that they typically cannot maintain a long-term brightness that is acceptable for middle to large-scale illumination applications. Instead, more traditional incandescent or gas-filled light bulbs are often used.
[0006] An increase of the electrical current supplied to an LED generally increases the brightness of the light emitted by the LED. However, increased current also increases the junction temperature of the LED. Increased juncture temperature may reduce the efficiency and the lifetime of the LED. For example, it has been noted that for every 10° C. increase in temperature, silicone and gallium arsenide lifetime drops by a factor of 2.5-3. LEDs are often constructed of semiconductor materials that share many similar properties with silicone and gallium arsenide.
SUMMARY OF THE INVENTION
[0007] Accordingly, there is a need in the art for an LED lighting apparatus having heat removal properties that allow an LED on the apparatus to operate at relatively high current levels without increasing the juncture temperature of the LED beyond desired levels.
[0008] In accordance with an aspect of the present invention, an LED module is provided for mounting on a heat conducting surface that is substantially larger than the module. The module comprises a plurality of LED packages and a circuit board. Each LED package has an LED and at least one lead. The circuit board comprises a thin dielectric sheet and a plurality of electrically-conductive contacts on a first side of the dielectric sheet. Each of the contacts is configured to mount a lead of an LED package such that the LEDs are connected in series. A heat conductive plate is disposed on a second side of the dielectric sheet. The plate has a first side which is in thermal communication with the contacts through the dielectric sheet. The first side of the plate has a surface area substantially larger than a contact area between the contacts and the dielectric sheet. The plate has a second side adapted to provide thermal contact with the heat conducting surface. In this manner, heat is transferred from the module to the heat conducting surface.
[0009] In accordance with another aspect of the present invention, a modular lighting apparatus is provided for conducting heat away from a light source of the apparatus. The apparatus comprises a plurality of LEDs and a circuit board. The circuit board has a main body and a plurality of electrically conductive contacts. Each of the LEDs electrically communicates with at least one of the contacts in a manner so that the LEDs are configured in a series array. Each of the LEDs electrically communicates with corresponding contacts at an attachment area defined on each contact. An overall surface of the contact is substantially larger than the attachment area. The plurality of contacts are arranged adjacent a first side of the main body and are in thermal communication with the first side of the main body. The main body electrically insulates the plurality of contacts relative to one another.
[0010] For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
[0011] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of an LED module having features in accordance with the present invention.
[0013] FIG. 2 is a schematic side view of a typical pre-packaged LED lamp.
[0014] FIG. 3 is a top plan view of the LED module of FIG. 1 .
[0015] FIG. 4 is a side plan view of the apparatus of FIG. 3 .
[0016] FIG. 5 is a close-up side view of the apparatus of FIG. 3 mounted on a heat conductive member.
[0017] FIG. 6 is another sectional side view of the apparatus of FIG. 3 mounted onto a heat conductive flat surface.
[0018] FIG. 7 is a side plan view of an LED module having features in accordance with another embodiment of the present invention.
[0019] FIG. 8 is a side plan view of another LED module having features in accordance with yet another embodiment of the present invention.
[0020] FIG. 9 is a perspective view of an illumination apparatus having features in accordance with the present invention.
[0021] FIG. 10 is a side view of the apparatus of FIG. 9 .
[0022] FIG. 11 is a bottom view of the apparatus of FIG. 9 .
[0023] FIG. 12 is a top view of the apparatus of FIG. 9 .
[0024] FIG. 13 is a schematic view of the apparatus of FIG. 9 mounted on a theater seat row end.
[0025] FIG. 14 is a side view of the apparatus of FIG. 13 showing the mounting orientation.
[0026] FIG. 15 is a side view of a mounting barb.
[0027] FIG. 16 is a front plan view of the illumination apparatus of FIG. 9 .
[0028] FIG. 17 is a cutaway side plan view of the apparatus of FIG. 20 .
[0029] FIG. 18 is a schematic plan view of a heat sink base plate.
[0030] FIG. 19 is a close-up side sectional view of an LED module mounted on a mount tab of a base plate.
[0031] FIG. 20 is a plan view of a lens for use with the apparatus of FIG. 9 .
[0032] FIG. 21 is a perspective view of a channel illumination apparatus incorporating LED modules having features in accordance with the present invention.
[0033] FIG. 22 is a close-up side view of an LED module mounted on a mount tab.
[0034] FIG. 23 is a partial view of a wall of the apparatus of FIG. 21 , taken along line 23 - 23 .
[0035] FIG. 24 is a top view of an LED module mounted to a wall of the apparatus of FIG. 21 .
[0036] FIG. 25 is a top view of an alternative embodiment of an LED module mounted to a wall of the apparatus of FIG. 21 .
[0037] FIG. 26A is a side view of an alternative embodiment of a lighting module being mounted onto a channel illumination apparatus wall member.
[0038] FIG. 26B shows the apparatus of the arrangement of FIG. 26A with the lighting module installed.
[0039] FIG. 26C shows the arrangement of FIG. 26B with a lens installed on the wall member.
[0040] FIG. 26D shows a side view of an alternative embodiment of a lighting module installed on a channel illumination apparatus wall member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] With reference first to FIG. 1 , an embodiment of a light-emitting diode (LED) lighting module 30 is disclosed. In the illustrated embodiment, the LED module 30 includes five pre-packaged LEDs 32 arranged on one side of the module 30 . It is to be understood, however, that LED modules having features in accordance with the present invention can be constructed having any number of LEDs 32 mounted in any desired configuration.
[0042] With next reference to FIG. 2 , a typical pre-packaged LED 32 includes a diode chip 34 encased within a resin body 36 . The body 36 typically has a focusing lens portion 38 . A negative lead 40 connects to an anode side 42 of the diode chip 34 and a positive lead 44 connects to a cathode side 46 of the diode chip 34 . The positive lead 44 preferably includes a reflector portion 48 to help direct light from the diode 34 to the lens portion 38 .
[0043] With next reference to FIGS. 1-5 , the LED module 30 preferably comprises the five pre-packaged LED lamps 32 mounted in a linear array on a circuit board 50 and electrically connected in series. The illustrated embodiment employs pre-packaged aluminum indium gallium phosphide (AlInGaP) LED lamps 32 such as model HLMT-PL00, which is available from Hewlett Packard. In the illustrated embodiment, each of the pre-packaged LEDs is substantially identical so that they emit the same color of light. It is to be understood, however, that nonidentical LEDs may be used to achieve certain desired lighting effects.
[0044] The illustrated circuit board 50 preferably is about 0.05 inches thick, 1 inch long and 0.5 inch wide. It includes three layers: a copper contact layer 52 , an epoxy dielectric layer 54 and an aluminum main body layer 56 . The copper contact layer 52 is made up of a series of six elongate and generally parallel flat copper plates 60 that are adapted to attach to the leads 40 , 44 of the LEDs 32 . Each of the copper contacts 60 is electrically insulated from the other copper contacts 60 by the dielectric layer 54 . Preferably, the copper contacts 60 are substantially coplanar.
[0045] The pre-packaged LEDs 32 are attached to one side of the circuit board 50 , with the body portion 36 of each LED generally abutting a side of the circuit board 50 . The LED lens portion 38 is thus pointed outwardly so as to direct light in a direction substantially coplanar with the circuit board 50 . The LED leads 40 , 44 are soldered onto the contacts 60 in order to create a series array of LEDs. Excess material from the leads of the individual pre-packaged LED lamps may be removed, if desired. Each of the contacts 60 , except for the first and last contact 62 , 64 , have both a negative lead 40 and a positive lead 44 attached thereto. One of the first and last contacts 62 , 64 has only a negative lead 40 attached thereto; the other has only a positive lead 44 attached thereto.
[0046] A bonding area of the contacts accommodates the leads 40 , 44 , which are preferably bonded to the contact 60 with solder 68 ; however, each contact 60 preferably has a surface area much larger than is required for adequate bonding in the bonding area 66 . The enlarged contact surface area allows each contact 60 to operate as a heat sink, efficiently absorbing heat from the LED leads 40 , 44 . To maximize this role, the contacts 60 are shaped to be as large as possible while still fitting upon the circuit board 50 .
[0047] The dielectric layer 54 preferably has strong electrical insulation properties but also relatively high heat conductance properties. In the illustrated embodiment, the layer 54 is preferably as thin as practicable. For example in the illustrated embodiment, the dielectric layer 54 comprises a layer of Thermagon® epoxy about 0.002 inches thick.
[0048] It is to be understood that various materials and thicknesses can be used for the dielectric layer 54 . Generally, the lower the thermal conductivity of the material used for the dielectric layer, the thinner that dielectric layer should be in order to maximize heat transfer properties of the module. For example, in the illustrated embodiment, the layer of epoxy is very thin. Certain ceramic materials, such as beryllium oxide and aluminum nitride, are electrically non-conductive but highly thermally conductive. When the dielectric layer is constructed of such materials, it is not as crucial for the dielectric layer to be so very thin, because of the high thermal conductivity of the material.
[0049] In the illustrated embodiment, the main body 56 makes up the bulk of the thickness of the circuit board 50 and preferably comprises a flat aluminum plate. As with each of the individual contacts 60 , the main body 56 functions as a heat conduit, absorbing heat from the contacts 60 through the dielectric layer 54 to conduct heat away from the LEDs 32 . However, rather than just absorbing heat from a single LED 32 , the main body 56 acts as a common heat conduit, absorbing heat from all of the contacts 60 . As such, in the illustrated embodiment, the surface area of the main body 56 is about the same as the combined surface area of all of the individual contacts 60 . The main body 56 can be significantly larger than shown in the illustrated embodiment, but its relatively compact shape is preferable in order to increase versatility when mounting the light module 30 . Additionally, the main body 56 is relatively rigid and provides structural support for the lighting module 30 .
[0050] In the illustrated embodiment, aluminum has been chosen for its high thermal conductance properties and ease of manufacture. It is to be understood, however, that any material having advantageous thermal conductance properties, such as having thermal conductivity greater than about 100 watts per meter per Kelvin (W/m-K), would be acceptable.
[0051] A pair of holes 70 are preferably formed through the circuit board 50 and are adapted to accommodate a pair of aluminum pop rivets 72 . The pop rivets 72 hold the circuit board 50 securely onto a heat conductive mount member 76 . The mount member 76 functions as or communicates with a heat sink. Thus, heat from the LEDs 32 is conducted with relatively little resistance through the module 30 to the attached heat sink 76 so that the junction temperature of the diode chip 34 within the LED 32 does not exceed a maximum desired level.
[0052] With reference again to FIGS. 3 and 5 , a power supply wire 78 is attached across the first and last contacts 62 , 64 of the circuit board 50 so that electrical current is provided to the series-connected LEDs 32 . The power supply is preferably a 12-volt system and may be AC, DC or any other suitable power supply. A 12-volt AC system may be fully rectified.
[0053] The small size of the LED module 30 provides versatility so that modules can be mounted at various places and in various configurations. For instance, some applications will include only a single module for a particular lighting application, while other lighting applications will employ a plurality of modules electrically connected in parallel relative to each other.
[0054] It is also to be understood that any number of LEDs can be included in one module. For example, some modules may use two LEDs, while other modules may use 10 or more LEDs. One manner of determining the number of LEDs to include in a single module is to first determine the desired operating voltage of a single LED of the module and also the voltage of the power supply. The number of LEDs desired for the module is then roughly equal to the voltage of the power supply divided by the operating voltage of each of the LEDs.
[0055] The present invention rapidly conducts heat away from the diode chip 34 of each LED 32 so as to permit the LEDs 32 to be operated in regimes that exceed normal operating parameters of the pre-packaged LEDs 32 . In particular, the heat sinks allow the LED circuit to be driven in a continuous, non-pulsed manner at a higher long-term electrical current than is possible for typical LED mounting configurations. This operating current is substantially greater than manufacturer-recommended maximums. The optical emission of the LEDs at the higher current is also markedly greater than at manufacturer-suggested maximum currents.
[0056] The heat transfer arrangement of the LED modules 30 is especially advantageous for pre-packaged LEDs 32 having relatively small packaging and for single-diode LED lamps. For instance, the HLMT-PL00 model LED lamps used in the illustrated embodiment employ only a single diode, but since heat can be drawn efficiently from that single diode through the leads and circuit board and into the heat sink, the diode can be run at a higher current than such LEDs are traditionally operated. At such a current, the single-diode LED shines brighter than LED lamps that employ two or more diodes and which are brighter than a single-diode lamp during traditional operation. Of course, pre-packaged LED lamps having multiple diodes can also be employed with the present invention. It is also to be understood that the relatively small packaging of the model HLMT-PL00 lamps aids in heat transfer by allowing the heat sink to be attached to the leads closer to the diode chip.
[0057] With next reference to FIG. 5 , a first reflective layer 80 is preferably attached immediately on top of the contacts 60 of the circuit board 50 and is held in position by the rivets 72 . The first reflector 80 preferably extends outwardly beyond the LEDs 32 . The reflective material preferably comprises an electrically non-conductive film such as visible mirror film available from 3M. A second reflective layer 82 is preferably attached to the mount member 76 at a point immediately adjacent the LED lamps 32 . The second strip 82 is preferably bonded to the mount surface 76 using adhesive in a manner known in the art.
[0058] With reference also to FIG. 6 , the first reflective strip 80 is preferably bent so as to form a convex reflective trough about the LEDs 32 . The convex trough is adapted to direct light rays emitted by the LEDs 32 outward with a minimum of reflections between the reflector strips 80 , 82 . Additionally, light from the LEDs is limited to being directed in a specified general direction by the reflecting films 80 , 82 . As also shown in FIG. 6 , the circuit board 50 can be mounted directly to any mount surface 76 .
[0059] In another embodiment, the aluminum main body portion 56 may be of reduced thickness or may be formed of a softer metal so that the module 30 can be partially deformed by a user. In this manner, the module 30 can be adjusted to fit onto various surfaces, whether they are flat or curved. By being able to adjust the fit of the module to the surface, the shared contact surface between the main body and the adjacent heat sink is maximized, improving heat transfer properties. Additional embodiments can use fasteners other than rivets to hold the module into place on the mount surface/heat sink material. These additional fasteners can include any known fastening means such as welding, heat conductive adhesives, and the like.
[0060] As discussed above, a number of materials may be used for the circuit board portion of the LED module. With specific reference to FIG. 7 , another embodiment of an LED module 86 comprises a series of elongate, flat contacts 88 similar to those described above with reference to FIG. 3 . The contacts 88 are mounted directly onto the main body portion 89 . The main body 89 comprises a rigid, substantially flat ceramic plate. The ceramic plate makes up the bulk of the circuit board and provides structural support for the contacts 88 . Also, the ceramic plate has a surface area about the same as the combined surface area of the contacts. In this manner, the plate is large enough to provide structural support for the contacts 88 and conduct heat away from each of the contacts 88 , but is small enough to allow the module 86 to be relatively small and easy to work with. The ceramic plate 89 is preferably electrically non-conductive but has high heat conductivity. Thus, the contacts 88 are electrically insulated relative to each other, but heat from the contacts 88 is readily transferred to the ceramic plate 89 and into an adjoining heat sink.
[0061] With next reference to FIG. 8 , another embodiment of an LED lighting module 90 is shown. The LED module 90 comprises a circuit board 92 having features substantially similar to the circuit board 50 described above with reference to FIG. 3 . The diode portion 94 of the LED 96 is mounted substantially directly onto the contacts 60 of the lighting module 90 . In this manner, any thermal resistance from leads of pre-packaged LEDs is eliminated by transferring heat directly from the diode 94 onto each heat sink contact 60 , from which the heat is conducted to the main body 56 and then out of the module 90 . In this configuration, heat transfer properties are yet further improved.
[0062] As discussed above, an LED module having features as described above can be used in many applications such as, for example, indoor and outdoor decorative lighting, commercial lighting, spot lighting, and even room lighting. With next reference to FIGS. 9-12 , a self-contained lighting apparatus 100 incorporates an LED module 30 and can be used in many such applications. In the illustrated embodiment, the lighting apparatus 100 is adapted to be installed on the side of a row of theater seats 102 , as shown in FIG. 13 , and is adapted to illuminate an aisle 104 next to the theater seats 102 .
[0063] The self-contained lighting apparatus 100 comprises a base plate 106 , a housing 108 , and an LED module 30 arranged within the housing 108 . As shown in FIGS. 9, 10 and 13 , the base plate 106 is preferably substantially circular and has a diameter of about 5.75 inches. The base plate 106 is preferably formed of 1/16 th inch thick aluminum sheet. As described in more detail below, the plate functions as a heat sink to absorb and dissipate heat from the LED module. As such, the base plate 106 is preferably formed as large as is practicable, given aesthetic and installation concerns.
[0064] As discussed above, the lighting apparatus 100 is especially adapted to be mounted on an end panel 110 of a row of theater chairs 102 in order to illuminate an adjacent aisle 104 . As shown in FIGS. 13 and 14 , the base plate 106 is preferably installed in a vertical orientation. Such vertical orientation aids conductive heat transfer from the base plate 106 to the environment.
[0065] The base plate 106 includes three holes 112 adapted to facilitate mounting. A ratcheting barb 116 (see FIG. 15 ) secures the plate 106 to the panel 110 . The barb 116 has an elongate main body 118 having a plurality of biased ribs 120 and terminating at a domed top 122 .
[0066] To mount the apparatus on the end panel 110 , a hole is first formed in the end panel surface on which the apparatus is to be mounted. The base plate holes 112 are aligned with mount surface holes and the barbs 116 are inserted through the base plate 106 into the holes. The ribs 120 prevent the barbs 116 from being drawn out of the holes once inserted. Thus, the apparatus is securely held in place and cannot be easily removed. The barbs 116 are especially advantageous because they enable the device to be mounted on various surfaces. For example, the barbs will securely mount the illumination apparatus on wooden or fabric surfaces.
[0067] With reference next to FIGS. 16-19 , a mount tab 130 is provided as an integral part of the base plate 106 . The mounting tab 130 is adapted to receive an LED module 30 mounted thereon. The tab 30 is preferably plastically deformed along a hinge line 132 to an angle θ between about 20-45° relative to the main body 134 of the base plate 106 . More preferably, the mounting tab 130 is bent at an angle θ of about 33°. The inclusion of the tab 130 as an integral part of the base plate 106 facilitates heat transfer from the tab 130 to the main body 134 of the base plate. It is to be understood that the angle θ of the tab 130 relative to the base plate body 134 can be any desired angle as appropriate for the particular application of the lighting apparatus 100 .
[0068] A cut out portion 136 of the base plate 106 is provided surrounding the mount tab 130 . The cut out portion 136 provides space for components of the mount tab 130 to fit onto the base plate 106 . Also, the cut out portion 136 helps define the shape of the mount tab 130 . As discussed above, the mount tab 130 is preferably plastically deformed along the hinge line 132 . The length of the hinge line 132 is determined by the shape of the cut out portion 136 in that area. Also, a hole 138 is preferably formed in the hinge line 132 . The hole 138 further facilitates plastic deformation along the hinge line 132 .
[0069] Power for the light source assembly 100 is preferably provided through a power cord 78 that enters the apparatus 100 through a back side of the base plate 106 . The cord 78 preferably includes two 18 AWG conductors surrounded by an insulating sheet. Preferably, the power supply is in the low voltage range. For example, the power supply is preferably a 12-volt alternating current power source. As depicted in FIG. 18 , power is preferably first provided through a full wave ridge rectifier 140 which rectifies the alternating current in a manner known in the art so that substantially all of the current range can be used by the LED module 40 . In the illustrated embodiment, the LEDs are preferably not electrically connected to a current-limiting resistor. Thus, maximum light output can be achieved. It is to be understood, however, that resistors may be desirable in some embodiments to regulate current. Supply wires 142 extend from the rectifier 140 and provide rectified power to the LED module 30 mounted on the mounting tab 130 .
[0070] With reference again to FIGS. 9-12 , 16 and 17 , the housing 108 is positioned on the base plate 106 and preferably encloses the wiring connections in the light source assembly 100 . The housing 108 is preferably substantially semi-spherical in shape and has a notch 144 formed on the bottom side. A cavity 146 is formed through the notch 144 and allows visual access to the light source assembly 100 . A second cavity 148 is formed on the top side and preferably includes a plug 150 which may, if desired, include a marking such as a row number. In an additional embodiment, a portion of the light from the LED module 30 , or even from an alternative light source, may provide light to light up the aisle marker.
[0071] The housing 108 is preferably secured to the base plate 106 by a pair of screws 152 . Preferably, the screws 152 extend through countersunk holes 154 in the base plate 106 . This enables the base plate 106 to be substantially flat on the back side, allowing the plate to be mounted flush with the mount surface. As shown in FIG. 17 , threaded screw receiver posts 156 are formed within the housing 108 and are adapted to accommodate the screw threads.
[0072] The LED module 30 is attached to the mount tab 130 by the pop rivets 72 . The module 30 and rivets 72 conduct heat from the LEDs 32 to the mount tab 130 . Since the tab 130 is integrally formed as a part of the base plate 106 , heat flows freely from the tab 130 to the main body 134 of the base plate. The base plate 106 has high heat conductance properties and a relatively large surface area, thus facilitating efficient heat transfer to the environment and allowing the base plate 106 to function as a heat sink.
[0073] As discussed above, the first reflective strip 80 of the LED module 30 is preferably bent so as to form a convex trough about the LEDs. The second reflector strip 82 is attached to the base plate mount tab 130 at a point immediately adjacent the LED lamps 32 . Thus, light from the LEDs is collimated and directed out of the bottom cavity 146 of the housing 108 , while minimizing the number of reflections the light must make between the reflectors (see FIG. 6 ). Such reflections may each reduce the intensity of light reflected.
[0074] A lens or shield 160 is provided and is adapted to be positioned between the LEDs 32 and the environment outside of the housing cavity 108 . The shield 160 prevents direct access to the LEDs 32 and thus prevents harm that may occur from vandalism or the like, but also transmits light emitted by the light source 100 .
[0075] FIG. 20 shows an embodiment of the shield 160 adapted for use in the present invention. As shown, the shield 160 is substantially lenticularly shaped and has a notch 162 formed on either end thereof. With reference back to FIG. 18 , the mounting tab 130 of the base plate 106 also has a pair of notches 164 formed therein.
[0076] As shown in FIG. 16 , the lens/shield notches 162 are adapted to fit within the tab notches 164 so that the shield 160 is held in place in a substantially arcuate position. The shield thus, in effect, wraps around one side of the LEDs 32 . When the shield 160 is wrapped around the LEDs 32 , the shield 160 contacts the first reflector film 80 , deflecting the film 80 to further form the film in a convex arrangement. The shield 160 is preferably formed of a clear polycarbonate material, but it is to be understood that the shield 160 may be formed of any clear or colored transmissive material as desired by the user.
[0077] The LED module 30 of the present invention can also be used in applications using a plurality of such modules 30 to appropriately light a lighting apparatus such as a channel illumination device. Channel illumination devices are frequently used for signage including borders and lettering. In these devices, a wall structure outlines a desired shape to be illuminated, with one or more channels defined between the walls. A light source is mounted within the channel and a translucent diffusing lens is usually arranged at the top edges of the walls so as to enclose the channel. In this manner, a desired shape can be illuminated in a desired color as defined by the color of the lens.
[0078] Typically, a gas-containing light source such as a neon light is custom-shaped to fit within the channel. Although the diffusing lens is placed over the light source, the light apparatus may still produce “hot spots,” which are portions of the sign that are visibly brighter than other portions of the sign. Such hot spots result because the lighting apparatus shines directly at the lens, and the lens may have limited light-diffusing capability. Incandescent lamps may also be used to illuminate such a channel illumination apparatus; however, the hot spot problem typically is even more pronounced with incandescent lights.
[0079] Both incandescent and gas-filled lights have relatively high manufacturing and operation costs. For instance, gas-filled lights typically require custom shaping and installation and therefore can be very expensive to manufacture. Additionally, both incandescent and gas-filled lights have high power requirements.
[0080] With reference next to FIG. 21 , an embodiment of a channel illumination apparatus 170 is disclosed comprising a casing 172 in the shape of a “P.” The casing 172 includes a plurality of walls 174 and a bottom 176 , which together define at least one channel. The surfaces of the walls 174 and bottom 176 are diffusely-reflective, preferably being coated with a flat white coating. The walls 174 are preferably formed of a durable sturdy metal having relatively high heat conductivity. A plurality of LED lighting modules 30 are mounted to the walls 174 of the casing 172 in a spaced-apart manner. A translucent light-diffusing lens (not shown) is preferably disposed on a top edge 178 of the walls 174 and encloses the channel.
[0081] With next reference to FIG. 22 , the pop rivets 72 hold the LED module 30 securely onto a heat conductive mount tab 180 . The mount tab 180 , in turn, may be connected, by rivets 182 or any other fastening means, to the walls 174 of the channel apparatus as shown in FIG. 23 . Preferably, the connection of the mount tab 180 to the walls 174 facilitates heat transfer from the tab 180 to the wall 174 . The channel wall has a relatively large surface area, facilitating efficient heat transfer to the environment and enabling the channel wall 174 to function as a heat sink.
[0082] In additional embodiments, the casing 172 may be constructed of materials, such as certain plastics, that may not be capable of functioning as heat sinks because of inferior heat conductance properties. In such embodiments, the LED module 30 can be connected to its own relatively large heat sink base plate, which is mounted to the wall of the casing. An example of such a heat sink plate in conjunction with an LED lighting module has been disclosed above with reference to the self-contained lighting apparatus 100 .
[0083] With continued reference to FIGS. 22 and 23 , the LED modules 30 are preferably electrically connected in parallel relative to other modules 30 in the illumination apparatus 170 . A power supply cord 184 preferably enters through a wall 174 or bottom surface 176 of the casing 172 and preferably comprises two 18 AWG main conductors 186 . Short wires 188 are attached to the first and last contacts 62 , 64 of each module 30 and preferably connect with respective main conductors 186 using insulation displacement connectors (IDCs) 190 as shown in FIG. 23 .
[0084] Although the LEDs 32 in the modules 30 are operated at currents higher than typical LEDs, the power efficiency characteristic of LEDs is retained. For example, a typical channel light employing a neon-filled light could be expected to use about 60 watts of power during operation. A corresponding channel illumination apparatus 170 using a plurality of LED modules can be expected to use about 4.5 watts of power.
[0085] With reference again to FIG. 23 , the LED modules 30 are preferably positioned so that the LEDs 32 face generally downwardly, directing light away from the lens. The light is preferably directed to the diffusely-reflective wall and bottom surfaces 174 , 176 of the casing 172 . The hot spots associated with more direct forms of lighting, such as typical incandescent and gas-filled bulb arrangements, are thus avoided.
[0086] The reflectors 80 , 82 of the LED modules 30 aid in directing light rays emanating from the LEDs toward the diffusely-reflective surfaces. It is to be understood, however, that an LED module 30 not employing reflectors can also be appropriately used.
[0087] The relatively low profile of each LED module 30 facilitates the indirect method of lighting because substantially no shadow is created by the module when it is positioned on the wall 174 . A higher-profile light module would cast a shadow on the lens, producing an undesirable, visibly darkened area. To minimize the potential of shadowing, it is desired to space the modules 30 and accompanying power wires 186 , 188 a distance of at least about ½ inch from the top edge 178 of the wall 174 . More preferably, the modules 30 are spaced more than one inch from the top 178 of the wall 174 .
[0088] The small size and low profile of the LED modules 30 enables the modules to be mounted at various places along the channel wall 174 . For instance, with reference to FIGS. 21 and 24 , light modules 30 must sometimes be mounted to curving portions 192 of walls 174 . The modules 30 are preferably about 1 inch to 1½ inch long, including the mounting tab 180 , and thus can be acceptably mounted to a curving wall 192 . As shown, the mounting tab 180 may be separated from the curving wall 192 along a portion of its length, but the module is small enough that it is suitable for riveting to the wall.
[0089] In an additional embodiment shown in FIG. 25 , the module 30 comprises the circuit board without the mount tab 180 . In such an embodiment, the circuit board 50 may be mounted directly to the wall, having an even better fit relative to the curved surface 192 than the embodiment using a mount tab. In still another embodiment, the LED module's main body 56 is formed of a bendable material, which allows the module to fit more closely and easily to the curved wall surface.
[0090] Although the LED modules 30 disclosed above are mounted to the channel casing wall 174 with rivets 182 , it is to be understood that any method of mounting may be acceptably used. With reference next to FIGS. 26 A-C, an additional embodiment comprises an LED module 30 mounted to a mounting tab 200 which comprises an elongate body portion 202 and a clip portion 204 . The clip portion 204 is urged over the top edge 178 of the casing wall 172 , firmly holding the mounting tab 200 to the wall 174 as shown in FIG. 26B . The lens 206 preferably has a channel portion 208 which is adapted to engage the top edge 178 of the casing wall 174 and can be fit over the clip portion 204 of the mount tab 200 as shown in FIGS. 26B and 26C . This mounting arrangement is simple and provides ample surface area contact between the casing wall 174 and the mounting tab 200 so that heat transfer is facilitated.
[0091] In the embodiment shown in FIG. 21 , the casing walls 174 are about 3 to 4 inches deep and the width of the channel is about 3 to 4 inches between the walls. In an apparatus of this size, LED modules 30 positioned on one side of the channel can provide sufficient lighting. The modules are preferably spaced about 5-6 inches apart. As may be anticipated, larger channel apparatus will likely require somewhat different arrangements of LED modules, including employing more LED modules. For example, a channel illumination apparatus having a channel width of 1 to 2 feet may employ LED modules on both walls and may even use multiple rows of LED modules. Additionally, the orientation of each of the modules may be varied in such a large channel illumination apparatus. For instance, with reference to FIG. 26D , some of the LED modules may desirably be angled so as to direct light at various angles relative to the diffusely reflective surfaces.
[0092] In order to avoid creating hot spots, a direct light path from the LED 32 to the lens 206 is preferably avoided. However, it is to be understood that pre-packaged LED lamps 32 having diffusely-reflective lenses may advantageously be directed toward the channel letter lens 206 .
[0093] Using LED modules 30 to illuminate a channel illumination apparatus 170 provides significant savings during manufacturing. For example, a number of LED modules, along with appropriate wiring and hardware, can be included in a kit which allows a technician to easily assemble a light by simply securing the modules in place along the wall of the casing and connecting the wiring appropriately using the IDCs. Although rivet holes may have to be drilled through the wall, there is no need for custom shaping, as is required with gas-filled bulbs. Accordingly, manufacturing effort and costs are significantly reduced.
[0094] Individual LEDs emit generally monochromatic light. Thus, it is preferable that an LED type be chosen which corresponds to the desired illumination color. Additionally, the diffuser is preferably chosen to be substantially the same color as the LEDs. Such an arrangement facilitates desirable brightness and color results. It is also to be understood that the diffusely-reflective wall and bottom surfaces may advantageously be coated to match the desired illumination color.
[0095] Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically-disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.
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A modular light emitting diode (LED) mounting configuration is provided including a light source module having a plurality of pre-packaged LEDs arranged in a serial array. The module includes a heat conductive body portion adapted to conduct heat generated by the LEDs to an adjacent heat sink. As a result, the LEDs are able to be operated with a higher current than normally allowed. Thus, brightness and performance of the LEDs is increased without decreasing the life expectancy of the LEDs. The LED modules can be used in a variety of illumination applications employing one or more modules.
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BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for decontaminating soil and waste materials, particularly to a method and apparatus for removing volatile and semivolatile hazardous organic contaminants from soil, municipal, chemical and refinery sludges and other particulate materials.
DISCUSSION OF THE PRIOR ART
With increased environmental awareness and discovery of many landfills, dumps sites and the like containing contaminated soils and waste materials, a number of soil decontamination methods and apparatus have been proposed. These include systems disclosed in U.S. Pat. Nos. 4,738,206, 4,782,625 and 4,864,942. It is vitally important that many of these contaminated areas be freed from hazardous contaminants because of their potential toxicity. Many sites are so close to areas inhabited by humans that direct contact with the soil or waste materials or ingestion of fugitive vapors can be lethal. Also, many sites have the potential to leach hazardous contaminants into ground water supplies, thereby posing further danger. It has accordingly become necessary to develop methods which effectively remove all of the contaminants in a cost efficient manner and dispose of them in an environmentally safe manner.
U.S. Pat. No. 4,738,206, issued to one of the inventors hereof and owned by the assignee hereof, discloses an apparatus and method for removing volatile organic contaminants containing moisture by sealing the soil in a stripping conveyor against contact with air and countercurrently vapor stripping the contaminants at a temperature below the boiling points of the contaminants. This method and apparatus has proven to be quite effective for decontaminating soils in many situations.
U.S. Pat. No. 4,782,625 discloses a mobile decontamination apparatus for removing halogenated hydrocarbons, petroleum hydrocarbon and derivatives of petroleum hydrocarbons from soil. However, this apparatus suffers the severe problem of being open to the environment. Open systems can be quite hazardous and frequently cause difficulties in obtaining proper permitting for operation thereof.
U.S. Pat. No. 4,864,942 discloses a process and apparatus for thermally separating organic contaminants such as PCB's from soils and sludges. This apparatus provides inadequate disposition of vaporized organic contaminants after volatilization from the soils and sludges.
Other prior art known to applicant in completely different areas of endeavor include U.S. Pat. Nos. 2,753,159; 2,731,241; 3,751,267; 4,098,200; 4,139,462; 4,167,909; 4,319,410; 4,330,946; 4,411,074; 4,504,222; 4,544,374; 4,628,828; 4,875,420 and 4,881,473.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a method and apparatus for removing volatile and semivolatile hazardous organic contaminants from soil and sediments.
It is a further object of the invention to provide a method and apparatus for removing volatile and semivolatile hazardous organic contaminants from waste materials such as municipal, refinery and chemical sludges and other particulate wastes.
It is another object of the invention to provide a method and apparatus capable of decontaminating large quantities of natural soil without transporting the soil to remote locations.
It is yet another object of the invention to decontaminate soil in a manner which poses no environmental risk to surrounding areas and is free from danger of explosion of fire.
Other objects and advantages of the invention will become apparent to those skilled in the art from the drawings, the detailed description of preferred embodiments and the appended claims.
SUMMARY OF THE INVENTION
This invention provides a method for removing volatile organic contaminants from soil and waste materials including removing contaminated material to be treated from its existing location, transporting and placing the contaminated material into a hopper wherein the hopper is substantially sealed from the atmosphere to prevent fugitive emissions of the contaminants from escaping into the atmosphere. The contaminated material is then conveyed under sealed conditions into a heated vapor stripping conveyor. The contaminated material is conveyed under sealed conditions along the vapor stripping conveyor to heat the contaminated material and thereby cause moisture in the material and the contaminants to be stripped from the material.
At the same time the contaminated material is conveyed along the vapor stripping conveyor, non-oxidizing gases are concurrently swept along the surface of the material beginning at a point downstream but directly adjacent to the introduction point of the material to carry volatilized contaminants and moisture emanating from the material across and away from the material. The sweep of non-oxidizing gas is maintained at a rate of flow and temperature to prevent undue surface drying of the material as the material passes through the conveyor.
The invention further provides an apparatus for removing volatile organic contaminants from the contaminated material including a hopper, means for sealing the material from atmospheric air, a heated vapor stripping conveyor sealed from the atmospheric air to vapor strip the volatile contaminants from the material and means for conveying the material in a sealed condition from the hopper to the vapor stripping conveyor.
The apparatus further includes means for supplying non-oxidative gases at a temperature greater than ambient to the vapor stripping conveyor, means for introducing the non-oxidative gases into the vapor stripping conveyor beginning at a point downstream but directly adjacent to the introduction point of the material and means for removing the non-oxidative gases from the conveyor located to cause the non-oxidative gases to co-currently sweep over the material to convey volatile contaminants stripped from the material out of the vapor stripping conveyor. The apparatus still further includes means for controlling the flow rate and temperature of the non-oxidative gases as they flow through the vapor stripping conveyor and across the material to prevent undue surface drying of the material as it passes through the vapor stripping conveyor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a schematic diagram showing one preferred form according to which the invention may be practiced.
FIG. 2 shows a schematic top plan view of a vapor stripping material conveyor utilized in accordance with aspects of the invention.
FIG. 3 is a schematic diagram showing preferred vapor treatment apparatus utilized in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
Although a particular form of apparatus and method has been selected for illustration in the drawings, and although specific terms will be used in the specification, for the sake of clarity in describing the apparatus and method steps shown, the scope of this invention is defined in the appended claims and is not intended to be limited either by the drawings selected or the terms used in the specification or abstract. When referring to contaminated soil or waste materials such as municipal, refinery or chemical sludges or waste particulates, waterway and lagoon sediments and the like, the terms "contaminated materials" or "materials" will be used hereinafter for the sake of convenience.
Referring now to the drawings in general and FIG. 1 in particular, one embodiment of a decontamination system 10 is shown. Removing conveyor 12, which may be a conventional belt conveyor, belt conveyor with scoops, front and loader, backhoe or the like, removes contaminated material 14 from the ground and places it in container 16. Container 16 connects to feeder 18, which connects to sealed conveyor 20. Contaminated material 14 travels under sealed condition to the front end 22 of vapor stripping conveyor 24 by way of hopper 23. Vapor stripping conveyor 24 contains a stripping conveyor 26 (see FIG. 2). Stripping conveyor 26 connects to heat transfer fluid supply line 28 and fluid return line 30. Fluid supply line 28 and fluid return line 30 connect to fluid heater 32.
Vapor stripping conveyor 24 has a non-oxidative gas feed line 33 connected downstream of but directly adjacent to the introduction point of sealed conveyor 22 and hopper 23 and channels non-oxidative gasses into vapor stripping conveyor 24. Non-oxidative gas feed line 33 connects to a non-oxidative gas supply line 40, with one branch 40a connecting to heater 32 and another branch 40b connecting to non-oxidative gas supply blower 42. Non-oxidative gas supply pump 42 connects to non-oxidative gas source 44. Valve 43 may be opened or closed to control the rate of non-oxidative gas channelled to blower 42.
The end 34 of vapor stripping conveyor 24 opposite non-oxidative gas feed line 33 has a vapor exhaust line 46 which connects to vapor exhaust manifold 54. Supplemental vapor exhaust conduit 56 extends between sealed conveyor 20 and vapor exhaust manifold 54. Vapor exhaust manifold 54 also connects to vapor exhaust blower 58, which connects to vapor exhaust cleaner apparatus 60. Vapor exhaust cleaner apparatus 60 has exhaust purge conduit 62 and exhaust purge recycle conduit 64 connected downstream. Exhaust purge recycle conduit 64 connects to non-oxidative gas supply 44. Heater 32 has air intake line 66 to supply combustion air and exhaust line 68 to exhaust combustion gases to the air or to vapor stripping conveyor 24. Decontaminated material exits the bottom of vapor stripping conveyor 24 at chute 70.
FIG. 2 shows one preferred embodiment of a vapor stripping conveyor 24 which may be used to practice the invention. Vapor stripping conveyor 24 has non-oxidative gas feed line 33 connected on the top thereof as designated by dashed lines 34 and vapor exhaust line 46 connected on the top thereof on the other side as designated by dashed lines 46. Non-oxidative gas feed line 33 connects to non-oxidative gas supply line 40 (also shown in FIG. 1) and vapor exhaust line 46 connects to vapor exhaust manifold 54, also shown in FIG. 1.
The interior of vapor stripping conveyor 24 shows two stripping conveyors 26, which include hollow shafts 72 and hollow flights or fins 74. These conveyors are rotated by a motor and gear reducer 73 (shown schematically). The dashed lines 34 on front end 22 of vapor stripping conveyor 24 represent the entry point of sealed conveyor 20 from above, while the dashed lines 30 on the other end of vapor stripping conveyor 24 represent the exit point for the contaminated material flowing through chute 70.
FIG. 3 is an exploded representation of one preferred form of exhaust cleaner apparatus 60. The number 61 represents a burner for burning organics received from stripping conveyor 24 and vapor exhaust blower 58. Condenser and carbon absorber 67 connects to blower 58 and condenses some of the hazardous constituents. Catalytic thermal destructor 65 connects to blower 58 and receives exhaust gases from stripping conveyor 24. Wet scrubber 63 connects to burner 61 and catalytic thermal destructor 65 to further treat the exhausted gases.
Referring now to FIGS. 1-3 of the drawings, one preferred method of decontaminating soil will now be illustrated. As shown in FIG. 1, contaminated material is removed from its existing location by known conventional means, travels along removing conveyor 12 and enters into container 16. Feeder 18, which may be a pug mill, shredder, screen or the like, creates a seal between container 16 and sealed conveyor 20, accepts material from container 16 and then deposits it in sealed conveyor 20. Contaminated material travels through sealed conveyor 20 upwardly into hopper 23 and then into the front end 22 of vapor stripping conveyor 24. Contaminated material 14 spills downwardly through the top of vapor stripping conveyor 24 and engages stripping conveyors 26. Stripping conveyors 26 are rotated and cause contaminated material 14 to move along the length of vapor stripping conveyor 24.
Stripping conveyors 26 receive heated heat transfer fluid, such as air, oil, water, steam, eutectic salts, Dowtherm®, gas and the like through hollow shafts 72 and optionally through flights 74. Heated heat transfer fluid is received from fluid supply line 28, which is heated in heater 32. The heated heat transfer fluid travels along hollow shafts 72 and exits vapor stripping conveyor 24 through fluid return line 30, which returns cooled heat transfer fluid to heater 32 for reheating. It is also possible for heat transfer fluid to be directed into the exterior walls and/or bottom of vapor stripping conveyor 24 if it is constructed to that capacity and if desired. This is especially true in the event conveyors, such as continuous belts or screens or the like, are substituted for rotating screw conveyors. Flowing heated heat transfer fluid through the exterior walls and/or bottom increases the heated surface exposed to the material, thereby enhancing vapor stripping in apparatus utilizing rotating screw conveyors and acting as the primary heat transfer vehicle in the case of alternate conveyors.
Contaminated material 14 travels through vapor stripping conveyor 24 and is heated as it progresses from one end to the other by absorbing heat from hollow shafts 72, flights 74 and optionally from the exterior walls and/or bottom of vapor stripping conveyor 24. Absorbed heat causes volatile and semivolatile hazardous organic contaminants contained within the material, as well as moisture contained in the material, to vaporize at points below their boiling temperatures. The combined vaporized organic compounds and water vapor travel upwardly into the open space within vapor stripping conveyor 24 above the material.
Because of the potentially toxic nature of the vaporized organic contaminants, it is necessary to ensure that all of the vaporized organics are carried away from vapor stripping conveyor 24. This has proven to be a difficult task for several reasons. One problem has been the need to ensure that vapor stripping conveyor 24 does not leak or permit fugitive toxic vapors to escape into the atmosphere. Another severe problem encountered is the tendency of the material to dry out upon heating. However, this tendency defeats the goal of driving out substantially all (such as 99.99%, for example) of the hazardous organic contaminants contained in the material. Often in prior art apparatus, a dry crust tends to form on the surface of the material due to rapid heating on outer portions thereof, which forms into a vapor impermeable capsule around inner portions of the material. This prevents proper heating of all of the material and results in trapped hazardous organics within the material, thereby defeating the decontamination objectives.
Yet another problem encountered in the prior art has been the extremely high flammability of many of the volatilized contaminants, especially under elevated temperatures. The danger of explosion has proven to be very real.
It has been surprisingly discovered that precise channeling of particular gases over the surface of the material surprisingly solves the problem of undue drying of the surface portion of the material, which permits substantially all of the hazardous organic contaminants within the material to volatilize and escape. Use of non-oxidative gas has also virtually eliminated the possibility of fire and/or explosion despite the presence of substantial quantities of vaporized, highly flammable organic compounds within the stripping conveyor. It has further been surprisingly discovered that the particular manner of channeling gases inside the conveyor prevents fugitive vapor emissions from vapor stripping conveyor 24.
To solve the problems outlined above, non-oxidative gases, such as nitrogen, argon, steam and carbon dioxide, for example, are channeled from a non-oxidative gas supply in a special precise manner into vapor stripping conveyor 24. As shown in FIG. 1, gases such as nitrogen, argon or carbon dioxide and the like may be supplied from an on site non-oxidative gas source 44, through non-oxidative gas supply blower 42, into branch 40b, through non-oxidative gas supply line 40 and into non-oxidative gas feed line 33. These gases are preferably supplied at temperatures greater than ambient. In the alternative, exhaust gases generated by heater 32 in heating fluids for passage through vapor stripping conveyor 24 may be channeled through branch 40a and into non-oxidative gas supply line 40.
As shown in FIG. 2, non-oxidative gases are swept into vapor stripping conveyor 24 through an opening in the top of the conveyor. The opening is introduced above the surface of the material. Non-oxidative gases are blown directly onto the top of the material beginning downstream of but directly adjacent to the introduction point of the material. Specifically, non-oxidative gas feed line 33 connects to vapor stripping conveyor 24 at a point immediately adjacent, but downstream of the entrance point of sealed material hopper 23 (designated by dashed lines 34). Vapor exhaust line 46 receives non-oxidative gas, contaminant vapors and moisture wherein they exit vapor stripping conveyor 24. Providing the precisely placed gas inlet at a point adjacent to but downstream of the introduction point of material into vapor stripping conveyor 24 to co-currently sweep vapors and moisture residing in the space above the material has proven to be an especially advantageous and effective way to remove vapors and moisture from the material as soon as the newly formed vapor emerges from the material.
It is also advantageous that the precisely introduced cocurrent sweep gases be introduced at a controlled temperature higher than the ambient temperature of the material entering the conveyor. For example, one preferred range includes those higher than the boiling point of water. Another especially preferred range includes temperatures greater than the boiling point of the volatile organic(s) to be removed. Higher than ambient temperature sweep gases provide enhanced vapor and moisture absorbance by the sweep gases. Utilization of greater than ambient temperature sweep gases ensures that the vapors do not have an opportunity to condense into liquid prior to being swept out of the vapor stripping conveyor. Condensation of vapors is to be avoided because it recontaminates previously cleaned material. Greater than ambient temperatures also ensure increased partial pressures of the vapors, which increases vapor absorbance. Another advantage of greater than ambient temperatures lies with reduced corrosion tendencies that normally result from acid-gas condensation at lower temperatures. Higher than ambient temperatures for the sweep gases still further increase the total thermal efficiency of the process.
After hazardous organic vapors and moisture exit vapor stripping conveyor 24, they travel through vapor exhaust line 46 and into vapor exhaust manifold 54. Vapor exhaust blower 58 conveys the mixture to vapor exhaust cleaner apparatus 60. Vapor exhaust cleaner apparatus 60 can be any decontamination apparatus well known in the art. For example, exhaust cleaner 60 may be capable of filtering to remove dust, scrubbing with wet scrubber 63 for removal of acid gases, burning the organics with burner 61, burning the organics with burner 61 followed by scrubbing with wet scrubber 63, absorbing a portion of the hazardous organics on activated carbon, catalytic thermal destruction with catalytic thermal destructor 65, recovering the hazardous organics by condensation or recovering by condensation followed by absorption on activated carbon. All of these cleaning apparatus, as well as others, are well known in the art and are not described in detail herein. Cleaned gases may be exhausted into the atmosphere without danger to the surrounding environment through exhaust purge conduit 62 or may be recycled to non-oxidative gas source 44 for reuse by way of exhaust purge recycle conduit 64.
It has surprisingly been discovered that excellent material decontamination may be achieved by supplying further non-oxidative gas into vapor stripping conveyor 124 at a point downstream of but directly adjacent to the point of introduction of the material. This is in contrast to introducing the non-oxidative gases into vapor stripping conveyor 24 at the same point of introduction of the material. Such introduction tends to unduly dry the material as previously described, thereby precluding complete removal of the contaminants. I have further discovered that introduction of non-oxidative gases into vapor stripping conveyor 24 at points downstream of but not adjacent to the introduction point of the material, such as mid-way along conveyor 24, does not achieve the desired amount of volatilization required to remove the contaminants from the material.
Removal of as much as 99.99%, or more, of volatile and semivolatile organic contaminants in various materials has been continuously achieved at high rates of treatment utilizing the apparatus and method of the invention claimed below.
The system 10 further contains various valves, dampers, gauges and the like that are not illustrated for the sake of simplicity and ease of understanding. They are employed in the usual manner to control or direct gases and/or fluids through the various conduits in the desired manner. Vapor stripping conveyor 24 has also been illustrated and described in a simplified manner for ease of understanding. For example, the number of flights 74 has been reduced below the number practically employed in use. Also, no specific means for rotating the flights has been shown. Although heating fluid entrances and exits for vapor stripping conveyor 24 have been illustrated as connecting at opposing ends, it should be understood that other constructions are possible, such as by use of standard, commercially available rotary joints. These design features are well known and may be commercially obtained in various forms and configurations. It should further be appreciated that conveying means other than rotating screens may be used to convey materials through vapor stripping conveyor 24.
Although this invention has been described with reference to specific forms selected for illustrations in the drawings, it will be appreciated that many modifications may be made, that certain steps may be performed independently of other steps, and that a wide variety of equivalent forms of apparatus may be utilized, all without departing from the spirit and scope of this invention, which is defined in the appended claims.
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A method and apparatus for removing volatile organic contaminants from soil and waste materials including transporting and placing the contaminated material into a hopper, the hopper being substantially sealed from the atmosphere to prevent fugitive emissions of the contaminants from escaping into the atmosphere; conveying the material under substantially sealed conditions into a heated vapor stripping conveyor; conveying material under substantially sealed conditions along the vapor stripping conveyor to heat the material and thereby cause moisture in the material and the contaminants to be stripped from the material; streaming non-oxidizing gases at a controlled temperature over the material, in the direction of travel of the material, beginning at a point downstream of and adjacent to the introduction of the material into the vapor stripping conveyor to carry the contaminants and moisture away from the material; and maintaining the rate of flow and temperature of the gases to prevent undue surface drying of the material as the material passes through the conveyor.
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FIELD OF THE INVENTION
This invention relates generally to systems for providing users with status of consumables used in image forming devices, and more particularly, to a system and method which displays dynamic consumable status in a driver user interface.
BACKGROUND OF THE INVENTION
Image forming devices such as printers, copiers and multi-function devices provide users with the ability to output documents on a wide variety of different media, such as paper, transparencies, card stock, etc. Each of these image forming devices, for example, may include multiple trays for storing media. Users typically load different media in each tray and adjust the tray to accommodate the particular size and type. Some image forming devices have counters and tracking devices which count and track the quantity of media in the tray as well as when the tray is empty. Many image forming devices also have monitors for detecting the level of other consumables, such as toner or ink level in the toner or ink cartridge.
Many image forming devices also have a built-in display and/or a touch screen for providing operator input for control of the device and for displaying operating information, diagnostic results, error messages and inventory information. Inventory information may include the status of the media trays, i.e., what type of media is loaded in which tray, and ink or toner level in the different ink or toner cartridges. Error messages may include which media tray is jammed.
Some network printers, such as the Xerox Phaser printers, are provided with special software which enables a network administrator to view printer input/output tray levels. consumable status and total pages printed (information which is typically available at the printer's display). This information is available through a built-in web server installed in the printer. Network administrators can access and manage this information directly from a standard web browser or any web-enabled application.
If a user wishes to print a document at a desktop printer connected to the user's personal computer, all media and consumable information for the printer is available to the user at the printer. However, if the user wishes to print a document from a networked printer located remotely from the user, the user has no first hand knowledge of the media and consumable information from that printer.
In order to send a print job to any printer, whether it is a desktop printer connected directly to the user's personal computer or to a networked printer, a printer driver must be installed on the user's personal computer. A printer driver is software which controls the printer from the user's personal computer. The printer driver provides a user interface which may be accessed by the user through either through the operation system or an application program such as a word processing program.
A typical printer driver user interface allows a user to select items such as paper size, paper source (auto, upper, lower, manual), copy count, orientation (landscape or portrait), color or gray scale. While the printer driver user interface may allow the user to select a tray to print from, the driver does not necessarily know what trays are in the printer, or what media is in those trays. Selecting from these trays is risky for the user unless the user knows the precise configuration of that printer, and even then, the user may not know if the trays are empty or not.
Some driver user interfaces simply display the available media tray choices; some may depict certain “constrained” choices with special icons alerting the user that it was unlikely that they could select that tray. No tray status or other dynamic information is displayed. Nor does the printer driver user interface display any information pertaining to status or other dynamic information about other printer consumables, such as ink or toner.
SUMMARY OF THE INVENTION
A driver for controlling operation of an image forming device, such as a printer, having at least one container for storing a consumable and a monitor for monitoring status of the consumable in the container, according to one aspect of the invention, includes a controller, responsive to a request for an image forming job, for controlling operation of the image forming device from a host device; means, responsive to the job request, for querying the image forming device for consumable status information; and a user interface, responsive to the querying means, for displaying consumable status information.
A printer driver queries the printer for the printer's tray configuration and displays the results to the user in the driver's user-interface. This allows the user to know precisely what size and type of media is currently loaded into each tray, as well as any error status, such as being empty or jammed. The user may then use this up-to-date information during tray selection. In addition to querying for status of media, the printer driver may also query the printer for status of consumables such as toner and ink. The printer driver can query the printer for consumable status when a print job request is received, during the time the print job is completing, on a predetermined periodic basis and in response to a user input. Updated information is then displayed in the user interface to provide the user with updated information about consumables.
If a consumable container, such as a paper tray is empty, the printer driver can display an alert in the user interface. Detailed information such as container count, and for each container, media type, media size, container status and container name can be queried and the status displayed in the user interface.
A system, according to another feature of the invention, includes a printer having at least one container for storing a consumable and a monitor for monitoring the status of the consumable in the at least one container; a host device for sending a print job to the printer, wherein the host device includes a display; and a printer driver for controlling operation of the printer from the host device, for querying the printer for consumable status information, and for providing a user interface in the host device display; wherein the printer driver, responsive to the print job, queries the printer for consumable status information and displays the status of the consumable in the at least one container in the printer in the user interface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system which provides a dynamic printer configuration in the printer driver user interface; and
FIGS. 2, 3 and 4 are exemplary user interfaces.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring to FIG. 1, system 100 includes printer 20 and host device 30 . Printer 20 includes trays 22 and 24 for holding media and monitor 26 for monitoring the status of the media in each of trays 22 and 24 . Monitor 26 may include sensors for detecting the level of media in each tray, sensors for detecting when a tray is empty, sensors for detecting the type of media in each tray. Alternatively, printer 20 may be configured such that the user may specify, though a panel menu 28 the type and size of media in each tray.
Host device 30 , which may be a personal computer, includes a display 36 . Host device 30 and printer 20 are shown as connected to a network. However, they may be directly connected to each other, such as if printer 20 were directly connected to a parallel port or USB port of host device 30 .
Printer driver 32 has been installed on host device 30 and resides on the host device's hard drive. Printer driver 32 includes a controller for controlling operation of the printer from the host device 30 , a query routine for querying the printer 20 for consumable status information, and a user interface 34 which displays the status in the host device display 36 . When a user wants to send a print job to printer 20 , the user opens the printer driver user interface 34 . The printer driver user interface displays the available media trays for the printer 20 , the type of media in each tray and the size of the media in the tray. Additionally, in response to the user's request for a print job (which may mean in response to opening up the printer driver user interface), the query routine queries the printer for status of the media in the printer” trays. This status information is displayed in the user interface for each media tray.
The printer driver 32 includes a query routine which can be configured to query different aspects of the printer 20 . Indeed, whatever information is available about printer 20 can be queried and displayed in the printer driver user interface 34 . For example, many printers provide the following information: installable options, tray count, media type (for each tray), media size (for each tray), status (for each tray) and name (for each tray). Additionally, if the printer is configured to monitor ink or toner consumables (for each container, for example, color, quantity or level, name) that information can be queried and displayed in the printer driver user interface.
If the printer 20 is directly connected to host device 30 , the printer driver 32 can easily obtain this information from the printer by querying the printer through the parallel port or USB port. If the printer 20 is located on a network, the printer driver can query the printer by simply having an IP address of the printer to query the information via socket communications. Once the information is obtained, the printer drive displays it in a runtime representation of the printer in the printer driver user interface.
The query routine may be configured to query the printer when the user first opens the printer driver user interface. This provides the user with instantaneous status information. The query routine can be configured to query the printer in accordance with a predetermined period schedule. The period can be very short: seconds or fractions of seconds. Whatever information is received in response to the query routine is provided to the printer driver user interface. This provides the user with dynamic updates. Consumable status information is not statically generated at load time; it is continually monitored and refreshed within the user interface. The query routine can be configured to query the printer in response to a user input. For example, if the refresh rate is not as quick as the user would like it to be, the user can select a refresh button and the printer will be queried and the information presented in the user interface. The query routine can be configured to query during the time a print job is completing. This provides the user with real-time information if a tray becomes “low” or empty during a large print job.
The query routine may be configured such that updating occurs with minimal user interruption, so that this feature is not an annoyance, but a useful tool. The dynamic update feature of the query routine should not interfere with the user's tray selection process.
Example: A user opens the printer driver user interface and notices that Tray 2 is empty. The user wishes to print from Tray 2 because this is the tray that contains the letterhead media. Using this information, the user walks over to the printer and loads Tray 2 . By the time the user returns to her desk, the user interface will reflect that Tray 2 is no longer empty. This provides her with information she may use prior to printing, to avoid having to learn that her job would not print after printing it and walking up to pick it up.
The actual implementation, presentation or display of the user interface will depend on the platform and the target audience. Consumable information may be used in many ways by the printer driver. Referring to the exemplary user interface shown FIG. 2, printer media tray selection is made using a list control and icons. This example shows how information might be presented to the user in a very visual way. In FIG. 2 the user interface indicates that the particular printer has three trays: Tray 1 , Tray 2 and Tray 3 as well as a manual paper tray, MPT. The status information displayed tells the user that Tray 1 is low, Tray 3 is empty and MPT is loaded with thick card stock.
Tray selection in a more constrained environment using simple combo-box controls and text to depict current information is shown in FIG. 3 . Only status of Trays 1 , 2 , 3 and MPT are shown; no information about type of media is shown for the selection “Cover Page.” In FIG. 3, Tray 1 is indicated as being low in quantity and Tray 3 is indicated as being empty. Both Trays 1 and 3 have an alert icon next to them to alert the user of the status of these trays. Tray selection for any printer feature that needs to specify trays, such as separation pages, cover sheets, or other printer features may also be displayed in the user interface.
A more comprehensive printer driver user interface is shown in FIG. 3. A separate dialog box is shown under “Paper/Quality.” Under “Automatic” tray selection, both paper size and paper type are displayed. If “Automatic” is selected, “Statement” paper size is selected. If the user wants to manually select a tray, the “Choose Specific Tray” box indicates there are only two trays on this printer: Tray 1 which has letter paper and MPT which has statement sized plain paper.
The printer driver can be configured such that the printer driver user interface eliminates all tray selection constraints. For example, if Tray 3 is shown as empty, the printer driver can be configured so that the user cannot select Tray 3 until Tray 3 has been loaded with media. By only showing the valid selections, the user is much less likely to err during tray selection, and much more likely to get the desired output.
The invention has been described with reference to particular embodiments for convenience only. Modifications and alterations will occur to others upon reading and understanding this specification taken together with the drawings. The embodiments are but examples, and various alternatives, modifications, variations or improvements may be made by those skilled in the art from this teaching which are intended to be encompassed by the following claims.
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A system includes a printer having at least one container for storing a consumable and a monitor for monitoring the status of the consumable in the at least one container; a host device for sending a print job to the printer, wherein the host device includes a display; and a printer driver for controlling operation of the printer from the host device, for querying the printer for consumable status information, and for providing a user interface in the host device display; wherein the printer driver, responsive to the print job, queries the printer for consumable status information and displays the status of the consumable in the at least one container in the printer in the user interface.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Priority is hereby claimed from provisional patent application No. 60/407,669 filed on Sep. 3, 2002, and also from provisional patent application No. 60/407,620 filed on Sep. 3, 2002.
BACKGROUND OF INVENTION
FIELD OF THE INVENTION
[0002] A device for attaching to the face of a golf club, and more particularly, a device which enables a golf club to function as if it were new.
BACKGROUND OF THE PRESENT INVENTION
[0003] The popular game of golf is normally played on an outdoor course of 18 holes. The idea is to put the golf-ball into a hole or cup at the end of each of these 18 legs. A player uses a variety of clubs or golf tools to enable them to strike the ball with precision in order to utilize the least strokes. It is therefore the goal of each manufacturer to provide the golfer the best possible tools to accomplish this task.
[0004] New technology has changed the game by employing new materials. These include the metals or composites in the shafts and in the club heads. The golf club face or striking surface, is prone to wear & polishing from the repetitive hits on the ball & terrain. Independent tests prove that standard steel, titanium or similar clubs may be worn in about 50 100 hits or in about 5 rounds of golf for the average player.
[0005] The golf club striking surface needs improvement, plus there is a need for protection to be imparted to the club-face from further wear & damage.
[0006] The USGA and the Royal & Ancient Golf Club of St. Andrews govern the rules and standards of the game and have established certain standards for the roughness on golf club faces.
[0007] As the face of the golf club wears, it loses the Spin-Generating Traction of the face and the standards set by the USGA. The USGA rules state, “A club which conforms with the rules when NEW is deemed to conform after wear through normal use.” This is fine except it has affected the player“s abilities to play well.
[0008] There is a need for spin generating surfaces and designs, that may be applied to such a face quickly & easily by anyone without tools or special skills to restore the club face to the desired spin generating abilities or conform to the USGA roughness specifiations. There is a need to have a means for replacing such surfaces and designs with identical products as wear or stubborn soil causes change, such that a consistent playing surface can be maintained. Attempts in the past have failed due to the loss of energy transfer, from the clubface to the ball, causing the ball to fall short due to loss in velocity. In addition, unwanted debris filled the cavities in the surface changing the traction or grip characteristics of the surface. The continuing impacts of the ball will also loosen the granular structure causing their loss, affecting both the energy transfer & backspin. It is also felt that due to the large variety of clubface shapes & designs, large varied inventories would be necessary causing confusion in the selection.
[0009] About 2 yards is lost in distance for each 1% of lower COR with swing speeds of about 100 120 mph.
[0010] The first rule of ball flight is, “Overcome Gravity.” Gravity is a constant vertical force downward. Any shot that hopes to overcome gravity must have a greater upward vertical force.
[0011] To overcome this force lift is necessary.
[0012] The second rule is Drag or the Resistance of the atmosphere on the ball moving thru it. This causes friction with the air causing deceleration, reducing its Velocity & Spin. Velocity is also reduced by the air pressure in front of the ball along with the vacuum or suction behind it.
[0013] There are three initial performance parameters that help to overcome the forces of Gravity and Drag. These are Launch Angle, Spin Rate and Ball Speed.
[0014] The Ball Launch Angle, is determined by the Clubs Loft Angle, the Center Of Effort or Center of Mass of the club and the characteristics of the golf ball. Lower Center Of Effort and Higher Club Loft Angle both generate Higher Ball Launch Angle trajectory.
[0015] Spin Rate is generated by a combination of Swing Speed, COR, & Loft Angle & the Traction of the ball on the clubface. Harder, faster swings, as well as greater higher lofted clubs along with higher COR will produce Higher Spin Rates and more Lift. Spin Rate is a measure of how fast a ball turns around its axis, measured in RPMs (Revolutions Per Minute) Typically NEW drivers will spin a ball at about 2000 to 5000 RPM while NEW Wedges with a greater loft may spin at 10,000 RPM.
[0016] Ball Speed is generated by Swing Speed, COR of the club-head and characteristics of the ball. Higher Swing speeds & COR produce Higher Ball Speed and Spin Rates.
[0017] Lift is created by Backspin. It occurs at an angle perpendicular to the balls spin axis, typically upward. Higher Spin Rates produce Greater Lift. A golf ball has dimples that enhance its aerodynamics in flight. They create a turbulent boundary layer of air around a spinning golf ball allowing it to slice thru the air with less resistance smoothing out airflow. Lift occurs because the backspin rotation of the ball causes on-coming air to pass more quickly over the top half of the ball, generating lower pressure on top & greater pressure below, thus lifting the ball.
[0018] A High Spin Rate will overcome gravity, causing the ball to climb during its initial trajectory. The backspin will make a golf ball fly further, straighter & with more control. In the short game, it will permit a softer landing and with more control closer to the pin with minimum roll.
[0019] Worn or polished golf club faces will not have sufficient traction to produce the desired backspin. It is recommended by golf authorities to have the clubfaces restored to their original USGA specifications for NEW clubs at least once each year. This is usually a task that most golfers do not do because, they have not been properly advised or don“t know. The wear is so gradual, that many will not understand why their game is suffering.
[0020] Resurfacing or restoring the clubface entails that the clubs be sent or taken to a Qualified Golf Repair Shop. The standard method for reconditioning the clubface is to have the surface sand or bead blasted. However, in doing so, the edges of the grooves, which produce much of the spin, made the edges even more rounded by the peening of the sand blasting, thereby loosing much of the groove“s spin-generating abilities.
[0021] Resurfacing in this manner may not be consistent or very effective and is an inconvenience, a time with out clubs and it can be expensive, especially if the clubs have to have their grooves milled out. The milling may cause the grooves to be out of the USGA specifications, rendering the club as non-conforming. The USGA rules state that, “Any part of a club which has been purposely altered is regarded as new and must, in its altered state, conform to the rules.” That could mean that resurfacing as suggested could require the purchase of new clubs if one is to be in conformance. The shape, Width, Depth, corner dimensions and distance from one another are carefully illustrated & shown in the rules, making milling where material must be removed difficult if not impossible unless the entire face is first milled. This process may well exceed the cost of a new club.
[0022] Some of the leading golf companies such a PureSpin,™ Carbite™ & Taylormade™ are providing New Golf Clubs with Backspin Enhancement & Longer Wear characteristics, but you have to purchase their “New Clubs” to get these benefits.
[0023] Related patents are the following: U.S. Pat. No. 5,688,190, issued to Rowland et al. on Nov. 18, 1997, describes a ribbed adhesive backed pad for the face of a golf club. Unlike the present invention, by providing ribs, Rowland et al.“s device is not suitable for restoring the face of a golf club to its new or unadulterated state. Rather, Rowland“s device modifies an existing to club to allow it to perform as desired by the user, as opposed to the club“s own specifications.
[0024] U.S. Pat. No. 5,690,561, issued to Rowland et al. on Nov. 25, 1997, is directed to a two-sided pad that goes onto the face of a golf club. Unlike the present invention, Rowland et al. has ridges that add additional friction to the face of a golf club, as opposed to restoring it to its new condition by merely increasing friction where friction was intended.
[0025] The above patents and concepts do not provide consistency, but add more variables to a game that already has too many. They do not take into consideration the effects of their materials on the performance of distance, control, debris accumulation, etc. They only refer to backspin and not to any specification or standard.
[0026] U.S. Pat. No. 5,804,272, issued to Shrader on Sep. 8, 1998, shows a backspin sticker in combination with a golf club. Unlike the present invention, Shrader“s device is intended to provide a variety of faces for a single golf club so that a single golf club can be employed for an entire round of golf. Shrader“s device, unlike the present invention, is to be applied and removed repeatedly, such that there is no concept of restoring a club to its initial face before wear and tear.
[0027] U.S. Pat. No. 4,768,787, issued to Shira on Sep. 6, 1988, describes a golf club with a high friction striking face. Unlike the present invention, Shira“s device does not contemplate separate faces for golf clubs that can be replaced or used for a short duration of time so that the face can be returned to its unadulterated form.
[0028] U.S. Pat. No. 4,917,384, issued to Caiati on Apr. 17, 1990, shows a golf club with an improved face. Unlike the present invention, Caiati“s device does not contemplate separate faces for golf clubs that can be replaced or used for a short duration of time so that the face can be returned to its unadulterated form.
SUMMARY OF INVENTION
[0029] A surface for application to the face of a golf club so that the face performs if it were new. The surface allows the face to perform like or to the face“s original specifications.
[0030] In one embodiment of the present invention, one side of the present invention has an adhesive layer so that it can securely, but removable, attach to the face of a golf club. The other side of the present invention has a surface that conforms to the friction equivalent to the face of a new golf club.
BRIEF DESCRIPTION OF DRAWINGS
[0031] [0031]FIG. 1 shows grains, fill and the carrier.
[0032] [0032]FIG. 2 shows grains, fill, carrier and a slurry coating.
[0033] [0033]FIG. 3 shows the top view of the preferred shapes of the present invention
DETAILED DESCRIPTION
[0034] In order to provide a reliable & consistent backspin producing surface that may be applied to virtually any golf club face, new or used, easily & inexpensively, we have engineered the following: A simple but effective spin-generating shield, shaped to cover the striking area and offer protection to the face from further wear & damage.
[0035] In the preferred embodiment of the present invention, the shield 5 consists of a hard micron grains 10 , but not brittle to avoid fracturing, bonded with a hard tough resin 20 , to a strong, high-impact resisting carrier 30 such as a thin strong metal screen or special non metallic film or sheet. (Paper or soft materials such as Aluminum as a carrier will absorb energy resulting with a loss of COR.) The areas between the select grains 10 are filled to a desired level with a suitable fill 25 so that the valleys between the grains 10 are filled, further bonding the grains 10 to one-another. This reinforces the structure and also prevents unwanted debris from filling the voids that would cause a change in traction. The fill 25 may be filled or reinforced with micro balloons, fibers, or other reinforcing or extender materials. As wear takes place, the softer fill 25 erodes, exposing more of the harder longer wearing grain 10 , insuring continued traction. The fill 25 between the grains 10 could be the bonding resin 20 as well; as in a slurry coating. Pigments may be added to colorize the fill 25 if desired. This can show wear patterns and points where a golf face strikes a golf ball as the pigment be exposed, lighter, and or darker depending upon wear of the present invention. For example, if a golf ball is hit repeatedly, the resin 20 might erode in certain areas on top of and around the grains 10 simply because of wear as the ball hits the fill 25 and grains 10 . A pigment aids in assessing wear as the grains 10 could be one color and the resin 20 , fill 25 another color.
[0036] The fill 25 fill prevents the golf ball“s cover or surface from being greatly penetrated by the grains 10 that would absorb or rob energy in doing so, reducing the COR. The fill 25 also allows the impact pattern to be over a larger effective surface area, spreading the impact so that the supporting carrier 30 receives less grain 10 impact effect and also transferring more energy, increasing the COR. Smaller grains 10 with more surface points and contact area penetrate the ball less, do less damage to the ball and are more resistant to fracture and will transfer more energy.
[0037] The surface roughness can be controlled with a combination of sizing the grains 10 and shaping the grains 10 , grain 20 orientation, grain 10 proximity to other grains 10 , the level of fill 25 and manufacturing methods.
[0038] The USGA specifications on the roughness is that the surface irregularities that no peak stand more than 180 micro-inches above the average of the rest of them. We are able to have several grain 10 sizes that meet this spec as long as we fill in the valleys in-between the grains 10 to meet the roughness. That is we may select a larger grain 10 that has more distance between them and consequently makes a thicker matrix and requires more fill 25 and conversely, smaller grains 10 with less fill producing a finer, thinner, closer knit surface but still be within the limits with less fill. As mentioned earlier we prefer the smaller grain made by slurry coating.
[0039] Slurry coating is where the selected grains 10 are mixed into a suitable resin and flowed onto the carrier in the proper proportions. The grains 10 are like miniature icebergs settling onto the carrier.
[0040] The fill 25 bonds the grains to one another and reinforces the matrix and in filling the cavities, prevents unwanted debris from collecting within these cavities that could then affect the grip or traction on the ball. The fill 25 also makes it easier to keep the clubface clean.
[0041] The carrier should be strong to resist the impacts, but not really malleable as the ball impacts would cause the carrier to change. If it were in the malleable (aluminum) type the thickness would have to be increased to provide more resistance but it would then add more weight.
[0042] We try to keep the weight at a minimum. The weight for our heavier duty and longer lasting product that will allow hundreds of hits is more than twice the weight of the thinner face. Our added weight is therefore virtually imperceptible by golfers. A dime is what swing weight is usually measured by.
[0043] The size or dimensions of the face shields 5 range is preferably from 1.625″/2.50″ wide with a total height of 2.25″/3.50″ high for the combination used on the wedges. The lower part used for woods & drivers is from 0.75″/1.55″ according to the clubs manufactured in to-days standards.
[0044] The special shape 50 , 60 , makes for only one inventory and covers both left and rights for any club. It therefore reduces inventory costs, manufacturing costs, packaging and possible errors of shipping, returns and selection confusion by the customer. A golfer may have various clubs that they use from different manufacturers. With our universal shape there is no confusion or mistakes . . . they will fit virtually all clubs that we have tried them on.
[0045] The product is made flat and has a very uniform controlled surface distribution. It will conform to slight curvature in the clubface as some manufacturers have made.
[0046] In an other embodiment, Hard Crystals such as diamonds are fused or metallurgically bonded to a metal sheet or carrier with a metal matrix. Portions of the Hard Crystals protrude above the matrix to provide the roughness desired and the traction to the ball. Typically such a construction is used in “Sapphire nail-files”. The roughness, color and unwanted debris accumulation may be further controlled with a resin fill between the crystals as stated in the embodiments above.
[0047] Other Replaceable Faces may be made by various manufacturing techniques as extruding, pressing, molding, etc out of various materials as metals, composites, plastics, ceramics etc.
[0048] Resilient rebounding materials may also be utilized either as the face or under a new face to provide additional distance to the ball, similar to the effect of the new clubs that have been recently allowed by the USGA.
[0049] Special attention to the attachment of the shield to the Clubface is also necessary. Most pressure sensitive adhesives are made of soft materials that will cause a loss of energy transfer. This energy attenuation or cushioning, can be reduced with harder & or thinner adhesives, intermediate layers or reinforcements, or by employing other adhesive systems either temporary or permanent, as Waxes, heat activated, epoxies, cyanoacrylate esters or other suitable adhesives.
[0050] We have not found anything that even comes close to the shape & descriptions nor have the professionals or the golf media that usually would know of such existence now or prior.
[0051] We have found that the replaceable club faces replicate a new clubs performance very closely and that it is a very good way to see if a golfers clubs are indeed worn by simply testing the distance, control, and backspin of a used club, recording the test results and then repeating the test with the replaceable clubfaces applied. If the results are such that a large difference is seen between the before and after tests, the golfer should be advised that they are playing with tools or equipment that will affect their scores. The golfer should then make a decision whether to purchase, repair or replace if they play in tournaments. If they a just a regular golfer and only want good tools they could continue to use the replaceable faces. We are working with the USGA and at some time in the future the replaceable faces may be approved for tournament use.
[0052] The transparency of the carrier 30 allows printing on the carrier 30 so that identifications can be seen thru the face. This is important so that companies that wish to advertise their names or logos or provide these as premiums etc., may do so.
[0053] We have also demonstrated a metallic appearing clubface where the transparent friction causing materials are employed over a metalized surface, thus allowing the surface seen.
[0054] The non or less transparent shields may have Logos & names imprinted on their surface, but it is more difficult due to the roughness. Frequent cleaning & use may remove the markings on the surface.
[0055] Carrier 30 strength and thickness have an effect on their resistance to shearing over the unsupported area over the grooves. Thinner carriers will shear faster, indicating where the ball was struck by the clubface. This can be a benefit to many players. In using such a material, we recommend that the shields 5 be trimmed using a razor knife or other similar tool over and along the grooves either prior to or after play. In removing the excess, the worn or rounded groove edges become effective once again. The grooves aid in channeling away water in very wet conditions.
[0056] Using a thicker, stronger carrier 30 will resist the shearing over the groove area and provide a more durable product where trimming over the grooves is not necessary.
[0057] Grooves are not a requirement per the USGA rules and therefore the existing grooves may be filled with a suitable lasting filler and then covered with the shields 5 . A club made without grooves could also be employed. This would eliminate the trimming of the shields and using thinner carriers 30 . Patterns on the shield may be employed to provide edge traction and aid channeling or removal of water if desired.
[0058] Shields are quickly and easily replaced should they show signs of wear, damage or stubborn soil. A new shield 5 is then applied and the club now has the same roughness and spin-generating characteristics as a new club or to a desired specification. This ability will keep a players clubs with a consistent traction & backspin, allowing for greater control & distance, thereby improving their game with fewer required strokes and with a possible cost savings.
[0059] A replaceable face and covering that may be secured to and over an existing golf club face, thereby becoming the new and only face on the club. (If such a material is used on putters two faces are permitted.) Materials: Metals, Alloys, Plastics, Polymers, Ceramics, Composites, or other composition of matter.
[0060] Manufactured by: Extruded, Cast, Formed, Machined, Molded, Pressed, Stamped, By converting, Laminating, Printing, Calendaring, Transferring, Coating, Etching, Corona or Electrical Discharge, Electrostatic methods, Vacuum Deposition, Plasma Spray, Metallurgical fusion or bonding, Laser, water or fluid jet, Embossing, or other methods to produce the items, the surface and treatments.
[0061] A golf-club face surface, with or without the grooves that can be manufactured to conform to a given standard or specification of surface roughness, impact resistance, replace-ability, durability, resilience, Coefficient of Restitution, color, transparency, the filling of the surface to provide added strength, roughness & wear control, and control the accumulation of unwanted soil and debris that could influence ball control.
[0062] A golf-club surface, with or without grooves, that meets the Rules & Standards of golf club faces as set by the USGA and or the Royal & Ancient Golf Club of St. Andrews, which may be affixed or secured to and over an existing golf-club face. After application, which is manufacturing, the pre-existing club-face now becomes the supporting structure and part of the golf-club structure and may no longer be considered a face unless the removable face is removed.
[0063] The golf club has now been purposely altered and manufactured to be in conformance to the USGA and of the Royal & Ancient Golf Club of St. Andrews and is therefore deemed to be in conformance.
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A golf club face and protective shield for adhesion to the face of a golf club is provided such that a renewed surface for proper backspin is obtained. Adhesive holds the shield to the face of the golf club, and the striking surface is generally flat with a plurality of materials to mimic the surface of the face of a new golf club.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority on provisional patent application Ser. No. 60/625,641, entitled A COOKING APPLIANCE, filed Nov. 5, 2004.
FIELD OF THE INVENTION
[0002] The invention is directed towards a burner shield for use with a cooking appliance and more specifically, a burner shield that can enhance the flavor of cooking foods.
BACKGROUND OF THE INVENTION
[0003] It is well known that drippings, such as grease, make foods taste better when grilled. This fact is known for charcoal, gas, and other fueled grills. By collecting and vaporizing the excess grease that drips from the cooking food, the individual is able to enhance the flavor of the meal. It is advantageous to trap grease on a surface capable of vaporizing the grease to increase the amount of vapors that reach the meat being grilled. However, when using grills, temporarily trapping the grease on a surface hot enough to vaporize the grease can be difficult. Further, it is advantageous to protect the heat source, such as the burners, from being splattered with grease.
[0004] Traditionally, burner shields are used to provide some vaporization and protect the burners. Typically, these burner shields have a first and second side which define at least one peak, thereby creating generally an inverted “V” shape. However, these burner shields can accelerate the dripping grease and speed the grease flow reducing the amount of grease vaporized. Because the current burner shields lack a design that is aimed at slowing the rate at which the grease travels down the burner shield, much of the flavor from the grease vapor is lost.
[0005] Therefore, it is desirable to have a burner shield which is designed to keep the grease on the burner shield's surface for as long as possible before draining into the debris tray so that the maximum amount of grease is vaporized, thereby maximizing the flavor of the meat being grilled.
[0006] It is further desirable to have a burner shield that can be provided originally with a cooking appliance or can be provided subsequently to obtaining a cooking appliance and added to the cooking appliance.
SUMMARY OF THE INVENTION
[0007] This invention is directed towards a burner shield for placement between the heat source a grill and the cooking area comprising a first side and a second side connected to form a radiused peak having generally an inverted V shape, the sides sloping outwardly from the radiused peak. The burner shield also includes a protrusion extending outwardly from at least one of the sides to help inhibit the flow of grease down at least one of the sides, increasing the time the grease is in contact with the burner shield and to help prevent grease from dripping on the heat source.
[0008] The burner shield may also include a vent defined by the protrusion and at least one of the sides allowing heat from the heat source to escape through the vent and into the cooking area. The protrusion may include a front portion partially obstructing the vent to help prevent grease from dripping on the heat source and may also include a left portion and a right portion for directing grease away from the vent.
[0009] The burner shield may include an upper arrangement of protrusions in generally a horizontally spaced configuration and a lower arrangement of protrusions in generally a horizontally spaced configuration and offset from the upper arrangement of protrusions so that grease traveling between protrusions of the upper arrangement of protrusions will contact at least one protrusion of the lower arrangement of protrusions.
[0010] The burner shield may include a flange carried by the first side and arranged generally upward from the slope of the first side. The first side of the burner shield may have a length less than the second side of the burner shield.
[0011] The invention may also include a plurality of integral sides angled to define a plurality of peaks and troughs and arranged generally in an undulating shape and having a protrusion extending outwardly from at least one of the plurality of integral sides to help inhibit the flow of grease down at least one of the integral sides, increasing the time the grease is in contact with the burner shield and to help prevent grease from dripping on said heat source. A vent may be defined in the burner shield by the protrusion and at least one of the plurality of integral sides.
[0012] The burner shield may further include at least one opening defined in the plurality of troughs for allowing grease that reaches one of the plurality of troughs to drain from the burner shield.
[0013] The burner shield may include a first exterior integral side and a second exterior integral side having a length less than the first exterior integral side. Additionally, the burner shield may have a first exterior integral side, a second exterior integral side, a plurality of interior integral sides wherein the first and second exterior integral sides have a length less than the plurality of interior integral sides.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a grill having a burner shield;
[0015] FIG. 2 is a perspective view of an alternate embodiment of a burner shield;
[0016] FIG. 3 is a side elevation view of a burner shield; and
[0017] FIG. 4 a is an end view of one embodiment of a burner shield; and,
[0018] FIG. 4 b is an end view of one embodiment of a burner shield.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Typically, cooking appliances comprise a housing, a burner assembly, a cooking area, a heating area, a debris trap, and a heating source, such as charcoal or gas. The cooking assembly housing or frame may be a standard grill housing having four sides, a bottom, and a flip-top lid.
[0020] Referring now to FIG. 1 , a cooking appliance is shown generally as 10 and includes an upper-lid flip-top lid 12 that is hingeably connected to frame 14 in such a fashion that the flip-top lid is able to be easily opened and closed. The cooking appliance can include a burner assembly 16 that includes at least one burner 18 having a plurality of ports for the excretion of gas. The burner assembly is carried by frame 14 in such a fashion that at least one burner 18 extends into the heating area shown generally as 20 . Burner assembly 16 can be connected to a gas tank by a gas line. The gas tank may have a variable setting knob, which controls the rate at which the gas exits the gas tank to the burner assembly through the gas line. The cooking appliance may also employ charcoal as a heat source or other fuels.
[0021] Located above one burner 18 of burner assembly 16 is a burner shield 22 . The burner shield is located below cooking surface 24 , but above burner 18 . The burner shield comprises a first side 22 a and a second side 22 b that are connected at an angle to form a radiused peak. First side 22 a and second side 22 b slope away from the radiused peak 30 to define a generally inverted “V” shape. Located at the outer edge of either or both of the first and second side is a flange 23 , that is angled upward from one or both of the downward sloping sides 22 a and 22 b. In at least one embodiment, the flange is angled so that is generally parallel to cooking surface 24 .
[0022] When placed adjacent to one another, several burner shields can define a plurality of peaks. Further, when arranged in such a horizontally spaced relation, flanges 23 provide a space that can be located over drip openings 26 that are disposed between burners 18 of burner assembly 16 . Because the burner shields need not be integral with one another, the excess grease that is not vaporized by burner shield 22 is allowed to drain off of flanges 23 and into drip openings 26 . In such an arrangement, burner shield 22 is carried by the frame and may be attached to the frame via hooks, slots, snaps or the burner shield may rest on a lip that extends from the frame or may be carried by other means known by those skilled in the art.
[0023] Referring now to FIG. 2 , an alternate embodiment of burner shield 28 , integrates a plurality of burner shields 22 by connecting a plurality of burner shields to define a plurality of peaks 30 and troughs 32 , giving this embodiment of the burner shield an undulating or generally “W” shape. Because this embodiment connects the burner shields rather than placing the burner shields adjacent to one another as shown in FIG. 1 , openings 33 can be formed in trough 32 to allow grease that has flowed down from peak 30 to drain from the burner shield and into the drip openings, shown as 26 in FIG. 1 .
[0024] As can be seen in this embodiment, burner shield 28 , regardless of the embodiment used, may be carried by hooks formed in the frame of the grill. The hooks may extend out from the frame and pass through the openings 36 defined in the peaks so that the burner shield rests on the hooks. However, any means generally known in the art for carrying the burner shields may be used for any of the embodiments disclosed.
[0025] Regardless of whether the burner shields are integral with one another as shown in FIG. 2 or are arranged in a horizontally spaced relation to one another as shown in FIG. 1 , each burner shield 22 includes a protrusion, coined flavor steps, 34 that help to direct the flowing grease and help slow the velocity at which the grease flows down one of the sides of the burner shield, so as to help increase vaporization of the grease.
[0026] Referring now to FIG. 3 , a side view of the burner shield showing protrusions or flavor steps 34 ()-( q ). In the shown embodiment, the flavor step comprises a top side 36 , a first side 38 , and a second side 40 . Each side extends outwardly from the burner shield to help inhibit the flow of grease and increase vaporization of the grease. While it need not be, in at least one embodiment, the top side 36 of the flavor step, protrudes from the burner shield so that it is generally parallel to the cooking surface (shown as 24 in FIG. 1 ). In alternate embodiments, the top side 36 of the flavor step may protrude from the burner shield 22 so that an angle less than 180 degrees is formed between one of the sides of the burner shield (shown as 22 a or 22 b in FIG. 1 ) and top side 36 of protrusion 34 .
[0027] As can be seen in FIG. 3 , in at least one embodiment, a vent 42 is formed by top side 36 , first side 38 and second side 40 of the flavor step and at least one of the sides of the burner shield. This vent promotes convection heating of the items being grilled. In this embodiment, the flavor step may further include a front portion 44 that extends downwardly from top side 36 , at least partially obstructing the opening 42 that is defined by one of the sides of the burner shield (shown as 22 a or 22 b in FIG. 1 ) and flavor step 34 .
[0028] In alternate embodiments, flavor step 34 need not define an opening 42 in one of the sides 22 a and/or 22 b of burner shield 22 . Further, while the flavor step in the shown embodiment includes a top side 36 a first side 38 and a second side 40 , alternate embodiments include steps having alternate configurations. Essentially, all that is required of flavor step 34 is an upper portion that is defined by a protrusion that can slow the velocity or alter the direction of the grease flowing down one of the sides of the burner shield. Such embodiments include a first and second side that protrude from one of the sides of the burner shield and connect to form a radiused peak extending from the burner shield. Also included in such embodiments is a ledge that protrudes from one of the sides of the burner shield at an angle less than 180 degrees as well as a dome that protrudes from the burner shield.
[0029] Regardless of the type of flavor step used, in one embodiment, at least two arrangements of flavor steps are carried by at least one side of the burner shield and arranged so that each flavor step in an upper arrangement 46 is positioned so that it may direct the flowing grease to a flavor step in a lower arrangement 48 . The angle at which first side 38 and second side 40 of the flavor step are connected to top side 36 of the flavor step is determined in conjunction with the position of each flavor step 34 so that when grease flows down from the peak of the burner shield, the flavor steps in upper arrangement 46 help to direct the grease generally to a flavor step in lower arrangement 48 . In at least one embodiment, the rows of flavor steps are arranged so that upper arrangement 46 of flavor steps help direct the flowing grease specifically to top side 36 of a flavor step 34 located in lower arrangement 48 .
[0030] Referring now to FIG. 4 a, a first side 22 a and a second side 22 b of the burner shield 22 define a peak 30 . The first and second side extend away from the peak in order to promote the flow of grease towards the flanges 23 a and 23 b formed at the outer edges of first and second sides 22 a and 22 b of the burner shield 22 . The top side of each flavor step, generally shown as 34 a, 34 b, 34 c and 34 d, extends outward from the first and second sides and can be generally parallel to the primary path formed by the cooking grid (shown as 24 in FIG. 1 ) such that a step is created. This step serves as a stopping or slowing point for grease which drips onto the burner shield.
[0031] Referring now to FIG. 4 b, first side 22 a of burner shield 22 may have a length that is less than the length of second side 22 b. In this embodiment, the length of first side 22 a may be such that only one arrangement of flavor steps may be disposed on first side 22 a. Such an arrangement allows the burner shield to be positioned more closely to the burner (shown as 18 in FIG. 1 ). For example, if flange 23 a is carried by or engaged by the frame to hold burner shield 22 in place, opposite flange 23 b is allowed to extend below the portion of the frame which carries flange 50 a. Such an arrangement places burner shield 22 in a closer proximity to the flame and exposes the burner shield to a greater degree of heat, thus increasing the vaporization of the grease that drips onto the burner shield.
[0032] Typically, this embodiment is used in combination with the embodiment shown in FIG. 2 as a means for disposing the burner shield on the frame (shown as 14 in FIG. 1 ). In one embodiment, both of the outer edges that are carried by the frame (shown as 14 in FIG. 1 ) have shorter lengths than the interior sides, thus allowing troughs 32 to be located more closely to the heat source of the grill. However, in an alternate embodiment, burner shield 28 may have only one outer side that is carried by the frame and shorter in length than the interior sides. This embodiment allows burner shield 28 to be sectional, where more than one section is required to cover the entire heat source. In this embodiment, the burner shield may be carried by the frame by hooks that pass through the openings 36 formed in the peaks or by other means generally known in the art.
[0033] Modifications to the present invention may occur to those of ordinary skill in the art. Accordingly, it is to be understood that the present invention is not limited to the particular embodiments disclose herein, but rather is intended to cover all modifications within the scope of the present invention as set forth in the following claims.
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The invention is directed towards a burner shield for placement between a grill's heat source and cooking surface. The burner shield comprises two sides connected to form a radiused peak. The burner shield includes protrusions that extend outwardly from at least one of the sides for inhibiting the flow of grease down one of the sides, increasing the time that the grease is in contact with the burner shield and thus the amount of grease that is vaporized. Vents may be defined by the protrusions and at least one of the sides for providing convection heating. The burner shield may include a upper arrangement of protrusions and a lower arrangement of protrusions that are off set from the upper arrangement so that grease flowing from or between the protrusions in the upper arrangement will contact at least one of the protrusions in the lower arrangement.
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BACKGROUND
The present invention pertains to protective chaps of a pant-like construction to cover the legs of a wearer. More particularly, the chaps provide protection against a chainsaw cut or, optionally, the bite of a poisonous snake, but typically not both.
Protective chaps for use in the forestry industry are typically made from a heavy woven cloth-like shell such as, for example, Cordura™. This material has inherent protective quality against chainsaw cuts by virtue of its tough construction. In addition, however, the outer shell material is often covered, on the inside face, with another chainsaw protective layer, for example, a polyester/aramid fiber. Snake bite protective chaps, on the other hand, more typically utilize a second inner layer of material similar to the outer shell, but lighter.
Prior art chaps are intended to be worn over the user's pants and, because of the heavy-duty shell material, may be somewhat bulky and difficult to put on either before or after the user puts on boots. Also typically, the chaps are made from generally rectangular leg panels which are folded around the user's legs and connected by their inner edges to form a generally tubular leg. The opposite vertical edges of the leg panel are connected with different types of fasteners including straps and buckles, and hook-and-loop fasteners. When using straps and buckles, adjustable fitting can be attained, but the fastener straps are unwieldy, have loose ends, and result in potential hazards possibly causing the user to trip and fall. Also, the opposite vertical edges of the panel typically extend from the bottom edge only a portion of the distance to the upper edge, resulting in added difficulty in the user slipping a leg into the closed upper tubular leg portion, especially over boots.
Because loggers and other forestry workers often work in areas inhabited by poisonous snakes, there is a need for material or materials that address both chainsaw cut and snake bite hazards. However, adding a completely separate layer of protective material can add to the bulkiness and difficulty in handling the heavier chaps. In a typical pair of prior art chaps, using straps and buckles to close the legs, the connecting buckles are exposed and may become clogged with snow, ice or other materials. If zippers are used instead of buckles, the problem may be even worst with the zippers becoming clogged and frozen and difficult to use.
SUMMARY OF THE INVENTION
In accordance with the present invention, a protective leg chap includes a pair of leg assemblies each having an outer cloth shell with the shells connected to one another by an upper rear support section. Each leg assembly includes a leg panel of generally rectangular shape and having opposite, substantially parallel edges when the leg panel is open and flat. The legs include an open-and-closed arrangement that extends substantially the full length of the edges and defines a tubular leg when the leg panel edges are overlapped and connected. The open-and-close arrangement has a first closure half that extends along one panel edge, the first closure half defined by a first half of one type of fastener and a first half of a different type of fastener. A second closure half extends along the other panel edge and has the second closure half that is defined by a second half of said one type of fastener and a second half of said different type of fastener. The first and second halves of said one type of fastener and the first and second halves of said different type of fastener are positioned such that, when the one type of fastener is closed, the first half of said different type of fastener attaches to the second half of the different type of fastener and covers and encloses said one type of fastener.
Preferably, the one type of fastener is a zipper and the different type of fastener is a hook-and-loop fastener. The first halves of said one type of fastener and the different type of fastener comprise a pair of parallel strips, the second halves of said one type of fastener and the different type of fastener each comprise a pair of parallel strips.
The first half of the zipper and the first half of the hook-and-loop fastener are positioned along one panel edge on the inside thereof, and a second half of the zipper and the second half of the hook-and-loop fastener are positioned along the other panel edge on the outside of the leg panel when the panel edges are overlapped. Preferably, the second closure half comprises a pair of parallel spaced zipper strips and a pair of parallel spaced hook-and-loop fastener strips. The respective pairs of a second zipper strip and a second hook-and-loop fastener strip are selectively attachable to the first halves of the zipper and the hook-and-loop fastener on said one panel edge, thereby permitting tubular leg size adjustment.
In a preferred embodiment, the outer cloth shell is covered on an inside surface with a thin polyester fabric. A chainsaw protective layer of polyester/aramid fiber is positioned between the shell and the polyester fabric. Also, a lower portion of the inside surface of the leg panel may be provided with a snake bite protective layer. The snake bite protective layer may comprise a woven material.
In a basic embodiment of the present invention, a protective leg chap includes a leg, assembly made from an outer cloth shell and including a leg panel of generally rectangular shape defined by opposite edges when the leg panel is open and flat. A leg fastener arrangement extends substantially the full length of the panel edges and defines a tubular leg when the leg panel edges are overlapped, connected and closed. The open-and-close fastener arrangement includes a first closure half that extends along one panel edge and includes a first half of a zipper and a first half of a hook-and-loop fastener. A second closure half extends along the other panel edge and includes a second half of said zipper and a second half of said hook-and-loop fastener. The first and second halves of the zipper and the first and second halves of the hook-and-loop fastener are all of generally the same length or coextensive and are positioned such that when the zipper is closed the first half of the hook-and-loop fastener attaches to the second half of said hook-and-loop fastener and encloses the zipper.
The leg chap typically comprises a pair of leg assemblies that are connected to one another by an upper rear support section. The overlying layer of a chainsaw protective material and, optionally, a snake bite protective material, are applied to the inside surface of the outer shell and covered by the thin polyester fabric layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the outer surface of a leg panel showing the panel open and flat and the layered lining shown broken away.
FIG. 2 is a plan view of the panel in FIG. 1 showing the inner panel face.
FIG. 3 is a view of the leg panel with the left edge of the panel being folded over toward the right edge to form a larger diameter tubular leg.
FIG. 4 is a plan view similar to FIG. 3 showing the left edge of the panel folded further over to the right edge to form a smaller diameter tubular leg.
FIG. 5 is a perspective view of the tubular leg panel of FIG. 3 in its final tubular shape for a larger of two tubular legs.
FIG. 6 is a view similar to FIG. 5 showing the tubular leg panel of FIG. 4 in the smaller of the two alternate tubular sizes.
FIG. 7 is a generalized plan view of a pair of interconnected chap assemblies showing the inner cloth shell faces.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-6 show portions of one chap leg assembly 11 comprising half of a pair of chaps 10 . Each leg assembly 11 is connected to another leg assembly to form a pair of chaps 10 as shown in FIG. 7 . The leg assemblies 11 are connected by an upper rear support section 13 using adjustable straps 14 to hold the chaps 10 as they are wrapped around the user's waist.
Each of the leg assemblies 11 has an outer cloth shell 12 that extends vertically from the lower edge of the leg assembly and is formed of a heavy woven material, such as Cordura™, as is well known in the industry. Each leg assembly includes a leg panel 15 , that is rectangular in shape and includes opposite vertical edges 16 and 17 when the leg panel 15 is open and flat. The outside face 18 of the leg panel is shown in FIG. 1 and the inside face 20 of the panel is shown in FIG. 2 .
Leg panel 15 is folded over to bring the vertical edge 16 toward the opposite vertical edge 17 which is folded toward edge 16 until the edges 16 and 17 overlap and are closed with closing arrangement in accordance with the present invention.
The leg assemblies 11 for a pair of leg chaps are identical and are connected to the upper support sections 13 with the adjustable pairs of waist straps 14 . In FIG. 2 , there is shown the inside face 20 of the leg panel 15 . On one edge of the inside face 20 , there is shown the tint half 22 of the closing arrangement 21 of the present invention. The first half 22 extends substantially the full length of vertical edge 17 and, when connected to the second half of the closing arrangement 21 , connection of first vertical edge 16 to the second vertical edge 17 on the opposite edge of the leg panel 15 , the closing arrangement defines a tubular leg 24 which is shown in FIGS. 5 and 6 in the two size connection of overlaps of panel edges 16 and 17 .
The first half 22 of the closing arrangement includes half of a first hook-and-loop fastener strip 25 attached at the edge 17 and the first half of a zipper 26 attached parallel to and spaced from the first hook-and-loop strip 25 . The second half 23 of the closing arrangement 21 is shown in the plan view of FIG. 2 and is also shown in phantom in the opposite plan view of FIG. 1 . The second half 23 of the closing arrangement 21 includes alternate pairs of a second half of a hook-and-loop fastener 27 , 27 ′ and alternate pairs of second zipper strips 28 , 28 ′. The alternate pairs of second hook-and-loop fastener strips 27 , 27 ′ and corresponding alternate second zipper strips 28 , 28 ′ permit circumferential size adjustment of the tubular leg 24 of the leg panel 15 . Referring to FIGS. 1 and 2 , when the first half 22 along edge 17 is folded over toward the second half 23 positioned along vertical edge 16 , the first half 22 of the closing arrangement 21 (comprising first hook-and-loop fastener strip 25 and first zipper strip 26 ), the first zipper strip 26 and the first hook-and-loop fastener strip 25 may be selectively and respectively attached to a pair of a second hook-and-loop fastener strip 27 and a second zipper strip 28 or second hook-and-loop fastener strip 27 ′ and second zipper strip 28 ′. In forming the tubular leg 24 , as shown in FIGS. 3 and 4 , the first zipper strip 26 is connected to either of the second zipper strips 28 , 28 ′, and the first hook-and-loop fastener strip 25 is correspondingly attached either the second hook-and-loop fastener strip 27 or second hook-and-loop fastener strip 27 ′. Attaching the first half 22 of the closing arrangement comprising the first zipper strip 26 and the first hook-and-loop fastener strip 25 to the second zipper 28 and the second hook-and-loop fastener strip 27 results in a larger diameter tubular leg 24 , whereas, attachment of the first zipper strip 28 ′ and second zipper strip 28 ′ results in smaller tubular leg 24 .
When the vertical edges 16 and 17 of the leg panel 15 are connected, the first hook-and-loop fastener strip 27 or 27 ′, the corresponding zipper halves 26 and 28 or 28 ′ are completely covered and enclosed. This is an important feature in snow or icy conditions, as well as muddy conditions, to keep the zippers from freezing up and becoming difficult to open or close.
Although different types of fasteners may be used such as a zip-lock fastener for either the zipper or the hook-and-loop fastener, these are clearly inferior and do not provide the versatility and utility of the present invention combining zippers with hook-and-loop fasteners. The features of the present invention may also be applied to so-called “gators” or sometimes referred to as “gaiters” where separate leg assemblies are worn like conventional hip boots.
In the preferred embodiment of this invention, the inside surface 18 of the leg panel 15 is covered with a thin polyester fibric 30 . The space between the inside surface 18 of the leg panel and the thin polyester fabric 30 is filled with a chainsaw cut protective layer 32 of polyester/aramid fiber (or similar protective layer) and, in order to provide dual protection against chainsaw cuts and snake bites, the inside surface of the leg panel may be provided with a snake bite protective layer 31 comprising a suitable woven material. The optional snake bite protective layer need not extend the full height of the leg panel, but rather only about 12″-16″ thereby defining the region more likely to be susceptible to snake bites. Preferably, the chainsaw protective material is used to fill narrow portions of the leg assemblies 11 such as the thin region between the first hook-and-loop fastener strip 25 and the first zipper strip 26 . Similarly, the narrow layer between the second zippers 28 , 28 ′ may be filled with chainsaw protective material.
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Protective chaps to provide protection against chainsaw cuts and, optionally, poisonous snake bites has a woven cloth-like shell lined by a layer of polyester/aramid fiber and, optionally, a partial layer of a woven material, all enclosed by an inside thin polyester fabric. The combination of zippers and hook-and-loop fasteners provides a dual fastener system that protects against freeze up and clogging of exposed zippers and may include alternate connections to provide two different tubular leg sizes.
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BACKGROUND OF THE INVENTION
The invention relates to a an apparatus for removing liquids from the surface of a strip conveyed from a strip processing machine, more particularly a rolling stand, by means of a gas jet, having an outlet nozzle, from which the gas jet emerges, and a suctional opening, via which the gas jet can be removed by suction mixed with the liquid.
Apparatuses of the kind specified are needed to remove residues of lubricant, more particularly from high-speed rolled metal strips. After the rolling operation residues of the lubricant remain adhering to the strip, to which they were applied during rolling. If the lubricant liquid is inadequately removed, after the strip has been wound into a coil, the lubricant residues form between its individual windings a film which may cause the individual windings of the coil to telescope--i.e. become displaced axially of the reel during reeling. Moreover, as a rule the further processing of the strips requires very low residual quantities of lubricant, referred to the surface of the rolled strip.
For a considerable period attempts have been made to remove, for example, by air blasts, residues remaining on the ship after its treatment. For example, U.S. Pat. No. 3 607 366 discloses an apparatus of the art mentioned above wherein slot jet nozzles extending substantially over the width of the strip are adjusted to a predetermined inclination of their jets against the direction in which the strip to be cleaned travels. The gas jet emerging from the nozzles is directed substantially against the conveying direction of the strip. Practical tests of such apparatuses for removing residues from strips have shown that the cleaning effect achievable by said apparatuses is inadequate to completely remove residues of lubricant left on strips after each rolling operation, more particularly on strips processed on rolling stands.
An improved apparatus for the removal of liquids from the surface of a strip is disclosed in German Offen-legungsschrift DE 42 15 602 A1. In that apparatus the gas jet is blown, also via a slot jet nozzle disposed at a predetermined angle of inclination transversely of the direction in which the strip travels, on to the strip against its conveying direction, the relation between the width of the slot jet nozzle and its distance from the strip being so selected that the gas jet impinges on the strip at high velocity. At the same time, disposed at a predetermined distance in the strip conveying direction upstream of the slot jet nozzle in this prior art apparatus is a suctional removal gap via which the gas flow and the liquid mixed therewith is removed from the strip by suction.
Use in practice of the apparatus known from DE 42 15 602 A1 has shown that an adequate cleaning effect can be achieved thereby in the zone of the centre of the strip. However, it was also found that the cleaning effect is frequently inadequate in the zone of the strip longitudinal edges, the place where particularly large residues of liquid often collect.
It is an object of the invention so to improve an apparatus of the kind specified that it enables a sufficient cleaning of the strip surface to be achieved over its whole width.
This problem is solved according to the invention by the feature that in an apparatus of the kind specified the gas jet is guided over the strip in a flow directed in the direction of at least one of the lateral edges of the strip and that a suction opening is associated with that lateral edge of the strip at which the flow is directed.
According to the invention the gas jet for cleaning the surface of the strip is not blown onto the strip in a flow directed substantially against the strip conveying direction any more, as done by the apparatus of the prior art, but a lateral flow can be additionally produced which is directed at one or both of the lateral edges of the strip. The suctional removal opening is disposed laterally of the strip, so that the mixture of gas and liquid can be removed immediately alongside the strip. In this way a large volumetric flow of gas can be taken over the strip at high flow velocity. The mass impulse of the high volumetric flow is enough to remove even fairly large quantities of liquid from the surface of the strip to be cleaned and more particularly from its marginal zones.
SUMMARY OF THE INVENTION
It is advantageous for the creation of volumetric flows which are as large as possible and which at the same time are directed over the width of the strip in a concentrated volumetric flow over the strip, if the apparatus according to the invention is furnished with at least two outlet nozzles arranged in pairs, which lie opposite each other in the conveying direction of the strip. With such an arrangement of the outlet nozzles it can be achieved that the individual gas jets emerging from the nozzles unite in a volumetric flow which can pass on a particularly high mass impulse/a particularly high kinetic energy. At the same time, eddying takes place in the zone in which the gas jets are mixed with one another. The eddying encourages the atomization of the liquid adhering to the strip surface. The mixing of the gas jets emerging from at least two outlet nozzles can be boosted by the feature that at least one component flow of the gas jet emerging from each of the outlet nozzles is directed against that gas jet which emerges from each opposite outlet nozzle.
Since a large volumetric flow is required more particularly in the marginal zone of the strip for the removal of the liquid adhering thereto at that place, it makes sense for the apparatus according to the invention to be furnished with a plurality of outlet nozzles disposed one beside the other in series over the width of the strip. In that case the volumetric flow of gas increases in the direction of the lateral edge of the strip, due to the fact that an additional component flow from each of the outlet nozzles is added to said volumetric flow. The outlet nozzles can be so arranged as to give an optimum adaptation of the increase in volumetric flow over strip width to the conditions created by the collection of liquid. Another advantage of the arrangement of outlet nozzles one beside the other in series is that a certain number of nozzles can be so directed that the gas jet emerging therefrom is blown on to the strip immediately into the direction of its lateral edge, while a certain number of the remaining nozzles are aligned, for example, in or against the conveying direction of the strip. The result of the gas jet flows then impinging on one another in different directions is that the gas jets unite with increased eddying to give a concentrated flow of high kinetic energy. A favorable development of flow can also be achieved by combining with one another rows of differently directed nozzles.
As an alternative to the use of a plurality of outlet nozzles disposed one beside the other in series, the outlet nozzle can also take the form of a flat jet nozzle. With the use of such a flat jet nozzle the volumetric flow increases, for example, linearly in the direction of the lateral edge of the strip, starting at the strip center. The gas jet emerging from the flat jet nozzle can be so directed against the strip that if two oppositely disposed flat jet nozzles are used, the gas jets emerging therefrom unite in a volumetric flow which also has a high kinetic energy.
Alternatively or in addition to a particular direction of the outlet nozzles, in the zone of the outlet nozzles at least one deflecting device can be disposed for the deflection of the gas jet in the required direction. This also favors the formation of a concentrated volumetric flow and the optimum atomization of the liquid adhering to the strip surface with the gas flow.
In such cases, in which the quantities of liquid collecting in the marginal zones of the strip are approximately equal, advantageously a component flow of the gas jet emerging from the outlet nozzle is guided in the direction of one lateral edge of the strip, while the other component flow is guided in the direction of the other edge of the strip, and at the same time a suctional removal opening is associated with each of the two edges of the strip. In this way, if collections of liquid occur on both sides, the strip surface can be freed from liquid adhering thereto uniformly over its whole width.
To boost the lateral flow of the gas jet, the gas jet can also be supplied directly to the discharge channel constructed between the outlet nozzles. This can be put into effect, for example, by the feature that disposed between the outlet nozzles is at least one further outlet nozzle which is positioned more particularly centrally between the lateral edges of the strip and via which a gas jet directed substantially transversely of the conveying direction impinges on the strip surface.
The versatility of the apparatus according to the invention can also be enhanced by the outlet nozzles being constructed in a nozzle body which is releasably retained in a recess in a casing element and, alternatively to the nozzle body, a seal support can be inserted in the recess which can moved therein substantially vertically in relation to the surface of the strip and which bears a stripper seal and can be acted upon by the pressure of the gas jet. If at least two such nozzles are used, in dependence on the particular application it may also be advantageous to combine an outlet nozzle with a corresponding stripper seal.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in greater detail with reference to the drawings, which illustrate an embodiment thereof and which show:
FIG. 1 a longitudinally sectioned view of part of an apparatus for removing liquid from the surface of a strip,
FIG. 2 a cross-sectional view of part of the apparatus shown in FIG. 1,
FIG. 3 a horizontally sectioned view of part of the apparatus shown in FIGS. 1 or 2,
FIG. 4a an enlarged detail A of FIG. 3,
FIG. 4b a detail, corresponding to detail A in FIG. 3, of an alternative embodiment of the apparatuses illustrated in FIGS. 1-4a,
FIG. 5a, b, c each a view, corresponding to detail A in FIG. 3, of further alternative embodiments of the apparatuses illustrated in FIGS. 1 to 4b and
FIG. 6 a view to an enlarged scale, corresponding to FIG. 1, of another alternative embodiment of the apparatuses illustrated in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus according to the invention for removing liquid from the top and bottom surfaces 0', 0" of a strip B conveyed from a rolling stand (not shown) has a casing 1 whose halves 1a, 1b are constructed laterally inverted in relation to the strip B, the upper casing half 1a being associated with the upper strip surface 0' and the lower half 1b being associated with the lower strip surface 0".
The casing halves 1a, 1b project laterally beyond the edges R of the strip B. They each have a first outlet nozzle 2 each associated with a pinch roller 3 disposed above and below the strip B respectively upstream of the casing halves 1a, 1b in the conveying direction F of the strip.
A second outlet nozzle 4 is constructed in each of the casing halves 1a, 1b spaced out from the first outlet nozzle 2 in the conveying direction F. A third outlet nozzle 5 is disposed in the marginal zone of the casing halves 1a, 1b remote from the pinch rollers 3.
In the embodiment illustrated in FIGS. 1, 2, 3 and 4a each of the outlet nozzles 2, 4, 5 takes the form of a flat jet nozzle extending over the width of the particular casing half 1a, 1b. Each of the flat jet nozzles 2 is so directed towards the pinch rollers 3 that any liquid adhering to the strip surfaces 0', 0" is blown into a pinch nip 6 by a gas jet G1, for example, an air jet, emerging from the outlet nozzles 2. In this way a first proportion of the liquid adhering to the strip surfaces 0', 0" is driven from said surfaces 0', 0" to the edges R of the strip B. The gas jet G1 acts outside the edge zones on the strip surfaces 0', 0" as a barrier jet for the liquid, directed towards the pinch nip 6. The second flat jet nozzle 4 is directed in the conveying direction F of the strip B, while the third flat jet nozzle 5 is directed against the conveying direction F.
In the gap between the flat jet nozzles 4, 5 a channel 7 is formed in the surface of the casing half 1a, 1b associated with the particular strip surface 0', 0". The channel 7 extends transversely of the conveying direction F of the strip B over the width of the casing halves 1a, 1b. The channel is symmetrical in structure in relation to the center M of the strip B and has in the zone of the strip center M a height h and width b increasing in the direction of the particular edge R of the strip B, to remove the volumetric flow of gas, which progressively increases in the direction of the edges R of the strip B.
Rows of correspondingly directed round jet nozzles can be used as an alternative to the aforementioned flat jet nozzles 2, 4, 5.
Disposed laterally of the strip B at the end of the channel 7 is in each case a suctional removal opening 8a of a suctional removal channel 8 which is connected to a suctional removal system (not shown).
An outlet nozzle 9 is constructed in each of the casing halves 1a, 1b in the zone of the strip center M and centrally between the outlet nozzles 4, 5. The additional outlet nozzle 9 has a substantially groove-shaped outlet opening 9a which widens after the fashion of a funnel in the direction of a strip and whose longitudinal axis extends transversely of the conveying direction F of the strip B. In this way the gas jet Gz emerging pressurized from the outlet nozzle 9 flows in two component flows Gzl and Gzr directly to the left-hand and right-hand edge R of the strip B respectively.
The outlet nozzles 2, 4, 5, 9 are connected via connecting channels 10 to a central gas supply system (not shown) via which the gas flow G is fed pressurized into the connecting channels 10.
Deflecting devices 11 disposed in the zone of the outlet openings of the outlet nozzles 2, 4, 5 ensure that the gas jet G4, G5 emerging from the respective outlet nozzle 4, 5 is directed at an acute angle against the particular edge R of the strip B and at the same time against the gas jet G5, G4 emerging from the particular opposite outlet nozzle 5, 4. The particular gas jet G4, G5 is so directed that in each case it is operative at a different place on the strip B from that of the other gas jet G5, G4. This ensures that the gas jets G4, G5 become mixed with one another with strong eddying and atomization of the liquid collected on the strip B and together form a lateral flow S in the direction of the particular edge R of the strip B, by which the liquid collected on the strip B is entrained.
The formation of the lateral flow S is encouraged by the gas flows Gzl; Gzr, which are directed immediately at the particular lateral edges R. At the same time the removal of the larger collections of fluid in the zone of the particular edges R of the strip B is further boosted by the feature that the quantity of flowing gas increases in the direction of the edge R.
The embodiment illustrated in FIG. 4b differs from the one explained hereinbefore by the feature that instead of outlet nozzles 4, 5, each constructed in the form of flat jet nozzles, a plurality of slot nozzles 12 are used which are directed at an angle towards a particular edge R and are disposed one beside the other in series symmetrically of the center M of the strip B. The width of the outlet openings of the slot nozzles 12 is relatively small. The direction of the slot nozzles 12 ensures that each gas jet G12 emerging therefrom impinges on the gas jets G12 emerging from each opposite slot nozzle and unites with said jets to form a lateral flow S2, accompanied by eddying and entrainment of the liquid adhering to the strip. The formation of the lateral flow S2 is also boosted by the gas jets Gzl and Gzr which emerge from the centrally placed additional outlet nozzle 9.
In the embodiment illustrated in FIG. 5a, a gas jet G13 flows from a first slot jet nozzle 13, extending at least over the width of the strip B, on to the strip B in a flow directed in the conveying direction F thereof. At the same time, a gas jet G14 directed against the conveying direction F flows from a slot jet nozzle 14 disposed at a distance from the slot jet nozzle 13 in the conveying direction F. Disposed in the gap between the slot jet nozzles 13, 14 are jet nozzles 15, 16, from each of which there emerges a gas jet G15, G16 directed immediately at the particular edge R. Due to the different mass impulses of the individual flows, the gas jets G15, G16 become mixed, accompanied by eddy formation, with the gas jets G13, G14 emerging from the slot nozzles 13, 14 to form a lateral flow S2 directed against the particular edge R.
In the embodiment illustrated in FIG. 5b, instead of the slot jet nozzles shown in FIG. 5a a plurality of jet nozzles 17, 18 are disposed one beside the other in series. The gas jet G17, G18 emerging therefrom is again directed towards/against the conveying direction F over the strip B and also becomes mixed with the gas jets G15, G16 emerging from the jet nozzles 15, 16 to form a lateral flow.
In distinction from the embodiment illustrated in FIG. 5b, in the embodiment illustrated in FIG. 5c, the gas jets G17', G18' emerging from the jet nozzles 17, 18 are not immediately directed towards/against the conveying direction F of the strip B. Instead, the gas jets G17', G18" emerge from the jet nozzles G17, G18 in a flow directed at the particular other edge R and at the same time impinge on the gas jets G15, G16 directed against the particular most closely adjacent edge R. This leads to an even stronger eddy formation, which again boosts the atomization of liquid collected on the strip.
Lastly in the embodiment illustrated in FIG. 6, the outlet nozzle 19 corresponding to the outlet nozzle 4 shown in FIG. 4 is constructed in a nozzle body 20. The nozzle body 20 is inserted into a rail-like recess 21 extending over the width of the particular casing half 1a, 1b and is releasably retained therein. Moreover, in the embodiment shown in FIG. 6, instead of the outlet nozzle 2 shown in FIG. 1, a lip stripper 22 is provided which is borne by a sealing member 23. The sealing member 23 is also releasably retained in a recess 24 in the particular casing half, so that if necessary it can be exchanged for a nozzle body constructed after the fashion of the nozzle body 20. The sealing member 24 has a height H smaller than the depth T of the recess, so that the sealing member 24 can move in the recess 24, guided by its side walls. At the same time the sealing member 23 is acted upon by the pressure of the gas present in the connecting line 10. This ensures that the lip stripper seal 21 always bears against the strip B with the necessary contact pressure and is also able to yield resiliently with strip unevenesses. The adjustability in height of the sealing member 23 also enables damage to the lip stripper 22 to be avoided when a fresh strip B is introduced.
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The invention provides an apparatus for the removal of liquid from the surface (0', 0") of a strip (B) conveyed from a strip processing machine, more particularly a rolling stand, by means of a gas jet (G1, G4, G5, Gzl, Gzr, G12-G18, G17', G18'), which has an outlet nozzle (2, 4, 5, 12-19) from which the gas jet (G1, G4, G5, Gzl, Gzr, G12-G18, G17', G18') emerges, and a suction opening (8a), via which the gas jet (G1, G4, G5, Gzl, Gzr, G12-G18, G17', G18') can be removed by suction mixed with the liquid, the apparatus enabling the surface of the strip to be adequately cleaned over its whole width. This is achieved by the feature that the gas jet (G1, G4, G5, Gzl, Gzr, G12-G18, G17', G18') is guided over the strip (B) in a flow (S, S2) directed towards at least one of the lateral edges (R) of the strip (B), and a suction opening (8a) is associated with that lateral edge (R) of the strip (B) at which the flow (S, S2) is directed.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division, of application Ser. No. 08/042,547, filed Apr. 5, 1993 now U.S. Pat. No. 5,461,998.
This application is related to Applicants' applications Ser. Nos. 07/711,315, now U.S. Pat. No. 5,375,545 and 07/711,659, now U.S. Pat. No. 5,315,946, both filed Jun. 6, 1991, the disclosures of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to sewing machines and, more particularly, to an apparatus for precisely feeding a collarette to a sewing apparatus for automatically attaching the collarette to a garment body.
(2) Description of the Prior Art
Garments such as shirts or blouses are typically manufactured using manual labor. Garment pieces are cut out of stock material, trimmed to proper dimensions, and then sewn together on a sewing machine by a sewing machine operator. Often in garment manufacturing, a piece of material, known in the art as a "collarette", is folded and sewn around the garment neck to form a continuous collar. The conventional method of sewing a collarette to a garment neck is performed by a sewing machine operator in the following manner.
First, the collarette is cut to a size slightly shorter than the garment neck edge where the collarette is to be sewn. Then, the operator positions the collarette on top of the garment body, places the material under a sewing machine and starts sewing. While sewing, the operator must continually maintain the alignment of the collarette and garment body to obtain an evenly manufactured finished product. Additionally, the operator must pull and stretch the collarette during the sewing operation. Stretching the collarette in such a manner will cause the completed garment and collarette to lie flat and have no wrinkles or gathers around the neck when worn.
The operator may also be required to attach a label (e.g. a manufacturer's identifier having the manufacturer's name and product information) to the garment with the same stitch being used to attach the collarette to the garment. To perform this operation, the operator must carefully position and hold the label in the desired location while sewing. Additionally, the operator may be required to sew a small strip of material, known in the art as a "display", to the inside of the garment neck to flatten and cover the seam joining the collarette and label to the garment body (the "joining seam"). The display is used to cover the area inside the garment where the joining seam would be partially visible after the garment is packaged for sale, i.e., on the inside back portion of the garment neck. To sew a display, the operator must carefully position the display on top of the collarette and garment body and hold the display in position while sewing.
Further complications to the above-described conventional sewing operation are encountered when the joining seam (known as an "overedge seam") is to be hidden from view from the outside of the garment (i.e. the side of the garment away from the body of the wearer). To hide the overedge seam, an operator must layer the collarette, display, and label on top of the garment body, and use an "overedge stitch" to join the pieces together. The resulting overedge seam is then hidden from the outside of the finished garment.
To sew a collarette, label, and display to a garment body with an overedge stitch, an operator must first manually arrange and layer the materials one on top of the other as follows: garment body, collarette, display, and label. The operator then passes the layered materials through the sewing machine, maintaining them in constant alignment while stretching the collarette as described above. If desired, a second sewing operation is then performed to attach the loose edge of the display to garment body with a cover stitch to assure that the display covers the overedge seam and a portion of the label.
The manual process of sewing a collarette, display, and label to a garment body is difficult and tedious. The quality of the finished product is often variable and is largely dependent on the experience and skill of the sewing machine operator. Moreover, the conventional process is time consuming due to the need to precisely arrange and sew the materials together.
A partial solution to the above-identified problems is disclosed in co-pending patent application U.S. Ser. No. 07/711,659. U.S. Ser. No. 07/711,659 discloses a method and apparatus for automatically attaching a collarette, display, and label to a garment body using, inter alia, a collarette feed means, display feed means, label feed means and a controller means. As disclosed therein, the controller means counts the total number of stitches since the start of a sewing operation. When the total stitch count equals certain predetermined stitch counts, the controller means commands the display feed means and label feed means to feed their respective material under a sewing head. Variations in garment body dimensions often occur within a particular garment body size. For example, a garment neck edge can vary in length from garment to garment within a garment size by as much as plus or minus one inch (+/-1") resulting in an overall length variation of four inches (4"). The use of predetermined total stitch count values based on the start of the sewing operation to command display and label feeding can not account for the above described variations that exist within a garment size. As a result, inconsistent placement of display and label can occur.
Additionally, using a motor to drive the label feed means independently from, i.e. unsynchronized with, the motor driving the sewing head can cause the label to be misaligned when placed under the sewing head and cause the label to skew. Further, feeding the collarette and display material on top of the garment body can obstruct the field of view of the sewing head, making it difficult for an operator to assure the sewing operation is being performed properly. Finally, the layering of garment body, collarette, display, and label can complicate the automation of a subsequent operation necessary to sew the loose edge of the display over the overedge seam with a cover stitch. Specifically, automating the second sewing operation when the display and collarette is placed on top of the garment body would require an apparatus to be able to fold the display underneath the garment body and then to sew "blind" through the garment body and collarette. Such an apparatus would be difficult to construct and operate and would prevent the operator from being able to visually check whether the display has been folded and sewn properly in the second sewing operation until after the operation is complete.
Another partial solution to the above-identified problems is disclosed in U.S. Ser. No. 07/711,315. U.S. Ser. No. 07/711,315 discloses a collarette feed means, display feed means, label feed means, a seam detector means, and a controller means. As disclosed, the placement of the collarette, display, and label is determined by detecting the presence of the garment body shoulder seam. As a result, the collarette, display, and label are accurately placed on a garment body. Additionally, feeding of the collarette and display is performed underneath the garment body allowing for a clear view of the sewing head and for simplifying the joining seam.
Both co-pending applications require manual feeding of the garment body through the sewing head. Manual feeding of the garment body would often yield an inconsistent finished product and require constant attending by the machine operator. Thus, there remains a need for an apparatus for automatically feeding one edge of a textile article to a sewing machine.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus for automatically feeding one edge of a textile article to a sewing machine. The apparatus includes a first gripper adjacent to the sewing machine for gripping the leading portion of the edge of the textile article. A feed dog is adjacent to the first gripper for advancing the edge of the textile article with respect to the sewing machine. A second gripper grips the trailing portion of the edge of the textile article. A positioner supporting the second gripper means moves the second gripper with respect to the feed means. Finally, a programmable controller controls the movement of the positioner to advance the trailing portion of the edge of the textile article in response to the movement of the leading portion of the edge of the textile article.
In the preferred embodiment, a frictionless support is located between the first gripper and the second gripper for supporting the body of the textile article as the edge of the textile article is moved toward the sewing machine. The support includes a flexible cable having one end attached adjacent to the feed dog for supporting the body of the textile article; and a retractor connected to the other end of the cable and mounted adjacent to the gripper, whereby the cable is retracted into the retractor as the edge of the textile article is moved.
Accordingly, one aspect of the present invention is to provide an apparatus for automatically feeding one edge of a textile article toga sewing machine. The apparatus includes: (a) first gripper means adjacent to the sewing machine for gripping the leading portion of the edge of the textile article; (b) feed means adjacent to the first gripper means for advancing the edge of the textile article with respect to the sewing machine; (c) second gripper means for gripping the trailing portion of the edge of the textile article; (d) positioner means supporting the second gripper means for moving the second gripper with respect to the feed means; and (e) control means for controlling the movement of the positioner to advance the trailing portion of the edge of the textile article in response to the movement of the leading portion of the edge of the textile article.
Another aspect of the present invention is to provide an apparatus for automatically feeding one edge of a textile article to a sewing machine. The apparatus includes: (a) first gripper means adjacent to the sewing machine for gripping the leading portion of the edge of the textile article; (b) feed means adjacent to the first gripper means for advancing the edge of the textile article with respect to the sewing machine; (c) second gripper means for gripping the trailing portion of the edge of the textile article; (d) positioner means supporting the second gripper means for moving the second gripper with respect to the feed means; (e) control means for controlling the movement of the positioner to advance the trailing portion of the edge of the textile article in response to the movement of the leading portion of the edge of the textile article; and (f) support means located between the first gripper means and the second gripper means for supporting the body of the textile article as the edge of the textile article is moved toward the sewing machine.
Another aspect of the present invention is to provide an apparatus for frictionlessly supporting the body of a textile article as one edge of the textile article is moved by a feed means and a movable gripper means. The apparatus includes: (a) a cable having one end connected to one of the feed means and the gripper means for supporting the body of the textile article; and (b) retracting means connected to the other end of the cable and mounted adjacent to the other of the feed means and the gripper means, whereby the cable is retracted into the retracting means as the edge of the textile article is moved.
Still another aspect of the present invention is to provide an apparatus for automatically feeding one edge of a textile article to a sewing machine. The apparatus includes: (a) first gripper means adjacent to the sewing machine for gripping the leading portion of the edge of the textile article; (b) feed means adjacent to the first gripper means for advancing the edge of the textile article with respect to the sewing machine; (c) second gripper means for gripping the trailing portion of the edge of the textile article; (d) positioner means supporting the second gripper means for moving the second gripper with respect to the feed means; (e) control means for controlling the movement of the positioner to advance the trailing portion of the edge of the textile article in response to the movement of the leading portion of the edge of the textile article; and (f) support means located between the first gripper means and the second gripper means for supporting the body of the textile article as the edge of the textile article is moved toward the sewing machine. The support means includes: (i) a cable having one end connected to one of the feed means and the gripper means for supporting the body of the textile article; and (ii) retracting means connected to the other end of the cable and mounted adjacent to the other of the feed means and the gripper means, whereby the cable is retracted into the retracting means as the edge of the textile article is moved.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view on a completed garment body having a collarette fabricated in part according to the present invention;
FIG. 2 is a front view of an uncompleted garment without the collarette prior to being fed to the sewing machine by the present invention;
FIG. 3 is a block diagram illustrating a guide/feeder constructed according to the present invention;
FIG. 4 is a perspective view of the guide/feeder constructed according to the present invention;
FIG. 5 is side elevational view of the guide/feeder shown in FIG. 4; and
FIG. 6 is a top plan view of the guide/feeder shown in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as "forward", "rearward", "left", "right", "upwardly", "downwardly", and the like are words of convenience and are not to be construed as limiting terms.
Referring now to the drawings in general and FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in FIG. 1, a sleeveless garment body 10 is shown. Garment body 10 includes a collarette 12 and a label 14 fashioned from known materials used for shirts, blouses or the like. The dimensions of various pieces are based on the desired size of the finished product. For example, in an average medium-sized T-shirt, the width of the collarette 12 is typically in the range of 13/16 to 17/16 inches. As will readily become apparent to those skilled in the art, the width of the collarette can be easily varied.
Label 14 provides the purchaser with information concerning the garment, for example, size, manufacturer and washing instructions. After being fabricated in part by guide/feeder constructed according to the present invention, semi-completed garment body 10 has a shoulder seam 16 which is sewn in an open shoulder 20 which is sewn in a subsequent operation. Right sleeve opening 22 and left sleeve opening 24 are likewise sewn in subsequent operations. However, by letting a single operator sew shoulder seam 16 and then feed the garment body 10 with the present invention, one operator can perform the work of three. In addition, the skills required to sew shoulder seam 16 and feed the garment body by means of the guide/feeder of the present invention are much less than required for an operator to sew the garment in a conventional manner.
Turning now to FIG. 2, there is shown a front view of an uncompleted garment body without the collarette prior to being fed to the sewing machine by the present invention. As can be seen, shoulder seam 16 has already been sewn and the collarette portion 12 and the left sleeve portion opening 24 are stretched outwardly. As can also be seen, the uncompleted garment body without the collarette has only one shoulder seam, the right shoulder seam 16, sewn prior to being fed to the sewing machine according to the present invention. The open shoulder seam 20 is sewn subsequently to the collarette 12 being sewn to the garment body.
As also can be seen, the collarette portion of the garment body does not form a straight line and neither is the collarette sewn in a straight line. Rather both the collarette body and the collarette itself are curved such that when shoulder seam 20 subsequently is sewn together a round collar is formed. Such an operation requires that the garment body be controlled during the sewing operation such that both forward and lateral motion is accounted for. An experienced operator can do this automatically, however, heretofore, it has been impossible to do this automatically.
As best seen in FIG. 3, there is shown a block diagram illustrating a guide/feeder constructed according to the present invention generally designated 30. The heart of the guide/feeder 30 is a programmable logic controller 32. Programmable logic controller (PLC) 32 is a conventional unit and one unit which has proven particularly satisfactory is a model TSX-17 manufactured by Telemecanique of France. In order to control the movement of garment body 10 through the sewing machine and allow for both forward and lateral motion, it is necessary to engage collarette portion of the garment body both on the leading edge and the trailing edge. In this regard, a first gripper 34 engages the leading edge of the garment body 10.
In a preferred embodiment, the first gripping means 34 is a presser foot of the sewing machine. In the preferred embodiment, a first fabric detector is located adjacent to the first gripper means and provides a control signal 40 when the leading edge of the fabric is detected. Control signal 40 is received by the first gripper means and is engaged. When first gripper 34 receives the control signal 40 indicating the presence of the leading edge of the fabric of the garment body, a control signal 42 is sent to PLC 32 to indicate this condition. A second fabric detector 44 is adjacent to the second gripper for indicating the presence of the trailing edge of the fabric of the garment body 10. When the fabric is detected by second detector 44, a control signal 46 is sent to PLC 32. When both first fabric detector 36 and second fabric detector 44 indicate the presence of the garment body 10, a control signal 52 is sent by PLC 32 to sewing machine 50 by means of control signal 52.
As sewing machine 50 operates, a stitch counter 54 connected to sewing machine 50 provides a control signal 56 indicating the X direction (forward direction) of the material passing through the sewing machine 50. At the same time, PLC 32 provides a control signal 62 to the XY feeder attached to the second gripping means holding the trailing edge of the fabric and causes the feeder to move in relation to the fabric passing through the sewing machine. Because the collarette portion of the garment body is curved, an edge detector 64 adjacent to the sewing head of the sewing machine 50 monitors the lateral (Y direction) of movement of the fabric through the sewing machine.
Edge detector 64 sends a control signal to 66 to PLC 32 indicating the position of the garment edge as it passes through the sewing machine. PLC 32 provides a changing control signal 62 to maintain the relative position of the fabric edge of the garment body with respect to the sewing machine.
The relationship of the various components of the present invention shown in FIG. 3 can best be seen in FIG. 4 which is a perspective view of the guide feeder constructed according to the present invention. Sewing machine 50 is conventional in design. One machine which has proved particularly satisfactory is a Model 9M sewing machine manufactured by Union Special Company of Chicago, Ill.. This sewing machine includes a presser foot 70 opposite a series of feed dogs 72 for engaging the leading edge of the garment body. The gripper and feeder means generally designated 60 includes a conventional XY feeder 74 and a pneumatic second gripper means 76 attached to feeder 74. XY feeder 74 is conventional in design and one unit which is produced particularly satisfactory is a rail table manufactured by Daedal and the motors by Compumotor of Rohnert Park, Calif..
In the preferred embodiment, a frictionless support assembly 80 supports the garment body while the edge of the garment is being fed through the sewing machine. This provides support for the garment while eliminating stretching which could occur with a conventional support surface. Frictionless support assembly 80 includes a retractor 82 mounted adjacent to sewing machine 50 and a flexible steel plastic-covered cable 84 which is attached to second gripper 76 by connector 86. Second connector 86 is attached to a pneumatic cylinder 90 which moves between a first position adjacent to second gripper 76 in a second position out of the way of second gripper 76. Sewing machine assembly 50 and gripper feeder assembly 60 are supported by a conventional first work surface 92 and a second work surface 94. An operator bar 96 is attached between work surface 92 and work surface 94 for supporting the lower half of the garment as it moves through the sewing machine.
In the preferred embodiment, an optional fabric guide assembly 100 is mounted to the frame of work surface 94 and moved between an operable and inoperable position with respect to second gripper 76. Fabric guide assembly 100 includes a fabric guide 102 for aiding the operator in placing the trailing edge of the fabric of the garment body 10 into gripper 76 and a pneumatic cylinder 104 for moving the fabric guide between the operable and inoperable positions with respect to the gripper.
Turning to FIG. 6, there is a top plan view of the guide feeder constructed according to the present invention shown in FIG. 4. As can be seen in the preferred embodiment, a pneumatically powered blower 106 is mounted to the frame of work surface 94 by means of adjustable bracket 110. Blower 106 provides a pulse burst of air against the back surface of garment body 10 which causes garment body 10 to lay flat across frictionless support surface 80 and operator bar 96.
Finally, FIG. 6 shows the location of the edge detector 64 adjacent to the presser foot of sewing machine 50. In the preferred embodiment, edge detector 64 includes an array of infrared LEDs and detectors mounted on one side of the textile article along the path of movement of the trailing portion of the edge of the textile article towards the sewing machine and a reflective surface on the other side of the textile article, whereby the position of the edge of the textile article is determined as the edge of the textile article moves through the path of the reflected light directed towards the detectors.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, conventional actuators with position indicators could be used in place of the servo actuators. Also, other known types of edge detectors could be used in place of the LED array of the preferred embodiment. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
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An apparatus for automatically feeding one edge of a textile article to a sewing machine. The apparatus includes a first gripper adjacent to the sewing machine for gripping the leading portion of the edge of the textile article. A feed dog is adjacent to the first gripper for advancing the edge of the textile article with respect to the sewing machine. A second gripper grips the trailing portion of the edge of the textile article. A positioner supporting the second gripper means moves the second gripper with respect to the feed means. Finally, a programmable controller controls the movement of the positioner to advance the trailing portion of the edge of the textile article in response to the movement of the leading portion of the edge of the textile article.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/748,764 (filed Jan. 4, 2013). The entire content of this related application is incorporated herein by reference.
BACKGROUND
Near field communication, or NFC, is a set of short-range wireless technologies, typically requiring a distance of 4 cm or less. NFC generally operates at 13.56 MHz and at rates ranging typically from about 106 kbits/s to 848 kbits/s. NFC requires that NFC devices be present within a relatively close proximity to each other so that their corresponding magnetic fields can couple and the devices can exchange information.
An NFC device is required to sense proximity of a target (usually a card) in order to initiate communication. One way to do this is for the NFC device to constantly initiate communications for all possible card types (A, B and F) until it receives a response. This approach has the disadvantage of draining the battery because of the continuous polling (tens of mA).
Therefore, there is a need for a better proximity sensing mechanism for an NFC device that does not drain the battery but can still detect any card which comes within its proximity.
SUMMARY
In accordance with exemplary embodiments of the present invention, a proximity sensing method using a loopback mechanism and a related wireless communications device are proposed to solve the above-mentioned problem.
According to a first aspect of the present invention, an exemplary proximity sensing method employed by a wireless communications device is disclosed. The exemplary proximity sensing method includes the steps of: performing a first predetermined operation to detect presence of transponder(s) in the proximity of the wireless communications device; when the presence of transponder (s) in the proximity of the wireless communications device is not detected by the first predetermined operation, performing a second predetermined operation to obtain a first characteristic value and after a period of time, performing the second predetermined operation to obtain a second characteristic value sequentially; checking if the first characteristic value and the second characteristic value satisfy a predetermined criteria; and when the predetermined criterion is satisfied, performing the first predetermined operation again to check the presence of the transponder in the proximity of the wireless communications device.
According to a second aspect of the present invention, a wireless communications device having proximity sensing capability is disclosed. The exemplary wireless communications device includes a first circuit and a second circuit. The first circuit is arranged for performing a first predetermined operation to detect the presence of transponder(s) in the proximity of the wireless communications device, and when the presence of transponder(s) in the proximity of the wireless communications device is not detected by the first predetermined operation, performing a second predetermined operation to obtain a first characteristic value and after a period of time, performing the second predetermined operation to obtain a second characteristic value sequentially. The second circuit is arranged for checking if the first characteristic value and the second characteristic value satisfy a predetermined criterion. When the predetermined criterion is satisfied, the first circuit performs the first predetermined operation again to check the presence of the transponder in the proximity of the wireless communications device.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a block diagram of a wireless communication device according to an embodiment of the present invention.
FIG. 1B is a schematic diagram of one possible implementation of the wireless communication device 100 according to an embodiment of the present invention.
FIG. 1C is a schematic diagram of a dual local oscillation scheme according to an embodiment of the present invention
FIG. 2 is a flowchart of a proximity sensing method employed by the wireless communications device.
FIG. 3 is another flowchart of a proximity sensing method employed by the wireless communications device.
DETAILED DESCRIPTION
Certain terms are used throughout the description and following claims to refer to particular components. As one skilled in the art will appreciate, manufacturers may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. In the following description and in the claims, the terms “include” and “comprise” are used in an open-ended fashion, and thus should be interpreted to mean “include, but not limited to . . . ”. Also, the term “couple” is intended to mean either an indirect or direct electrical connection. Accordingly, if one device is electrically connected to another device, that connection may be through a direct electrical connection, or through an indirect electrical connection via other devices and connections.
Conventionally, a first wireless communications device (a near field communications (NFC) reader) and a second wireless communications device (an NFC tag) operate in a conventional polling mode to establish communication. The first wireless communications device provides a polling command to the second wireless communications device. The second wireless communications device provides a response to the polling command. Since the first wireless communications device has no knowledge of the geographical location of the second wireless communications device, the first wireless communications device has to constantly perform the polling operation, which may drain the battery of the first wireless communications device.
The concept of the present invention is for the wireless communications device to have low power consumption. Instead of constantly polling for potential connection establishment, the wireless communications device only polls for connection establishment when it detects the presence of a transponder. The present invention proposes a low power consumption proximity sensing scheme for the first wireless communications device, to detect presence of the second wireless communications device in an operating distance of the first wireless communications device before the first wireless communications device performs the polling operation. Therefore, the present invention may optimize power consumption in the first wireless communication device and overcome the shortcomings described above. Further aspects and advantages of the present invention will become apparent from the following detailed description.
Please refer to FIG. 1A , which is a block diagram of a wireless communication device 100 according to an embodiment of the present invention. The wireless communication device 100 may be an NFC device, such as a radio frequency identification (RFID) card. The wireless communication device 100 includes a digital baseband 110 , a synthesizer 120 , a transmitter 130 , a receiver 140 , an antenna 160 and an antenna matching network 150 . The digital baseband 110 is arranged to issue a baseband transmission signal S_BT to the transmitter 130 , and receive a baseband reception signal S_BR from the receiver 140 . The synthesizer 120 includes a first local oscillator 130 and a second local oscillator 140 . The first local oscillator 130 is arranged to generate a first local oscillation (LO) frequency LO 1 to the receiver 140 , and the second local oscillator 140 is arranged to generate a second LO frequency LO 2 to the transmitter 130 . The transmitter is arranged to generate a transmission signal S_TX according to the baseband transmission signal S_BT and the second LO frequency LO 2 , and transmit the transmission signal S_TX to the antenna matching network 150 . The receiver 140 is arranged to receive a reception signal S_RX from the antenna matching network 150 , generate the baseband reception signal S_BR according to the reception signal S_RX and the first LO frequency LO 1 , and send the baseband reception signal S_BR to the digital baseband 110 . Please note that, in this embodiment, the reception signal S_RX uses the second LO frequency LO 2 as its center frequency and further mixes the reception signal S_RX with the first LO frequency LO 1 to obtain the baseband reception signal S_BR.
Please refer to FIG. 1B , which is a schematic diagram of the wireless communication device 100 according to an embodiment of the present invention. In FIG. 1B , the antenna 160 includes a resistor R 1 , an inductance L 1 and a capacitor C 1 . The inductance L 1 is connected with the resistor R 1 in series, and the capacitor C 1 is coupled to the R 1 -L 1 circuit in parallel. However, this is for illustrative purpose only, and not meant to be a limitation of the present invention. The value of each element of the antenna 160 may be changed according to different applications. As can be seen from FIG. 1B , the matching network 150 may include a pair of matching circuits, and each of the matching circuits may include a first capacitor C 2 b, a second capacitor C 2 a, a third capacitor C 3 , and a resistor RQ. Please note that the design of the matching network 150 is only for illustrative purpose only, and it not meant to be a limitation of the present invention. The matching circuits are coupled between the antenna 160 and the transmitter 130 (not shown), wherein one matching circuit is arranged for transmitting an output signal TXP of the transmitter 130 while the other matching circuit is arranged for transmitting the other output signal TXN of the transmitter 130 . Here, TXN is differential transmit signal of TXP. In addition, the matching network 150 can be optionally coupled to a signal rectifier (not shown) via the pair of the first capacitors C 2 b. In addition, the receiver 140 includes a mixer 142 and a frontend 144 . The mixer 142 mixes the first LO frequency LO 1 and the second LO frequency LO 2 in order to obtain the frequency of the baseband reception signal S_BR. In this embodiment, the first LO frequency LO 1 may be 12.05 MHz, the second LO frequency LO 2 is 13.26 MHz, and the frequency of the output of the mixer 142 is 15. MHz˜1.5 MHz. The frontend 144 process the output of the mixer 142 and then passes the processed signal to the digital baseband 110 .
Please refer to FIG. 1C , which is a schematic diagram of a dual local oscillation scheme according to an embodiment of the present invention. As shown n FIG. 1C , the synthesizer 120 includes a LO divider 122 . The LO divider 122 takes a frequency F_VCO as its input. In this embodiment, the frequency F_VCO is 162.72 MHz. The LO divider 122 divides the frequency F_VCO by 13.5 in order to obtain the first LO frequency LO 1 , and LO divider 122 divides the frequency F_VCO by 12 in order to obtain the second LO frequency LO 2 . As can be seen from FIG. 1C , the factor 13.5 can be derived from a series simple division.
Please note that the receiver architecture mentioned above is only one embodiment to the present invention. The present invention is not limited to direct or low-IF receiver architectures. For different implementations, one may use other types of receiver architecture, such as direct-sampling receiver. For example, when using direct-sampling receiver, LO 1 is the ADC sampling clock which can be any value higher than 13.56 MHz (can be 27.12 MHz or 54.24 MHJz, etc.).
It should be understood that, if a transponder appears in proximity to the wireless communication device 100 , the antenna matching network 150 will detect the difference in electro-magnetic fields caused by the presence of the transponder. The transmission signal S_TX will also be affected by the presence of the transponder. The change in characteristics of the transmission signal S_TX may be regarded as an ambient factor which indicates “a change in antenna environment”.
In this embodiment, the transmitter 130 first sends a polling command signal S_POLL to inquire if there is a potential connection establishment. If there is no response, the wireless communication device 100 enters a sensing loop where the ambient factor is periodically measured to monitor the change of surroundings; otherwise, the receiver will receive a response signal S_RES of the polling command signal S_POLL from a transponder, and the wireless communications device 100 will establish connection with the transponder. The ambient factor is measured as follows: the transmitter sends the transmission signal S_TX as a probe signal to the antenna matching network 150 , and then the transmission signal S_TX loops back through the antenna matching network to the wireless communication device 100 where it is received by the receiver 140 . The receiver 140 generates the baseband reception signal S_BR as a first ambient factor AF 1 . The first ambient factor AF 1 is saved as a “no communication” level in the digital baseband 110 . After a short period of time T 1 (e.g. 0.5 second), the wireless communication device 100 measure the ambient factor again, and obtains a second ambient factor AF 2 . If the digital baseband 110 determines that the difference between the first ambient factor AF 1 and the second ambient factor AF 2 is smaller than a threshold TH, it indicates that no change occurs, and hence no transponder appears in the proximity to the wireless communication device 100 . In this case, the sensing loop continues, and the wireless communication device 100 enters into a sleep mode for a period of time T 2 , wherein the measuring operation will be performed again after exiting the sleep mode. The wireless communication device 100 will keep measuring the ambient factor until the difference between the first ambient factor AF 1 and the second ambient factor AF 2 exceeds the threshold TH. Please note that the time period T 1 , T 2 and the threshold TH are all programmable.
If the digital baseband 110 determines that the difference between the first ambient factor AF 1 and the second ambient factor AF 2 exceeds the threshold TH, this may suggest that some noticeable change occurs in the antenna environment, and hence there might be a transponder in proximity to the wireless communication device 100 . The transmitter 130 will send another polling command signal S_POLL to inquire if there a potential connection establishment. If there is no response, the digital baseband 110 updates the first ambient factor AF 1 with the second ambient factor AF 2 , and the sensing loop continues; otherwise, the receiver will receive a response signal S_RES of the polling command signal S_POLL from a transponder, and the wireless communications device 100 will establish connection with the transponder. That is, if there is no response, the wireless communication device 100 will enter into the sleep mode after updating the first ambient factor AF 1 , and perform the measuring operation after exiting the sleep mode.
Please note that, in this embodiment, the transmission signal S_TX can be a single-tone signal. For example, the transmission signal S_TX may be a single-tone signal whose frequency is 13.56 MHz if the wireless communication device 100 is a NFC device. Both the transmitter 130 and the receiver 140 have to be turned on for a short period of time in order to realize the signal loopback. Please note that the transmission signal S_TX is not necessary a single tone signal. For example, it can be a square wave signal with fundamental frequency of 13.56 MHz. In some cases, it can also be an arbitrary signal, a triangular signal or a white noise signal.
The operations of the above-mentioned wireless communications device can be summarized into a flowchart. Please refer to FIG. 2 , which is a flowchart of a proximity sensing method employed by the wireless communications device 100 . The exemplary proximity sensing method may be briefly summarized by the following steps.
Step 200 : Start.
Step 201 : Poll for potential connection. The polling operation can be a full looping of transmitting A, B, F and any NFC protocol to see if there is any response.
Step 202 : Check if there is a response from a transponder. If yes, go to step 203 ; otherwise, go to step 204 .
Step 203 : Establish connection with the transponder. In a certain implementation, after establishing connection with transponder, the wireless communications device can enter into a sleep mode to save power, for example Step 208 . It will wait for a period of time and then wake up to re-perform the polling operation as stated in Step 201 for another potential connection.
Step 204 : Measure a first ambient factor.
Step 205 : Wait for a period of time. The waiting action can be implemented as entering a sleep mode. In other words, the wireless communications device will enter into a sleep mode after obtaining the first ambient factor to save power. It will then leave the sleep mode for Step 206 after the period of time.
Step 206 : Measure a second ambient factor.
Step 207 : Check if the difference between the first ambient factor and the second ambient factor exceeds a threshold. If yes, go to step 209 ; otherwise, go back to step 205 .
Step 208 : Wait for a period of time, go to step 201 .
Step 209 : Poll for potential connection. The polling operation can be a full looping of transmitting A, B, F and any NFC protocol to see if there is any response.
Step 210 : Check if there is a response from a transponder. If yes, go to step 211 ; otherwise, go to step 212 .
Step 212 : Update the first ambient factor. In a certain implementation, after the update, it can go back to step 205 , where it will wait for a period of time by entering into a sleep mode.
As a person skilled in the art can readily understand the operation of each step shown in FIG. 2 after reading the above paragraphs, further description is omitted here for brevity.
Please note that, provided that the result is substantially the same, the steps are not required to be executed in the exact order shown in FIG. 2 . For example, in another embodiment, the exemplary proximity sensing method may be summarized into another flowchart where the step of polling for potential connection is taking place after the step of measuring the first and/or second ambient factor. Please refer to FIG. 3 , which is another flowchart of a proximity sensing method employed by the wireless communications device 100 . The exemplary proximity sensing method may be briefly summarized by the following steps.
Step 300 : Start.
Step 301 : Check if a first ambient factor is available. If yes, go to step 302 ; otherwise, go to step 304 .
Step 302 : Measure a second ambient factor.
Step 303 : Check if the difference between the first ambient factor and the second ambient factor exceeds a threshold. If yes, go to step 304 ; otherwise, go to step 308 .
Step 304 : Poll for potential connection.
Step 305 : Check if there is a response from a transponder. If yes, go to step 306 ; otherwise, go to step 307 .
Step 306 : Inform the wireless communications device that a card is detected.
Step 307 : Measure the first ambient factor.
Step 308 : End.
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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A proximity sensing method employed by a wireless communications device includes the steps of: performing a first predetermined operation to detect a presence of at least a transponder in the proximity of the wireless communications device; when the presence of a transponder in the proximity of the wireless communications device is not detected by the first predetermined operation, performing a second predetermined operation to obtain a first characteristic value and after a period of time, performing the second predetermined operation to obtain a second characteristic value sequentially; checking if the first characteristic value and the second characteristic value satisfy a predetermined criteria; and when the predetermined criterion is satisfied, performing the first predetermined operation again to check the presence of the transponder in the proximity of the wireless communications device.
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BACKGROUND OF THE INVENTION
This invention relates to the production of grain-oriented silicon steel having very low core losses by a procedure employing simultaneous phosphorus flux-printing through the forsterite layer and phosphorus contamination of the exposed lines of substrate metal. The surface condition so developed permits a subsequent annealing treatment to develop heat-proof domain refinement of the steel.
DESCRIPTION OF THE PRIOR ART
There has been a long history in the steel industry of the production of steel containing 2.0 to 4.5% of silicon for electrical purposes. The premium grades are of the so-called grain-oriented variety. Grain-oriented silicon steel is conventionally used in electrical applications, such as power transformers, generators, and the like. The steel's ability to permit cyclic reversals of the applied magnetic field with only limited energy loss is a most important property. Reductions of this loss, which is termed "core loss", is desirable.
In the manufacture of grain-oriented silicon steel, it is known that the Goss secondary recrystallization texture, (110) [001] in terms of Miller's indices, results in improved magnetic properties, particularly permeability and core loss over nonoriented silicon steels. The Goss texture refers to the body-centered cubic lattice comprising the grain or crystal being oriented in the cube-on-edge position. The texture or grain orientation of this type has a cube edge paralleled to the rolling direction and in the plane of rolling, with the (110) plane being in the sheet plane. As is well known, steels having this orientation are characterized by a relatively high permeability in a direction at right angles thereto.
In the manufacture of grain-oriented silicon steel, typical steps include providing a melt having the order of 2-4.5% silicon, casting the melt, hot rolling to sheet, cold rolling the steel to final gauge typically of 7 or 9 mils, and up to 14 mils with an intermediate annealing when two or more cold rollings are used, decarburizing the steel, applying a refractory oxide base coating, such as a magnesium oxide coating, to the steel, and final texture annealing the steel at elevated temperatures in order to produce the desired secondary recrystallization and purification treatment to remove impurities such as nitrogen and sulfur. The development of the cube-on-edge orientation is dependent upon the mechanism of secondary recrystallization wherein during recrystallization, secondary cube-on-edge oriented grains are preferentially grown at the expense of primary grains having a different and undesirable orientation.
The final texture annealed grain-oriented silicon steel sheet has an insulation coating thereon resulting from an annealing separator coating, i.e., refractory oxide base coating, applied before the texture anneal to stop the laps of the coil from thermally welding or sticking together during the high temperature anneal and to promote formation of an oxide film on the steel surface. This film is desirable because it is an electrical insulator and can form part, or sometimes all, of the insulation needed when the steel is in operation in a transformer. Such an insulative oxide coating forming naturally during the texture anneal is known variously as forsterite, the base coating, or mill glass.
As used herein, "sheet" and "strip" are used interchangeably and mean the same unless otherwise specified.
It is also known through the efforts of many prior art workers, that cube-on-edge grain-oriented silicon steels generally fall into basic categories: first, regular or conventional grain-oriented silicon steel, and second, high permeability grain-oriented silicon steel. Permeability at 10 Oersteds is frequently used as an indicator of the degree of perfection of the grain orientation; complete perfection of the orientation would yield a permeability of about 2000. Regular grain-oriented silicon steel is generally characterized by permeability of less than 1850 at 10 Oersteds with a core loss of greater than 0.400 watts per pound (WPP) at 1.5 Tesla at 60 Hertz for nominally 9-mil material. High permeability grain-oriented silicon steels are characterized by permeabilities of about 1850-1950. Such higher permeabilities may be the result of compositional changes alone or together with process changes. For example, high permeability silicon steels may contain nitrides, sulfides, and/or borides which contribute to the precipitates and inclusions of the grain-growth inhibition system which contributes to the properties of the final steel product. High permeability silicon steels generally undergo heavier cold rolling reduction to final gauge than regular grain-oriented steels with final heavy cold reduction on the order of greater than 80%. While higher permeability materials are desirable because of their potential for lower core loss, such materials tend to produce larger magnetic domains than conventional material. Larger domains are deleterious to core loss and tend to offset the benefit to core loss of the improved permeability. Larger domains are also favored by lighter gauge. In other words, if one compares a 7-mil and a 9-mil material at identical permeability, the 7-mil sample would have larger domain size.
It is known that one of the ways that domain size and thereby core loss values of electrical steels may be reduced is if the steel is subjected to any of various practices designed to induce localized strains in the surface of the steel. Such practices may be generally referred to as "domain refining by scribing" and are performed after the final high temperature annealing operation. If the steel is scribed after the final texture annealing, then there is induced a localized stress state in the texture-annealed sheet so that the domain wall spacing is reduced. These disturbances typically are relatively narrow, straight lines, or scribes, generally spaced at regular intervals. The scribe lines are substantially transverse to the rolling direction and typically are applied to only one side of the steel. The scribing imposes mechanical damage to the steel either directly by some form of surface scratching, cutting, abrading, or, indirectly, by thermal shock treatment such as by a laser. See U.S. Pat. Nos. 3,647,575, issued Mar. 7, 1972; 4,513,597, issued Apr. 30, 1985; and 4,680,062, issued July 14, 1987.
In fabricating electrical steels into transformers, the steel inevitably suffers some deterioration in core loss quality due to cutting, bending, and construction of cores during fabrication, all of which impart undesirable stresses in the material. During fabrication incident to the production of stacked core transformers and, more particularly, in the power transformers of the United States, the deterioration in core loss quality due to fabrication is not so severe that a stress relief anneal (SRA), typically about 1475° F (801° C), is essential to restore usable properties. For such end uses there is a need for a flat, domain-refined silicon steel which need not be subjected to stress relief annealing. In other words, the scribed steel used for this purpose does not have to possess domain refinement which is heat resistant.
However, during the fabrication incident to the production of most distribution transformers in the United States, the steel strip is cut and subjected to various bending and shaping operations which produce more worked stresses in the steel than in the case of power transformers. In such instances, it is necessary and conventional for manufacturers to stress relief anneal (SRA) the product to relieve such stresses. During stress relief annealing, it has been found that the beneficial effect on core loss resulting from some scribing techniques, such as mechanical and thermal scribing, are lost. For such end uses, it is required and desired that the product exhibit heat resistant domain refinement (HRDR) in order to retain the improvements in the core loss values.
It is known in the art of making electrical steel to attempt to produce heat resistant domain refinement. It has been suggested in prior patent art that contaminants or intruders may be effective in refining the magnetic domain wall spacing of grain-oriented silicon steel. U.S. Pat. No. 3,990,923 - Takashina et al, dated Nov. 9, 1976, discloses that chemical treatment may be used on primary recrystallized silicon steel (i.e., before final texture annealing) to control or inhibit the growth of secondary recrystallization grains. British Patent Application 2,167,324A discloses a method of subdividing magnetic domains of grain-oriented silicon steels to survive a SRA. The method includes imparting a strain to the sheet, forming an intruder on the grain-oriented sheet, the intruder being of a different component or structure than the electrical sheet and doing so either prior to or after straining and thereafter annealing such as in a hydrogen reducing atmosphere to result in imparting the intruders into the steel body. Numerous metals and nonmetals are identified as suitable intruder materials.
Japanese Patent Document 61-133321A discloses removing surface coatings from final texture annealed magnetic steel sheet, forming permeable material coating on the sheet and heat treating to form material having components or structure different than those of the steel matrix at intervals which provide heat resistant domain refinement.
Japanese Patent Document 61-139-679A discloses a process of coating final texture annealed oriented magnetic steel sheet in the form of linear or spot shapes at intervals with at least one compound selected from the group of phosphoric acide, phosphates, boric acid, borates, sulfates, nitrates, and silicates, and thereafter baking at 300-1200° C., and forming a penetrated body different from that of the steel to refine the magnetic domains.
Japanese Patent Document 61-284529A discloses a method of removing the surface coatings from final texture annealed magnetic steel sheets at intervals, coating one or more of zinc, zinc alloys, and zincated alloy at specific coating weights, coating with one or more of metals having a lower vapor pressure than zinc, forming impregnated bodies different from the steel in composition or in structure at intervals by heat treatment or insulating film coating treatment to refine the magnetic domains.
In accordance with the teaching of a copending U.S. patent application, Ser. No. 206,152, filed June 10, 1988, now U.S. Pat. No. 4,911,766, filed by the common Assignee of this application, it is known to effect a heat resistant domain refinement of grain-oriented silicon steel by using an intrusion of phosphorus subsequent to some form of scribing technique. In a second copending U.S. patent application, Serial No. 327,946, filed March 23, 1989, now U.S. Pat. No. 4,968,361, by said common Assignee, it is known to use a flux printing agent made up of a group including phosphoric acid to effect the "striping" pattern in the forsterite base coating. Both of these copending applications disclose methods which, although relatively simple and effective, require a final diffusion anneal of sufficient duration, e.g., greater than 1 hour, that mandates a batch-type process. What is needed is an improvement in these methods in which all treatments are of short duration (e.g., less than about 15 minutes) so that the whole process is amenable to a continuous (strand) processing approach for potential commercial scale-up. Strand operations are widely used in the metallurgical industry because they are usually considerably less costly than their batch counterparts.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a rapid method of obtaining a heat resistant domain refinement of grain-oriented silicon steel having very low core losses by simultaneous phosphorus fluxprinting through the forsterite layer and charging the exposed lines of substrate metal with phosphorus. A subsequent heat treatment completes the development of domain-refined structure and lowered core loss.
According to the present invention the method includes effecting a striping of a predetermined pattern of parallel stripes in the forsterite layer formed in the outer surface of the steel, the pattern being formed by a combined printing of a fluxing and chemical striping agent made up in major part of phosphorus and phosphorus-bearing compounds to assure simultaneous effective flux printing and chemical striping.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of an offset printing press.
FIG. 2 is a schematic of a flexographic printing press.
FIGS. 3a and 3b are photomicrographs of a surface treated in accordance with the present invention.
FIGS. 4A and 4B are photomicrographs of the surface in cross section of a test specimen as continuously annealed in hydrogen showing phosphide particles.
FIG. 5 is a schematic arrangement of equipment modules in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention contemplates employing, in one and the same application, phosphorus as both a fluxing striping agent and as a chemical striping element to effect heat resistant domain-refinement to effect both results from one operation. It includes using a fluxing agent rich in phosphorus and using it in sufficient amount to not only dissolve the forsterite glass, but to charge enough residual phosphorus into the attacked region to provide magnetic domain refining. The invention includes employing an oxidizing atmosphere, such as air, firing of the printed flux, producing phosphate reaction products, followed by heating in a reducing atmosphere, such as hydrogen, to reduce the phosphates to phosphides. With restricted access to the underlying steel, e.g., only through the flux-produced craters in the base glass, iron phosphides will be produced with the wedge-shaped morphology associated with good domain refining.
In general terms in accordance with the teachings of the present invention, the method includes applying, preferably by printing, a phosphorus-rich flux agent to the base coated steel in a desired pattern. It has been found that conventional printing techniques and equipment may be suitable if modified so as to apply a suitable agent to the silicon steel at desired speeds, thicknesses and patterns.
The flux-printing agent of the present invention includes a major component selected from the group of phosphorus and phosphorus-bearing compounds. What is important is that the agent is rich in phosphorus in order that subsequent processing will cause the phosphorus to react to effect domain refinement.
Various printing techniques may be suitable for the present invention including stencil, offset, intagliotype, planographic, lithographic, and flexographic. Two methods and equipment of continuous printing are shown schematically in FIGS. 1 and 2.
FIG. 1 is a schematic of a widely-used conventional offset printing press in which a cluster of three rolls is used in applying the ink. The ink roll 1 rotates about its axis, dips into ink well 2, collects a layer of ink which is metered or wiped to a uniform layer as it passes against metering bar 3. The inked roll 1 then presses against the rotating second roll, i.e., print roll 4 on which the print, pattern, or design (hereinafter print-message) is located. The inked print roll 4 then presses against rotating third roll 5, the so-called blanket roll, on to which the print-message is transferred from roll 4. Finally, the rotating blanket message is transferred to the strip 6 as it moves continuously between roll 5 and backup roll 7. The backup roll 7 may or may not be necessary with this invention although it is conventionally used in the paper industry.
In FIG. 2, a schematic of known flexographic printing is illustrated. The process is a modification of conventional three-roll offset printing, with the important difference being that new materials which are both tough and flexible are used for the print roll 4A. Such new materials may be special rubbers or photo-polymers. They are sufficiently rugged for making direct contact with and printing on the moving substrate rather than via a blanket roll. Although the ink delivery roll 1 for offset printing of FIG. 1 is conventionally solid and smooth, the flexographic printer of FIG. 2 has a honeycombed surface of ink roll 1A against which the flexible print roll 4A presses, literally sucking the ink out of the honeycomb cells., the ink-delivery roll is called the anilox roll in the technology of flexographic printing. As with offset printing, the backup roll 7A included in FIG. 2 is conventional but may not be essential for strong substrates such as metal.
The consistency and viscosity of the ink used in printing techniques may vary and is dependent on the technique used. For example, the ink used for offset printing has to be of similar viscosity to thick syrup (e.g., 10,000 centipoise). Flexographic printing is much more tolerant of ink viscosity and is capable of printing inks from this liquid to paste consitencies.
Grain-oriented silicon steel used in the herein disclosed tests was produced by casting, hot rolling, normalizing, cold rolling to intermediate gauge, annealing and cold rolling to final gauge, decarburizing, and final texture annealing to achieve the desired secondary recrystallization of cube-one-edge orientation. Typical melts of nominal initial composition of conventional (Steel 1) and high permeability (Steel 2) grain-oriented silicon steels were:
______________________________________C N Mn S Si Cu B Fe______________________________________Steel 1 030 <50 ppm .07 .022 3.15 .22 -- Bal.Steel 2 030 <50 ppm .038 .017 3.15 .30 10 ppm Bal.______________________________________
After final texture annealing, the C, N, and S were reduced to trace levels of less than about 0.001%. The strip was cut into numerous pieces to produce samples of sizes sufficient for processing in accordance with the present invention. Final sample size for magnetic testing was that of the well known Epstein strip of 30 cm. long×3 cm. wide. Epstein strips were tested both as stacked packs and as single strips as indicated.
The method of the present invention recognizes that the layer of forsterite required to be broken through or substantially dissolved by the flux is very thin, typically 5 microns (0.005 mm). As is described in the above-mentioned U.S. Pat. No. 4,968,361 the layer can be penetrated easily and quickly, using a small amount of a fluxing agent. It was also found that phosphorus is an effective fluxing agent. The flux agent is applied to the forsterite surface in the precise pattern of lines needed for subsequent chemical and/or thermal treatment to develop heat-proof domain refinement.
As used herein, the pattern of exposed or substantially exposed pattern of lines through the forsterite to the silicon steel substrate is referred to as "metal stripes." The introduction of phosphorus from the flux in excess of that necessary to merely break through or dissolve the forsterite is known as "charging" the sample (with phosphorus). Subsequent reduction of the phosphate, to the required phosphide, is referred to as "curing." As will be evident from the examples, the phosphates do not lead to domain refinement while the phosphides (produced by curing) do.
After applying the flux-printing agent to the coated steel, it is necessary to cause a reaction therebetween to effect substantial removal of the coating to expose the steel. It has been found that the steel and coating should be heated. Any oxidizing atmosphere may be used, but this heating must be done in the presence of oxygen, such as in air, at temperatures up to 1700° C. (926° C.), as low as 900° F. (482° C.) and preferably 1200 to 1500° F. (649 to 816° C. ) to effect charging.
After heating the agent in the base coating to cause substantial removal in a line pattern, the steel undergoes further or second heating in a reducing atmosphere to cure the material. The atmosphere must be reducing and may include hydrogen and hydrogen mixtures, such as hydrogen-nitrogen, but preferably is substantially straight hydrogen. The curing temperature may range from 1500 to 1800° F. (816 to 982° C.) and preferably ranges from 1550 to 1700° C. (843 to 927° C.).
The charging and curing steps must be performed as two separate steps. However, the charging step may embrace intermediate steps, such as a second or more application or flux-printing agent. The times and temperatures for curing to produce the permanent bodies will vary, however, such times should be less than 15 minutes and preferably less than 7 minutes to be useful in commercial strand-type production operations. For batch-type curing, much longer times, e.g., several hours, are tolerable.
In order to better understand the present invention, the following examples are presented.
EXAMPLE I
Samples of 8-mil final texture annealed high permeability steel (of Steel 2) were treated as Epstein strips using a simulated printing operation. For these runs, full strength (85%) phosphoric acid was used as the printing ink base. The ink was stiffened by adding polyethylene glycol at 10% by weight to form a highly viscous liquid approaching printing ink consistency. Polyethylene glycol is the generic name for a series of water-soluble polymers of varying molecular weight of 200-20,000 with the general formula H(OCH 2 CH 2 ) n OH. As the molecular weight increases the polymer changes from a liquid to a waxy solid. In its various forms, polyethylene glycol is widely used in cosmetics, pharmaceuticals, special printing inks, water soluble lubricants, etc. For purposes herein to thicken the ink, polyethylene glycol Grade 20M (PEG 20M), which has molecular weight of 15,000-20,000, was used.
Printing was simulated very simply by dipping the edge of a razor blade into the ink and then applying the inked edge transversely to the surface of an Epstein strip. Thin lines of ink were applied along the whole length of the strip. The lines were spaced at about a 5 mm interval which is a conventional scribing spacing for domain refining. After printing, the strip was fired (heated) in air at 1300° F. (704° C.) and then the whole process was repeated to provide a second application of phosphorus. The second line of ink was applied directly over the firs to effectively double the amount of ink applied. The samples were then cured in hydrogen at 1650° F. (899° C.) for five hours (as described in the above-mentioned copending U.S. patent application Ser. No. 327,946). Eight strips were treated in this way and magnetic properties before and after firing were determined both as single strips and as an eight strip Epstein pack. The full magnetic properties is shown in Table I. The data show an 8% improvement in core loss by this method of flux printing and phosphorus striping.
TABLE I__________________________________________________________________________MAGNETIC PROPERTIES After After CuringOriginal as Scrubbed Phosphorus Charging (5 hrs/1650° F. Hydrogen)Sample Permeability Core Loss (WPP) Permeability Core Loss (WPP)* Permeability Core Loss (WPP)*No. @ 10 Oe 1.5 T 1.7 T @ 10 Oe 1.5 T 1.7 T @ 10 Oe 1.5 T 1.7__________________________________________________________________________ TPH-66 1933 .422 .619 1919 .436 .608 1897 .424 .593PH-67 1916 .436 .624 1913 .428 .605 1907 .428 .613PH-68 1945 .460 .625 1937 .548 .735 1925 .433 .624PH-69 1906 .425 .624 1892 .448 .655 1879 .396 .576PH-70 1924 .461 .638 1907 .463 .639 1897 .388 .538PH-71 1906 .409 .591 1901 .423 .594 1894 .374 .526PH-72 1895 .455 .659 1880 .489 .696 1868 .407 .587PH-73 1890 .429 .632 1873 .463 .669 1874 .377 .546Single Strip 1914 .442 .625 1903 .462 .650 1893 .403 .575Average: (+5%) (+4%) (-9%) (-8%)(n = 8)Epstein 1927 .434 .599 1914 .444 .630 1905 .401 .558Pack (+2%) (+5%) (-8%) (-7%)Props.__________________________________________________________________________ *(Numbers in parentheses = % change versus original.)
EXAMPLE II
Samples of final texture annealed high permeability oriented steel of Steel 2 were flux-printed continuously on a Matthews Model 6029 printing press which is capable of printing on 3-inch wide strip material. The press was operated in a flexographic mode (see FIG. 2), i.e., the print roll printed directly on the Epstein strips rather than through the action of a blanket roll. The ink was made by blending 85 parts of 85% phosphoric acid with 15 parts of PEG 20M polyethylene glycol. Viscosity was about 10,000 centipoise.
Printing of 5 mm spaced parallel lines of 0.5-1.0 mm width substantially transverse to the rolling direction of the steel was done at 50 ft/min. line speed. Ink thickness applied to the forsterite layer of steel was about 0.01 mm (0.065 mils). The samples were allowed to dry and then heated in air to 1300° F. (704° C.) to break through or dissolve the forsterite and partially charge the metal stripes with phosphorus. The operation was then repeated, synchronizing the second application to be on top of the first, to further charge the metal stripes with phosphorus so that the applied ink was thicker. The final treatment to cure the samples was done at 5 hours at 1650° F. in hydrogen. Magnetic properties are listed in Table II below. They show a moderate improvement in core loss of about 4% in a batch of strips which had excellent starting properties.
TABLE II__________________________________________________________________________MAGNETIC PROPERTIES After Phosphorus Charging (Continuous After CuringOriginal as Scrubbed Print and Fire-Twice) (5 hrs/1650° F. Hydrogen)Sample Permeability Core Loss (WPP) Permeability Core Loss (WPP)* Permeability Core Loss (WPP)*No. @ 10 Oe 1.5 T 1.7 T @ 10 Oe 1.5 T 1.7 T @ 10 Oe 1.5 T 1.7__________________________________________________________________________ TPH-74 1927 .351 .498 1923 .393 .552 1904 .359 .514PH-75 1933 .391 .553 1931 .414 .572 1920 .383 .505PH-76 1928 .373 .547 1926 .388 .551 1913 .350 .505PH-77 1913 .385 .564 1911 .470 .669 1903 .365 .537Single Strip 1925 .375 .541 1923 .416 .586 1910 .364 .515Average (+11%) (+8%) (-3%) (-5%)__________________________________________________________________________ *(Numbers in parentheses = % change versus original.)
EXAMPLE III
As in Example II, samples of high permeability oriented steel of Steel 2 were flux-printed continuously on a Matthews Model 6029 printing press. The press was operated in a flexographic mode (see FIG. 2), i.e., the print roll printed directly on the Epstein strips rather than through the action of a blanket roll. The ink was made by blending 85 parts of 85% phosphoric acid with 15 parts of PEG 20M polyethylene glycol. Viscosity was about 10,000 centipoise.
Printing of 5 mm spaced parallel lines of 0.5-1.0 mm width substantially transverse to the rolling direction of the steel was done at 50 ft/min. line speed. The printer was adjusted to yield about twice the thickness of ink to the forsterite layer compared with Example II (i.e., 0.02 mm (0.13 mils)). The samples were fired immediately in air at 1300° F. (704° C.) without waiting to dry as was done in Example II. The operation (print and fire) was then repeated three times synchronizing the print lines on top of those of the initial operation. Firing of the ink before completely dry caused some spread in the flux craters created, i.e., they were not in as straight a line as the originally-printed ink. It is known in the technology of scribing of electrical steels that the line-breaks in the domain structure need not be straight to effect domain refinement.
The phosphorus-charged strips were bulk analyzed for phosphorus and indicated total content of 0.3% compared with 0.025% in the initial starting material. The additional phosphorus was no doubt concentrated in the charged lines. FIGS. 3A and 3B are photomicrographs of the surface of the phosphorus-charged line.
In this example, samples were cured quickly using a furnace with a continuously-moving mesh belt on which samples could be laid. The atmosphere was dry (<-20°F. Dew Point) hydrogen and samples were given a 4-minute treatment at 1550° F. (843° C.), 1625° F. (885° C.), or 1700° F. (927° C.) and magnetic properties determined. The heat treatment was then repeated representing cumulatively an 8-minute treatment. These ties were selected to simulate ranges suitable for a continuous process line.
Results are shown in Table III and show improved properties with all the treatments. FIGS. 4A and 4B show an example of phosphide particles in the steel surface layers, generated during the curing operation and responsible for domain refinement. The data show 4 minutes at 1625° F. (885° C.) or 1700° F. (927° C.) to yield good magnetic response while minimizing the duration of the curing anneal.
TABLE III__________________________________________________________________________MAGNETIC PROPERTIES Cured in Hydrogen for Cured in Hydrogen forOriginal Properties 4 Mins. at Indicated Temp. 8 Mins. at Indicated Temp.Epstein Permeability Core Loss (WPP) Permeability Core Loss (WPP)* Permeability Core Loss (WPP)*Pack No. @ 10 Oe 1.5 T 1.7 T @ 10 Oe 1.5 T 1.7 T @ 10 Oe 1.5 T 1.7__________________________________________________________________________ TCURED AT 1550° F.1 1926 .514 .690 1898 .484 .656 1900 .432 .599 (-6%) (-5%) (-16%) (-13%)CURED AT 1625° F.2 1911 .537 .741 1886 .432 .606 1880 .428 .647 (-20%) (-18%) (-28%) (-17%)CURED AT 1700° F.3 1926 .437 .607 1896 .409 .546 1897 .398 .550 (-6%) (-10%) (-9%) (-9%)__________________________________________________________________________ *(Numbers in parentheses = % change versus original.)
EXAMPLE IV
In this Example, samples of high permeability oriented steel of Steel 2 were flux-printed and air-fired in identical manner to that described for Example 3. The curing cycle was also of similar brief duration using the mesh belt furnace. The difference from Example III was that 80:20 nitrogen-hydrogen (<-20° F. Dew Point) was substituted for pure hydrogen in the curing cycle. Results are displayed in Table IV. Those samples showed an improvement over original, the exception being the 8-minute treatment at 1700° F. which showed a deterioration in core loss. Generally the response was not as good in the mixed atmosphere as in hydrogen alone.
TABLE IV__________________________________________________________________________MAGNETIC PROPERTIES Cured in 80:20 Cured in 80:20 Nitrogen: Hydrogen for Nitrogen: Hydrogen forOriginal Properties 4 Mins. at Indicated Temp. 8 Mins. at Indicated Temp.Epstein Permeability Core Loss (WPP) Permeability Core Loss (WPP)* Permeability Core Loss (WPP)*Pack No. @ 10 Oe 1.5 T 1.7 T @ 10 Oe 1.5 T 1.7 T @ 10 Oe 1.5 T 1.7__________________________________________________________________________ TCURED AT 1625° F.1 1902 .451 .646 1888 .448 .639 1892 .437 .627 (-1%) (-1%) (-3%) (-3%)CURED AT 1700° F.2 1900 .446 .644 1890 .428 .618 1896 .425 .665 (-4%) (-4%) (+1%) (+3%)__________________________________________________________________________ *(Numbers in parentheses = % change versus original.)
EXAMPLE V
In this Example, 7-mil gauge strip samples of oriented steel of conventional permeability (Steel 1)were evaluated with respect to the flux-print-phosphorus-charge/fast-hydrogen-cure sequence. Procedure was then same a in Example III but evaluating only the one temperature-time combination for curing of 1625° F. for 4 minutes. Results are given in Table V and display significantly improved core losses. Note that this steel had a lower permeability than in the previous Examples which would make it less susceptible to domain refinement. However, it was also of lighter gauge (7 mil) which would make it more susceptible to domain refinement, independent of permeability, than the high permeability 8-mil material of Examples I through IV.
TABLE V__________________________________________________________________________MAGNETIC PROPERTIESOriginal Properties Cured in Hydrogen for 4 mins. at 1625° F. Core Loss (WPP) Core Loss (WPP)*Permeability @ 10 Oe 1.5 T 1.7 T Permeability @ 10 Oe 1.5 T 1.7 T__________________________________________________________________________1869 .414 .628 1850 .393 .604 (-5%) (-4%)__________________________________________________________________________ *(Numbers in parentheses = % change versus original.)
It is part of the present invention to provide a single method of both breaking through or dissolving the forsterite and charging sufficient extra phosphorus as phosphates into the exposed metal series to cause domain refinement on curing. The fluxing through the nominally 5-micron thick forsterite is relatively straight-forward and forms part of the basis of the previous copending application Ser. No. 327,946, filed Mar. 23, 1989, mentioned above. In this latter application, completion of domain refining was accomplished by supplying phosphorus vapor from an external source, namely through hydrogen reduction to breakdown a phosphate coating covering the complete strip surface. In the present invention, the excess phosphorus needed is delivered as part of the fluxing operation (i.e., the metal striping). The method of providing sufficient phosphorus to do the dual job (breaking through the for sterite and charging the necessary excess phosphorus for domain refining) may be accomplished in several ways in accordance with the present invention. These include using more concentrated (i.e., greater phosphorus content) ink, adding more per treatment, or using multiple treatments. These options will now be discussed.
In regard to phosphorus enrichment of the ink, it is noted that the ink used in the Examples described contained only about 24% P. Phosphoric acid itself contains only 32% P. Since in this approach phosphorus acid is to be used as the main fluxing agent, it should be kept as a major component of the ink and the ink made to contain phosphoric acid in an amount at least sufficient to break through the forsterite layer to expose the metal stripes. Further enrichment may be accomplished by substituting a phosphorus-containing solid, at least to replace the 15% polyethylene glycol which is added solely as a thickening agent to obtain the correct ink viscosity.
From the standpoint of adding more ink per treatment, the flexographic printing technology can offer rapid printing at thicknesses an order of magnitude thicker than the well known offset printing. The difference between these two methods has already been described. It should be noted in several of the above Examples that a machine designed of offset printing can be used in a flexographic mode, i.e., the print roll collected its ink from an ink roll and laid it directly on the strip. This simulation was deficient in that the honeycomb-surfaced ink roll (often referred to in flexographic printing as the anilox roll) was not present; instead the smooth ink roll characteristic of offset printing was in place. It is the absorbent anilus roll, coupled with a highly flexible print roll, that allows much tolerance and versatility in flexographic printing, including thick printing of the type desirable for this invention.
The multiple print and fire operations such as were used in the Examples may or may not be done in a single operation with true flexographic printing. While normally a multiple repeated step operation would be expected to be more complex and costly than a single operation, dividing the flux ink applications into several increments may have some advantages. The relatively smaller amount of ink needed to be deposited at each station means that conventional three-roller offset printers (see FIG. 1) could be used. These printers are basically simple, reliable and inexpensive. Although repeated firing of the flux-printed strip could be cumbersome, the employment of transverse flux heating furnaces such as has been described in U.S. Pat. No. 4,751,360 may be beneficial. These furnaces, most importantly, have the capability of extremely fast heating, ideal for the flux firing of the present invention. The printing device, likewise, need not be large, e.g., less than several feet long.
It is anticipated that a flux-print and fire module would take relatively small space. Several modules could be spaced in series in line. Synchronization of the modules could allow consecutive printing to be precisely controlled in phase similar to the technology available in the paper printing industry. FIG. 5 is a schematic arrangement of equipment modules with module 8 representing the printing module for applying the flux agent. Module 10 represents the module for heating in the oxidizing atmosphere and module 12 represents the module for the second heating in the reducing atmosphere. It should be understood that one or more modules 8 and 10 may be arranged in line to permit multiple sequencing of applying the agent and first heating.
Control of the amount of phosphorus added would be relatively easy since there would be several control points available (i.e., one at each module). The ability to precisely control the amount of phosphorus added would then allow optimization to produce the desired domain refinement with minimal surface effects. Undesirable ink spread could be minimized with the use of several small ink applications and the fast heat for firing. Such a multimode arrangement would permit, if desired, use of different ink compositions and different firing temperatures at each module. For example, it has been found that a trace of potassium fluoroborate in the phosphorus-bearing flux will make the flux extremely aggressive to forsterite. Accordingly, in some applications ink with this additive in the first module could be used to open up a thin line of deep craters, with use of 1400° F. (760° C.) firing temperature, for example. The ink in the second, and if desired additional modules, could be less aggressive, with phosphoric acid only as the active agent, and serving to further widen the existing craters and, importantly, to load or charge them with more phosphorus. A lower temperature, for example, 1000° F. (538° C.) could be used.
Although a preferred and alternative embodiments have been described, it will be apparent to one skilled in the art that changes can be made therein without departing from the scope of the invention.
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A method is provided to effect domain refinement of grain-oriented silicon steel sheets having a surface layer of forsterite by applying to the layer a phosphorus-rich flux-printing agent having a desired composition, and degree of fluidity in a sufficient amount to effect removal of the forsterite layer in a striped pattern with sufficient phosphorus to subsequently chemically stripe the underlying metal with phosphide-bearing bodies to produce in the steel a heat-proof domain refinement with improved lower core loss values, after first heating in an oxidizing atmosphere and second heating in a reducing atomsphere.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of PCT/US00/4180, filed Nov. 2, 2000, which is based on U.S. Provisional Application No. 60/163,017, filed Nov. 2, 1999, now closed.
FIELD OF THE INVENTION
[0002] The invention relates generally to cooling system pressure testing devices, and more specifically to an apparatus for monitoring the internal pressure and preferably temperature of a cooling system that uses liquid coolant to facilitate temperature reduction.
BACKGROUND OF THE INVENTION
[0003] Engines, such as those in motorcycles, automobiles, and other motive vehicles, typically utilize coolant systems with liquid coolant to facilitate temperature reduction. A variety of potential problems are associated with such cooling systems. In order to diagnose these problems, it is useful to measure the pressure of the cooling system, as well as the temperature of the coolant itself, during a running cycle. In this regard, it is further advantageous for the system to have the capability to pressurize the cooling system in order to obtain these readings and locate any leaks in the system. Various apparatus are known for testing such systems by pressurization in order to detect leaks therein. Each of these apparatus, however, has shortcoming in either design or operation.
[0004] U.S. Pat. No. 1,776,170 to Thimblethorpe discloses a cap-like device that fits over the opening of a radiator and includes a temperature sensor and a level sensor for indicating the level and temperature of the liquid in the radiator of an automotive vehicle.
[0005] U.S. Pat. No. 3,255,631 to Franks discloses a pressure/temperature indicating apparatus attached to a radiator cap with a sealing mechanism. The sealing mechanism includes a spring that bears against a metal washer, serving to seal the radiator with a rubber washer.
[0006] U.S. Pat. No. 3,100,391 to Mansfield discloses a pressure and temperature indicator that is adapted to fit over a radiator cap of an automotive cooling system. The radiator cooling system may be pressurized using a pump or a valve stem and pressurized air.
[0007] U.S. Pat. No. 4,702,620 to Ford discloses an electronic thermostat having a temperature sensor, which is inserted through a cap-like device adapted to fit over the opening of the radiator. The system is designed to monitor the temperature of the coolant and the radiator over time.
[0008] U.S. Pat. No. 5,324,114 to Vinci discloses a device for monitoring temperature and pressure of a liquid coolant in a cooling system. Vinci includes a particularized sealant that seals around the probes of a needle from a temperature or pressure probe and reseals itself upon removal of the needle.
[0009] U.S. Pat. No. 5,557,966 to Corry and U.S. Pat. No. 5,760,296 to Wilson disclose cooling system pressure testing devices that utilize bladders that may be inserted into an inlet in a deflated state and then inflated to couple the device to the inlet.
[0010] Systems available in the market typically include a pressure probe assembly and a plurality of adapter cap fittings designed to suit a variety of radiator neck configurations and sizes. Typically, such test systems require 25-30 different fittings in order to provide a system that may be utilized with the broad range of vehicles on the market. In use, an appropriately sized adapter cap fitting is selected to fit the radiator neck size and configuration of the cooling system being tested. The cap fitting is secured to the neck of the radiator, and a pressure probe and gas compressor coupled to the cap fitting. A typical pressure probe includes a pressure gauge, and has an outlet connectable to a selected one of the adapter cap fittings, the fitting also being adapted to receive pressurized gas from a compressor. The cooling system is then pressurized and the pressure measured.
[0011] Kits of this type are typically expensive and complex as they consist of a large number of parts, usually including a plurality of adapter cap fittings. Further, the range of cap fittings available generally does not cover all possible radiator neck configurations and sizes. Additionally, as these cap fittings are loose parts of a kit, they are often lost or misplaced.
[0012] Another attempt to simplify pressure-testing devices is the Uni-Cap Universal Cap Adapter, in which a single-size pressure probe adapter cup is permanently affixed to an expandable radiator orifice fitting. Although fitting a wide range of radiator necks, the principal disadvantage of the Uni-Cap device is that it can only be used with specific commercially available pressure probe assemblies sized to mate with the permanently affixed adapter cup. This limitation reduces the flexibility of the Uni-Cap device, particularly with respect to pressure probes that do not fit the permanently affixed adapter cup. Therefore, a need exists for a truly cooling system orifice adapter that fits a wide range of radiator necks and is not limited by commercially available pressure probes.
[0013] Another disadvantage of the Uni-Cap design is the difficulty in repair or replacement of its components. Since the radiator cup is welded or brazed to the internal shaft, the Uni-Cap cannot be disassembled, or its components replaced without damaging the device. The universal radiator orifice fitting, for example, cannot be replaced if damaged by scale build-up in the radiator neck, improper installation, or general wear and tear. Ultimately, if any component of the Uni-Cap is damaged, the entire assembly must be rebuilt or replaced. Both alternatives are generally more costly than component replacement.
[0014] Other universal-type adapters are marketed by companies such as Autotestgerate Leitenberger GmbH, which markets adapters which similarly include a tapered rubber plug. One such device, which includes a conical rubber plug, is disclosed, for example, in German Application DE 32 30 146 A1. Other devices marketed by Autotestgerate Leitenberger GmbH include a stepped rubber plug, or a conical plug having a plurality of spaced, thin rings encircling the cone and distributed along the length of the cone. Autotestgerate Leitenberger GmbH also markets a universal-type device which includes a cylindrical plug which seats along an inner surface of the radiator to seal the device to the radiator. The latter device also includes a pair of brackets which clamp around surfaces of the radiator orifice. Similar devices are marketed by at least one Taiwanese company.
[0015] In view of the generally conical or straight cylindrical structure of each of the devices, however, even when properly placed on a vehicle, the plug of the adapter can be ejected from the radiator opening when high pressures are developed within the radiator. Such forcible ejection not only prevents proper testing of the vehicle, it can also be extremely dangerous, causing damage to both the vehicle and the user.
OBJECTS OF THE INVENTION
[0016] An object of the present invention is to provide a diagnostic tool for measuring cooling system temperature and/or pressure, such that the tool may be conveniently utilized in a variety of applications without requiring assembly or disassembly of the diagnostic tool itself. A related object of the invention is to provide such a diagnostic tool that may be utilized to apply pressurized gas from a hand pump or the like, or directly from a shop source.
[0017] Another object of the invention is to provide a modular universal pressure and temperature diagnostic tool that affords easy repair and replacement of parts that are susceptible to damage and heavy wear during normal use.
[0018] A further object of the invention is to provide a single adapter that may be utilized in a broad range of vehicle applications, eliminating the need for multiple adapters in standard testing systems.
[0019] A related object is to provide an adapter which can be directly connected to standard testing systems currently available on the market, but that is not limited to use with standard testing systems or a single radiator cup size.
[0020] A collateral object of the invention is to provide a device that may be efficiently manufactured and repaired at a relatively low cost.
[0021] Another important object is to provide a device that can consistently be safely used without collateral damage to the vehicle, other property, observers or the user. It is a more specific object to provide such a device which will not be ejected from the cooling system orifice during high pressure use.
[0022] The present invention overcomes the disadvantages of the prior art. These and other objects and advantages of the present invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.
BRIEF SUMMARY OF THE INVENTION
[0023] The invention provides a modular cooling system orifice adapter that may be utilized as a diagnostic tool for evaluating a cooling system. In one embodiment, the device includes a relatively standard size orifice cup which is adapted to mate with a number of pressure testers available on the market. In another embodiment, the adapter includes a valve assembly having a shuttle valve that may be coupled to a source of pressurized gas, preferably a hand held pump. The shuttle valve is slidably received within a valve body that is coupled to a hollow shaft that may be placed in fluid communication with the cooling system. The shuttle valve may be used to selectively apply compressed gas to the cooling system by moving the shuttle valve between an open position wherein the source of compressed gas is in fluid communication with the hollow shaft and therefore the cooling system, and a closed position wherein there is no such fluid communication.
[0024] The valve assembly also includes a pressure gauge, which is preferably coupled to the shuttle valve to measure the pressure of the system. A temperature gauge may also be coupled to the valve body such that it is in fluid communication with the hollow shaft for determining the temperature within the system.
[0025] The valve assembly or cup is preferably coupled to cooling system by a universal fitting, which allows the adapter to be utilized with many sizes and shapes of cooling system openings. The universal fitting, in the form of a rubber adapter, has an exterior surface that generally decreases in diameter, preferably consisting of a plurality of round steps. The hollow shaft extends through the universal fitting and includes an enlarged head that is disposed at the small end of the universal fitting. A plate is disposed along the shaft at the opposite end of the universal fitting as is a compression device that may be actuated to draw the head and plate toward one another so as to axially compress the universal fitting, in turn causing the steps to bulge and seal against the opening in the radiator or the like after the adapter is partially inserted into the opening. The upper edges of the substantially axially extending walls of the steps of the universal fitting are preferably angled radially inward to minimize any possibility of the fitting separating from the cooling system orifice. In this way, the lower edge of the vertical step protrudes further outward than the upper, such that sufficient interference is created to typically prevent the lower edge of the vertical step from separating from the cooling system orifice when it is axially compressed and a pressure applied to the cooling system.
[0026] Preferably, the adapter is modular such that it may be readily disassembled for replacement of worn out or damaged components. In this regard, the hollow shaft is preferably threaded at one end. In this way, a compression device, such as a threaded knob may be simply rotated along the shaft threads to axially compress the universal fitting. Additionally, the valve or cup assembly may be coupled to the device by threads that mate with the threaded end of the shaft. A seal or gasket disposed between the shaft and the valve assembly or cup provides a sealed connection between the interior valve assembly or cup and the hollow interior of the shaft. Those of skill in the art will appreciate that the invention so provides an adapter that may be utilized as a practical and economical diagnostic tool in a large number of applications.
[0027] It will further be appreciated that this modular arrangement may also be utilized with other pressure testing devices available on the market by including the standardized radiator cup assembly in place of the valve assembly. In this way, the invention provides a repairable, and therefore practical and economical alternative to the use of multiple adapters typically provided with standard pressure testing devices.
[0028] These and other features and advantages of the invention will be more readily apparent upon reading the following description of a preferred exemplary embodiment of the invention and upon reference to the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 is a side elevational view of a cooling system orifice adapter assembly constructed according to teachings of the invention.
[0030] [0030]FIG. 2 is a bottom view of the universal fitting of FIG. 1.
[0031] [0031]FIG. 3 is an elevational view of the shaft of FIG. 1.
[0032] [0032]FIG. 4 is a bottom view of the head of the shaft of FIGS. 1 and 3.
[0033] [0033]FIG. 5 is a plan view of the knob of FIG. 1.
[0034] [0034]FIG. 6 is a cross-sectional view of the knob of FIGS. 1 and 5.
[0035] [0035]FIG. 7 is a plan view of the pressure plate of FIG. 1.
[0036] [0036]FIG. 8 is a plan view of the radiator cup of FIG. 1.
[0037] [0037]FIG. 9 is a plan view of the nut of FIG. 1.
[0038] [0038]FIG. 10 is a side elevational view of an alternate embodiment of the cooling system orifice adapter including a tester.
[0039] [0039]FIG. 11 is an exploded elevational view of the valve assembly of FIG. 10.
[0040] [0040]FIG. 12 is a plan view of the valve body of FIG. 10.
[0041] [0041]FIG. 13 is a cross-sectional view of the valve body of FIGS. 11 and 12.
[0042] [0042]FIG. 14 is a plan view of an alternate embodiment of the pressure plate of FIG. 7.
[0043] [0043]FIG. 15 is an exploded view of an alternate embodiment of the valve assembly of FIGS. 10 and 11.
[0044] [0044]FIG. 16 is a side elevational view of a third embodiment of the cooling system orifice adapter assembly constructed according to teachings of the invention.
[0045] [0045]FIG. 17 is a side elevational view of the universal fitting of FIG. 16.
[0046] [0046]FIG. 18 is an end view of the universal fitting of FIGS. 16 and 17.
[0047] [0047]FIG. 19 is a side elevational view of the shaft of FIG. 16.
[0048] [0048]FIG. 20 is an end view of the shaft of FIGS. 16 and 19.
[0049] [0049]FIG. 21 is an enlarged side view of the opposite end of the shaft of FIGS. 16, 19, and 20 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] Turning now to the drawings, FIG. 1 illustrates a side elevational view of a universal modular cooling system orifice adapter 30 constructed in accordance with teachings of the invention. According to an important feature of the invention, the adapter is of a modular assembly. This modular assembly allows a user of the invention to quickly disassemble the unit for repair or replacement of any individual component, and to easily reconfigure the device for use according to its various embodiments described herein. Moreover, disassembly and reassembly of the invention requires merely unscrewing the threaded portions of the device.
[0051] The adapter 30 includes a coupling assembly 32 whereby the adapter may be coupled to a broad range of sizes of radiator necks (not shown) of the cooling systems of a broad range of vehicles, and also to a pressure adapter 34 that allows the adapter 30 to be utilized with a broad range of cooling system testers (not shown) currently on the market. While the invention will be described with regard to the adapter 30 being coupled to a radiator neck, it will be appreciated that the adapter 30 may alternately be coupled to an opening of an overflow tank or other appropriate orifice.
[0052] The coupling assembly 32 includes a universal fitting 36 which is preferably formed of a rubber material with a durometer sufficient to withstand the axial and radial forces exerted on the fitting 36 , as well as temperatures, pressures, and other environmental stresses while providing a durable, reusable device. The universal fitting includes an exterior surface having a diameter that increases from the bottom to the top, that is, from the distal end to the proximal end. The illustrated design includes a number of steps 38 ranging from small to relatively large, each presenting a consecutively larger outer diameter. In operation, the universal fitting 36 is advanced into the radiator neck of the cooling system as deeply as possible, such that the largest diameter step 38 with a diameter smaller than the diameter of the radiator neck is disposed within the inner diameter of the radiator neck. The universal fitting 36 is then compressed axially in order to cause the universal fitting 36 to bulge outward to a greater diameter to contact and seal against the inner diameter of the radiator neck. It will be appreciated that as the universal fitting 36 continues to be axially compressed, the force exerted by the universal fitting against the inner diameter of the radiator neck, i.e., the retention force, increases.
[0053] In order to provide this axial compression of the universal fitting 36 , the universal fitting is provided with a bore 40 , which extends axially through the fitting 36 . A hollow shaft 42 having an enlarged head portion 44 and a central axial bore 43 is disposed within the axial bore 40 of the universal fitting 36 . As may be seen in FIG. 1, the enlarged head portion 44 of the shaft is disposed subjacent the smallest diameter step 38 a of the fitting 36 . It will thus be appreciated that the enlarged head portion 44 of the shaft 42 exerts an upward axial force against the lowermost surface 36 a of the universal fitting 36 as the head portion is drawn upward.
[0054] In order to provide a corresponding exertion of force on the uppermost surface 36 b of the universal fitting 36 , a pressure plate or tie down plate 48 is provided. As may be seen in FIG. 7, the pressure plate 48 includes a central bore 50 , which freely receives the shaft 42 . Thus, forcing the head portion 44 of the shaft 42 and the pressure plate 48 toward each other produces an axial force on the universal fitting 36 , in turn causing the steps 38 to bulge outward.
[0055] To provide this axial force, the adapter 30 is provided with a compression device. In the embodiment illustrated, the shaft 42 is provided with a threaded length 46 along its external surface (see FIG. 3) along which a knob 54 having a mating, threaded inner bore 56 extending axially therethrough is disposed along the shaft 42 (see FIGS. 1 , 5 - 6 ). In this way, once the user inserts the universal fitting 36 into the radiator neck or other aperture to a desired depth, the user tightens the knob 54 on the shaft 42 to exert a downward force on the pressure plate 48 , and a corresponding upward force on the universal fitting 36 by way of the head portion 44 of the shaft, to axially compress the fitting 36 .
[0056] The pressure plate 48 may be of any appropriate design, provided that adequate surface is provided to permit the application of force to the universal fitting 36 . In this regard, an alternate embodiment 48 a of the pressure plate is illustrated in FIG. 14. The pressure plate 48 a is a flat washer-like design with a central opening 50 a for receiving the shaft 42 .
[0057] A separate support ring 58 having an inner bore 60 with a diameter substantially equal to the outer diameter of the smallest diameter step 38 a is preferably provided. The support ring 58 is particularly useful in applications where the larger diameter steps 38 are utilized to seal the radiator neck. When disposed in this way, the support ring 58 provides additional support to the thinnest portion of the universal fitting 36 and minimizes any opportunity for the universal fitting 36 to disengage the head portion 44 of the shaft 42 and slide over the head portion 44 when the universal fitting 36 is axially compressed to an excessive degree.
[0058] The adapter 30 may additionally be provided with a second coupling mechanism for use in conjunction with the expansion of the universal fitting 36 . In this regard, the pressure plate 48 may be provided with one or more slots 52 for receiving a chain or the like (not shown) to further mechanically couple the adapter 30 to the radiator neck. It will be appreciated by those of skill in the art that the chain-coupling structure is not necessary to the operation of the adapter 30 , nor is it necessary with regard to the sealing of the adapter to the radiator neck. Rather, it is intended and operates merely as a back-up, precautionary measure to enhance safety when operating the adapter 30 .
[0059] An alternate embodiment of universal fitting 136 is shown in FIGS. 16 - 18 . In this embodiment, in order to minimize any opportunity for the universal fitting 136 , and, accordingly, the adapter 130 to disengage from the radiator orifice when air pressure is applied to the radiator system, the substantially axially extending portions 138 a of the steps 138 of the fitting 136 are preferably disposed at a slight negative angle a to normal or an annular plane disposed parallel the axis of fitting 136 . The angle α is preferably large enough to allow the desired step 138 of the fitting 136 to be properly advanced into and placed within the radiator orifice.
[0060] By way of example only, the steps 138 of the currently preferred embodiment of the radiator adapter fitting 136 are on the order of 1.5 inches in maximum diameter by 0.4 inches tall (39 mm maximum diameter by 11 mm tall), 1.5 inches maximum diameter by 0.4 inches tall (37 mm maximum diameter by 11 mm tall), 1.3 inches maximum diameter by 0.5 inches tall (34 mm maximum diameter by 13 mm tall), 1.1 inches maximum diameter by 0.6 inches tall (27 mm maximum diameter by 14 mm tall), and 0.8 inches maximum diameter by 0.5 inches tall (20 mm maximum diameter by 11 mm tall). In this embodiment, it has been determined that the preferred typical angle α is on the order of 6° from normal. It will be appreciated, however, that this angle α could vary from 4° to 8°, although other angles are envisioned. It will further be appreciated that the steps themselves may have an alternate shape. For example, the substantially axially extending 138 a wall of the universal fitting 136 may have a slight concavity, which likewise includes an angle α from normal.
[0061] Returning now to FIG. 1, to couple the adapter 30 to a source of pressurized gas, a pressure adapter 62 is removably disposed at the proximal end of the hollow shaft 42 . Significantly, a threaded segment 46 a is provided at the end of the hollow shaft 42 , which mates with a threaded portion of the pressure adapter 62 . In the embodiment illustrated, the threaded segment 46 a is contiguous with the externally threaded length 46 . It will be appreciated, however, that the pressure adapter 62 could alternately include an externally threaded portion which mates with an internally threaded segment at the proximal end of the hollow shaft bore 43 .
[0062] To allow the cooling system orifice adapter 30 to be coupled to most cooling system testers currently on the market for application of compressed gas and pressure testing, the pressure adapter may be in the form of a standardized radiator cup 62 . Significantly, the radiator cup 62 is removably coupled to the hollow shaft 42 by way of a coupler such as a brass nut 64 , which is welded to the lower surface of the radiator cup 62 . The internal threads within the primary bore 65 of the brass nut 64 are sized to receive the threaded segment 46 a at the end of the shaft 42 . In this way, the cup 62 may be readily removed from the shaft 42 , the adapter 30 disassembled, and any of the modular components replaced.
[0063] The bottom 63 of the radiator cup 62 includes a pressure passage, here, a center bore 68 . Thus, an axial passageway is formed in the universal adapter 30 by way of center bore 68 of the radiator cup 62 , the primary bore 65 of the brass nut 64 , and the center bore 43 of the hollow shaft 42 . Those of skill in the art will appreciate that as a cooling system tester is coupled to the radiator cup 62 , pressure may be applied to the cooling system through the passageway to test the cooling system.
[0064] Side elevational views of the shaft 142 of the embodiment of FIGS. 16 - 21 are shown in FIGS. 19 and 21. In order to provide a sealed pressure passage 168 from the cup 162 through the shaft center bore 143 , the shaft 142 includes a tapered end portion 145 with an annular channel 146 for receiving an annular seal, such as an O-ring. Once assembled, the annular seal is compressed between the shaft 142 annular channel 146 and the radiator cup 162 /brass nut 164 to seal gas passage between the components.
[0065] Further, in order to facilitate repair of the adapter 130 , the end of the shaft 142 displaying the enlarged head portion 144 may include structure for engagement by a tool. For example, the lowermost portion of the axial bore 143 of the shaft 142 may include recessed structure 143 a for engagement by an Allen wrench, as shown in FIG. 20. In this way, the operator could utilize an Allen wrench engaging the shaft opening 143 a and a wrench engaging the nut 164 disposed below the radiator cup 162 to readily disassemble the orifice adapter 130 for repair.
[0066] Another alternate embodiment of the invention is shown in FIG. 10. This adapter assembly 70 is designed to provide a mechanism by which pressure may be applied to the cooling system and pressure and temperature measured directly by gauges 74 , 76 coupled to the adapter assembly 70 . It will be appreciated by those of skill in the art, however, that a device constructed in accordance with teachings of the invention may include either, both or neither of the pressure and temperature gauges. In an arrangement that does not include a pressure gauge, however, the operator would typically utilize a pressure-testing device that would include a pressure gauge in monitoring cooling system pressures.
[0067] In this embodiment, the pressure adapter is in the form of a valve assembly 72 that facilitates direct application of pressure from a pressure source such as a hand pump, a compressor or shop air. An appropriate hand pump is disclosed, for example, in U.S. Pat. Nos. 4,775,302, 4,806,084, 4,954,054, 5,205,726, 5,217,354, or 5,362,214, which are hereby incorporated by reference. The adapter assembly 70 allows direct measurement of pressure and temperature within the cooling system by means of directly coupled pressure and temperature gauges 74 , 76 , respectively. The coupling system 32 of the adapter assembly 70 is identical to that of the first embodiment illustrated in FIG. 1, and, accordingly, the reference numerals utilized with regard to the coupling assembly in this embodiment are identical to those utilized in the first embodiment.
[0068] Referring now to FIG. 11, there is shown an exploded view of the valve assembly 72 of this embodiment. The valve assembly comprises a valve body 80 which includes an internally threaded primary bore 82 for coupling the valve assembly to the threaded segment 46 a at the proximal end of the threaded shaft 42 of the adapter assembly 70 . In order to provide connections to the pressure and temperature gauges 74 , 76 , and to facilitate the application of pressure from a pressure source, the valve body further includes bores 84 , 86 , and coupling pressure passage 88 (most clearly visible in FIG. 13). Bore 84 couples the threaded bore 82 to a threaded shaft 90 extending from the upper surface of the valve body 80 , the bore 84 providing an open channel between the threaded shaft 90 and the threaded bore 82 .
[0069] In order to couple the temperature gauge 76 to the valve body 80 , a knob 92 is provided which includes an internally threaded bore 94 for receiving the threaded shaft 90 . The knob 92 further includes a through opening 96 , which receives a temperature probe 77 and gauge 76 . To seal the temperature probe 77 in the valve assembly 72 , a stepped compression bushing 98 and O-ring 100 are provided. Preferably, the knob 92 and compression bushing 98 are formed of brass, while the O-ring 100 may be a standard rubber O-ring of an appropriate size. As may be seen in FIG. 11, the larger outer peripheral surface 98 a of the compression bushing is sized to be received in the threaded bore 94 of the knob 92 , while the smaller outer peripheral surface 98 b of the compression bushing 98 is sized to be received in an enlarged portion 84 a of the bore 84 . The compression bushing 98 further includes a bore 98 c extending axially therethrough.
[0070] In assembly, the temperature probe 77 is assembled into the through opening 96 and threaded bore 94 of the knob 92 , through the inner bore or internal passage 98 c of the compression bushing 98 . The temperature probe 77 further extends through the O-ring 100 as the temperature gauge 76 is assembled into the valve body 80 . The O-ring 100 about the temperature probe 77 is disposed within the enlarged portion 84 a of the bore 84 , and seats against the flange 84 b. As the knob 92 is threaded downward on the threaded shaft 90 , the compression bushing exerts a force on the O-ring 100 which compresses the O-ring to seal against the temperature probe 77 . It will thus be appreciated that the temperature probe 77 so coupled to the valve assembly 72 will effectively measure the temperature within the cooling system by way of the bore 84 and the center bore 43 of shaft 42 .
[0071] Returning now to the valve body 80 , as illustrated in FIGS. 11 - 13 , shuttle valve bore 86 extends substantially horizontally through valve body 80 , and is coupled to threaded bore 82 by means of the pressure passage, here, bore 88 (see FIG. 13). In order to apply pressure to the cooling system, shuttle valve 102 is received within pressure bore 86 . The shuttle valve comprises a central bore 104 that extends axially therethrough. The pressure gauge 74 may be coupled to axial bore 104 at end 102 a of the shuttle valve 102 by any appropriate means, so long as adequate sealing is provided. Shuttle valve 102 further comprises radial bore 106 that opens into axial bore 104 . It will thus be appreciated by those of skill in the art that when radial bore 106 is aligned with bore 88 of the valve body, axial bore 104 of the shuttle valve 102 is in communication with the cooling system by way of threaded bore 82 , and the center bore 43 of shaft 42 . In order to seal the shuttle valve 102 within bore 86 , O-rings 108 , 110 , and 112 are received in grooves 114 , 116 , and 118 along the circumferential surface of the shuttle valve 102 along either side of radial bore 106 and a closed circumferential surface 128 .
[0072] Travel of the shuttle valve 102 within bore 86 of the valve body 80 is limited by snap rings 120 , 122 received in grooves 124 , 126 along the circumferential surface of the shuttle valve 102 , although alternate travel limiting structure may be provided. In this way, the shuttle valve 102 may be shuttled between an open position and a closed position. The open position is defined by a configuration in which the radial bore 106 is aligned with bore 88 in valve body 80 such that the axial bore 104 of the shuttle valve 102 is in communication with bore 88 of the valve body 80 and, accordingly, center bore 43 of shaft 42 and ultimately with the cooling system. The closed position of the shuttle valve 102 is defined by the circumferential surface 128 of the shuttle valve being in alignment with bore 88 of the valve body 80 such that the axial bore 104 of the shuttle valve is not in communication with the cooling system. It will be appreciated that when the valve assembly 72 is in the open position, the pressure within the cooling system will register on the pressure gauge 74 .
[0073] In order to couple a source of compressed gas to the cooling system and to supply pressurized gas to test the cooling system, the shuttle valve 102 includes a plurality of barbs 130 along the outer circumferential surface at end 102 b. A hose 132 from a source of compressed gas, such as a hand-held pump or a compressor (not shown), may be coupled to the valve assembly 72 by way of end 102 b of the shuttle valve 102 .
[0074] In the alternate embodiment 72 a of the valve illustrated in FIG. 15, the bore 104 a does not extend the entire distance through the shuttle valve 102 c, but, rather, only to a distance beyond the radial bore 106 a. Other than this shorter length bore 106 a, the shuttle valve 102 c and the valve body 80 in this embodiment are identical to the embodiment illustrated in FIGS. 11 - 13 . As with the first embodiment, pressure source is in communication with the cooling system when radial bore 106 a is aligned with bore 88 of the valve body. In this embodiment, however, pressure is read from a pressure gauge (not illustrated) associated with the source of pressurized gas. For example, the pressure may be read directly from gauge associated with a hand pump, as shown in U.S. Pat. No. 5,362,214, coupled to the valve 72 a.
[0075] Those of skill in the art will appreciate that, in use, the operator must first ensure that the engine has sufficiently cooled to safely remove the radiator cap. The compression knob 54 of the cooling system orifice adapter 30 , 70 is rotated outward from the assembly (generally counterclockwise) until all compression has been relieved from the expandable rubber universal fitting 36 . The universal fitting 36 is then inserted into the filler neck of the radiator or expansion tank until a step 38 of the universal fitting 36 comes into contact with the interior wall of the filler neck. The compression knob 54 of the cooling system orifice adapter 30 , 70 is then rotated (generally clockwise) until the universal fitting 36 comes into firm contact with the interior wall of the filler neck. To test this connection, the operator may grip the cooling system orifice adapter 30 , 70 and carefully attempt to pull up on the adapter. The adapter 30 , 70 should hold firmly in the filler neck. If necessary, the universal fitting 36 should be further tightened by turning the compression knob 54 . It should be noted at this point that some late model vehicles are equipped with radiator tanks and expansion tanks made of plastic. Excessive overtightening of the universal fitting 36 could result in cracking of the radiator tank or expansion tank and, accordingly, caution should be used when tightening the same. Once the cooling system orifice adapter 30 , 70 is firmly connected to the radiator filler neck or expansion tank, the safety chain (not shown) may be coupled to the pressure plate 48 by way of the slots 52 and secured along the radiator neck as a safety precaution. In the case of the first embodiment, a radiator pressure tester of standard design may be connected to the cooling system orifice adapter 30 and the cooling system tested using a standard testing device.
[0076] Alternately, if the cooling system orifice adapter assembly 70 of the second embodiment is utilized, once coupled and sealed to the radiator neck or expansion tank, a source of compressed gas may be coupled to the valve assembly 72 by means of a tube 132 disposed along the barbs 130 at end 102 b of the shuttle valve 102 . Note that when the assembly 70 is first coupled to the radiator neck or expansion tank, the pressure and temperate gauges 74 , 76 are in place thereon. The shuttle valve 102 may then be advanced into the open position wherein the radial bore 106 is in alignment with bore 88 of the valve body 80 to open communication with the cooling system. Compressed gas is then introduced into the cooling system through the shuttle valve 102 until a desired pressure is attained, as may be read on the pressure gauge 74 .
[0077] The temperature may likewise be determined at this open position as registered on the temperature gauge 76 . Alternately, the temperature may be measured when the valve assembly 72 is in the closed position, that is, when the closed circumferential surface 128 of the shuttle valve 102 is in alignment with bore 88 of valve body 80 . Those of skill in the art will appreciate that in yet another embodiment, bore 84 may be eliminated such that the assembly measures only system pressure. During use, pressure may be added to the system as desired by way of the source of compressed gas.
[0078] Once all desired testing is complete, the valve assembly 72 may be moved into the closed position, that is, the shuttle valve 102 may be advanced to the left as illustrated in such FIGS. 10 and 11 that the closed circumferential surface 128 of the shuttle valve 102 is in alignment with the bore 88 of the valve body 80 . In releasing the pressurized gas from the cooling system, it is common for some of the hot fluid to be expelled through the testing device. Accordingly, in order to minimize the opportunity for injury as a result of such expulsion of hot liquid or hot gas, the hose, while still connected to the valve assembly, may be disconnected from the source of pressurized gas, and the hose moved to an overflow tank, or other receptacle. The valve assembly 72 may then be advanced to the open position, that is, the shuttle valve 102 may be shuttled to the right as illustrated in FIGS. 10 and 11, and the pressurized gas and/or fluid safely expelled into a designated receptacle without injury to the operator. Once all pressure is released, the compression knob 54 may be rotated to release compression on the expandable universal fitting 36 (generally counterclockwise), the security chain removed, and the radiator adapter 70 disconnected from the cooling system.
[0079] While this invention has been described with an emphasis upon preferred embodiments, variations of the preferred embodiments can be used and it is intended that the invention can be practiced otherwise and as specifically described herein. Accordingly, this invention includes all modifications encompassed within the spirit and scope of the invention as defined by the following.
[0080] All of the references cited herein, including patents, patent applications, and publications, are hereby incorporated in their entirety.
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A modular cooling system adapter for coupling to an orifice and applying pressure from a source of pressurized gas. The adapter includes a universal cooling orifice fitting for attaching the device to cooling system orifices of various sizes and configurations. The universal fitting preferably includes a plurality of steps having outer axially extending surfaces disposed at a slight negative angle to a plane parallel to the axial direction. The adapter may include a pressure adapter for coupling to a source of pressurized gas, such that the pressure adapter can be interchanged with other diagnostic tools including a valve assembly, a valve assembly incorporating a temperature probe and gauge and/or a pressure gauge. Additionally, the cooling system adapter is fully modular in that it allows quick disassembly for replacement of components and interchangeability of diagnostic tools.
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BACKGROUND OF THE INVENTION
The present invention relates to machine tools, and, more particularly, to machine tools for simultaneously machining a stack of plate-like workpieces.
In Herb et al. U.S. Pat. Nos. 4,270,253 and 4,462,147, there is described a machine tool for simultaneously mounting a stack of plate-like workpieces upon a base member, riveting the plate like workpieces thereto, drilling and riveting the workpieces to the base member, machining the group of workpieces by movement of the assembled stack relative to a machining station, and thereafter drilling the rivets so that the individual workpieces may be disassembled from the stack. This type of machine has proven highly satisfactory for machining of a multiplicity of relatively thin workpieces with similar contours. As described in the Herb et al. patents, it is generally necessary to replace the router bit or the like with different tools to enable the cutting of various contours which might be required in a particular workpiece.
In the machine illustrated in the aforementioned Herb et al. patents, the machine tool is one which has a series of stations between which the workpieces would be moved to effect the initial drilling, to effect riveting, to effect the machining, and to effect drilling of the rivets after the machining and any intermediate drilling steps have been performed. As will be appreciated, multiple work stations complicate the problems inherent in achieving precision operations on a workpiece and the control system for effecting such motion of the workpieces among the several work stations. Moreover, the machine tool of the aforementioned Herb et al. patents required a relatively long shutdown of the machine tool to effect the required manual exchange of router bits or other tools in the machining station, and frequently of the drill bits employed in the drilling station.
It is an object of the present invention to provide a novel machine tool for simultaneously drilling, riveting and machining a multiplicity of workpieces in which guidance of the workpieces relative to the machining station is simplified and in which tools may be automatically and rapidly exchanged.
It is also an object to provide such a machine tool in which but two work stations are required and in which the tools in the machining station may be exchanged rapidly.
Another object is to provide such a machine tool in which there is included a tool storage assembly in which a multiplicity of drill bits and router bits are stored. A tool changer mechanism rapidly selects desired tools in accordance with computer instructions and effects the exchange of tools in the machining station.
A further object is to provide such a machine tool which enables safe and rapid operation and exchange of tools and which may be readily controlled by computer program.
SUMMARY OF THE INVENTION
It has now been found that the foregoing and related objects may be readily attained in a machine for the simultaneous machining of a stack of plate-like workpieces. The machine has a frame with an overhead arm portion, a worktable below the arm portion, and a workpiece guidance assembly for moving a stack of workpieces on the worktable below the arm along a Y-axis parallel to the arm and an X-axis perpendicular thereto. A rotary tool drive assembly in the arm portion defines a first work station, and a riveting assembly in the arm portion defines a second work station which is spaced in the X-axis from the first work station.
Spaced in the Y-axis from the arm is a tool storage assembly having a support portion adapted to store a multiplicity of tools in a plurality of rows extending in the Y-axis and spaced apart along the X-axis. A tool changer assembly comprises a pair of carrier rails extending in the Y-axis from the tool storage assembly to adjacent the rotary tool drive assembly, and the rails are spaced in the X-axis to opposite sides of the tool drive assembly. Reciprocatable on the rails for transporting tools between the tool storage assembly and the rotary tool drive assembly is a pair of tool carriers, and they effect insertion into, and removal from, the tool assembly of tools. They are vertically movable relative to the rails to engage the tools stored in the tool storage means and to cooperate with the rotary tool drive assembly to effect insertion of tools thereinto and removal of tools therefrom. The tool carriers are also movable on the rails in the X-axis for movement between a first position in alignment with the rotary tool drive means and a second position spaced to the side thereof.
A computer control is operative to control the riveting and rotary tool drive assemblies and the tool changer and workpiece guidance assemblies.
Generally, a multiplicity of tool storage cartridges are provided on the support portion of the tool storage assembly, and the carriers are adapted to grip the tool storage cartridges to effect movement thereof. Each of the cartridges is adapted to store a tool having a shank extending upwardly therefrom for engagement in the rotary tool drive means, and the tool carriers are movable downwardly and upwardly relative to the rotary tool drive assembly and include releasable tool engaging means to effect tool engagement in the drive means and tool removal therefrom. Desirably, the cartridges releasably seat a stripper, and the rotary tool drive assembly includes a stripper support portion so that the vertical movement of the carrier relative to the tool drive assembly deposits or removes the stripper.
Preferably, two rows of tool cartridges are provided in the tool storage assembly, and there is included means for relative movement in the X-axis of the rows of cartridges and the tool carriers to effect vertical alignment thereof. The tool carriers are movable along the rails in the Y-axis, vertically thereon (the Z-axis) and transversely thereof in the Y-axis.
In the preferred embodiment, a closure on the frame provides a protective closure about the work stations and it is movable between a first protective position disposed about the rotary tool drive assembly and riveting assembly and a second open position in which the carriers may travel on the rails to and from the rotary drive assembly. The closure desirably includes a pair of doors pivoted on the frame, and means for opening and closing the doors.
In simultaneously machining a stack of plate-like workpieces, a stack of plate-like workpieces are initially assembled on a base plate and clamped thereto. One of the tool carriers is moved vertically relative to its rail to engage a drill stored on the support portion of the tool storage means and is then moved on its rail to a position adjacent the arm portion. It is then moved on the rail in the X-axis into alignment with the rotary tool drive means, and thereafter moved relative to the rotary tool drive means to engage the drill therein. The tool carrier is then moved on the rail in the X-axis to a position displaced to one side of the arm.
At this point the assembled stack is moved relative to the rotary drive assembly to drill a multiplicity of holes therein, after which it is moved relative to the riveting station to engage rivets in the holes.
The tool carrier is moved on the rail to remove the drill from the rotary drive assembly. A second tool carrier, which has been moved on the other of the rails to engage a milling tool, is moved on the other rail to insert the milling tool in the rotary drive assembly. The assembled stack is now moved relative to the rotary drive station to machine desired patterns in the workpieces. The tool carrier on the other rail is moved to remove the drill.
After all milling operations have been completed, a drill is again engaged in one of the tool carriers, and the carrier is advanced and moved on its rail to insert the drill in the rotary drive assembly. The assembled stack is then moved relative to the first work station and the rivets are drilled to remove them and thereby permit disassembly of the workpieces of the stack from the base plate.
Generally, the machining method will require several steps of replacing different milling tools in the tool carriers and thereby in the rotary drive assembly to effect machining of various patterns in the workpieces of the stack. Preferably, two rows of tool cartridges are provided in the tool storage assembly and they extend parallel to the rails, and the support portion is moved relative to the rails in the X-axis to effect vertical alignment of the rows of cartridges and the tool carriers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a factory installation employing a machine tool embodying the present invention with a portion of the enclosure broken away to reveal internal construction;
FIG. 2 is a side elevational view of the tool storage assembly and of the tool changer assembly with portions of the tool storage assembly removed or broken away for illustration of internal structure;
FIG. 3 is a rear elevational view of the tool storage assembly with the wall panels removed to show internal construction;
FIG. 4 is a side elevational view of a tool carrier supporting a cartridge;
FIG. 5 is a perspective view of the tool carrier seen in FIG. 4 with the cartridge removed;
FIG. 6 is a perspective view of the cartridge of FIG. 4;
FIG. 7 is a perspective view of the tool support portion of the tool storage assembly with tool cartridges supported thereon;
FIG. 8 is a schematic view showing the several motions and positions of the tool carrier;
FIG. 9 is a schematic view showing the relationship between the tool storage assembly, the rails and tool carriers of the tool changer assembly, and the rotary drive assembly of the machine tool;
FIG. 10 is a diagrammatic view showing the pivotal motion of the doors of the safety enclosure about the riveting and rotary drive tool stations;
FIG. 11 is a diagrammatic view of the rotary drive tool assembly;
FIG. 12 is a diagrammatic view of the riveting assembly; and
FIGS. 13A-13E are a series of partially schematic views showing the several steps in the machining method provided by the machine tools of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, therein illustrated is a factory installation of a machine tool embodying the present invention. The machine tool has a C-shaped frame generally designated by the numeral 10 with a bed 12 and an overhead arm 14 extending over the bed 12 and providing a throat therebetween. Extending perpendicularly to either side of the bed 12 are a pair of worktables generally designated by the numeral 16, 18 which are inclined to the horizontal and which are slidably supported for movement in the Y-axis upon the supports 20. Each worktable 16, 18 has a multiplicity of rollers 22 upon which stacks of workpieces (not shown) may be readily moved.
An X-Y guidance system generally designated by the numeral 24 is provided on the bed 12 to the rear of the worktables 16, 18, and it has a series of clamps 26 spaced therealong adapted to grip the workpiece assembly (not shown) for movement in the X-Y axes on the worktables 16, 18 relative to the overhead arm 14. The positioning of the worktables 16, 18 in the Y-axis may also be controlled by the guidance system 24.
At the outer end of the arm 14 and exposed by the cutaway section are a rotary tool drive assembly generally designated by the numeral 28 and a riveting assembly generally designated by the numeral 30.
Spaced from the overhead arm 14 is a tool storage assembly generally designated by the numeral 32 which has a pivoted side closure 34, and a computer control console 36 is spaced to one side thereof.
Electrical and computer controls for the machine tool are located in the cabinet 38. The pneumatic controls and lubrication controls are located in the cabinet 40, and the controls for the hydraulic system are located in the cabinet 42.
The coolant system is located in the cabinet 44 and coolant flows through conduits (not shown) to the overhead arm 14 to discharge about the rotary tool drive assembly 28 to facilitate the machining operation, and the coolant is collected in drain pans 46 below the worktables 16, 18 from which it flows into the sump 48, and it is filtered and recycled.
Four light beam sensor posts 50 are spaced about the work area and define a protected area designated by the beams 51, and a person entering the protected area will automatically terminate machine operation.
Extending forwardly from the tool storage assembly 32 are a pair of rails 52 of the tool changer assembly generally designated by the numeral 54, and tool carriers generally designated by the numeral 56 move between the storage assembly 32 and the rotary tool drive assembly 28 on the rails 52.
Turning next to FIGS. 2 and 3, therein is illustrated the tool storage assembly 32 which has a sturdy frame 58 in which the storage platform 60 is slidably supported on rails 62 for movement transversely of the frame 58 by a pneumatic drive mechanism only fragmentarily illustrated by the numeral 64. Seated on the surface of the storage platform 60 are a series of tool cartridges generally designated by the numeral 66 which are arranged in rows. The storage assembly 32 also includes a series of panels 68 mounted on the frame 58 and providing walls for the enclosure as well as the movable side closure 34 (seen in FIG. 1).
As seen in FIG. 3, two rows of tool cartridges 66 are provided on the movable storage platform 60 which can move from side to side on the transverse rail 62 of the frame 58 in order to be in vertical alignment below either one of the rails 52 of the tool changer assembly 54. Stops 70 on the frame 58 limit the transverse movement provided by the pneumatic cylinder 64.
Turning in detail to the tool changer assembly 54, the pair of support rails 52 are mounted on the upper portion of the frame 58 and extend towards the arm 14 above the bed 12, and they also extend rearwardly of the frame 58. The tool carriers 56 are supported on gripper carriages generally designated by the numeral 72 which are reciprocatable along the rails 52 by the servodrivers 74 which are powered by the motors 76.
The carriages 72 have mounted thereon cross slides 78 which provide movement of the tool carriers 56 transversely of the rails 52 in response to action of pneumatic cylinders (not shown), and the tool carriers 56 are vertically movable on the vertical rails 80 in response to action of pneumatic cylinders (not shown). The movement of the carriages 72 and the carriers 56 will be described more fully hereinafter.
Turning now to the carriers 56 seen in FIGS. 4 and 5, these include a mounting portion 82 slidably supported on the vertical rails 80 in the cross slide 78 and the depending legs 84 which have opposed clamping jaws 86 at their lower ends. The release spring 88 biases the legs 84 apart, and the cam discs 90 are driven by a double acting pneumatic cylinder and rack drive (not shown) to push the clamping jaws 86 together to effect clamping of a tool cartridge 66 therebetween.
An adjustable stop 92 enables adjustment of the up/down position, and sensors 94 enable determination of the up/down positions of the carrier 56. Sensors 96 enable determination of the open/closed position of the jaws 86. The sensor 98 enables determination that a cartridge 66 is clamped in the jaws 86.
Turning now to FIG. 6 for the detail of the cartridge 66, it has a body 100 with a top support 102 and a bottom tool support 104 extending forwardly therefrom. Extending generally vertically along the rear surface of the body 100 is a plate 106 providing side portions for engagement in the jaws 86. Seated in an aperture in the top tool support 102 is a drilling/milling cutter 108 with an expansion chuck 110 for seating in the rotary tool drive assembly 28. Seated between the arms 110 of the bottom tool support 104 is a stripper 112 which abuts the alignment pins 114. A sensor 116 is also provided.
As seen in FIG. 7, the storage platform 60 is shown in greater detail as configured to provide stations for two rows of six cartridges 66 each aligned in the Y axis direction (aid paired in the X-axis direction). Each cartridge position includes damping rings 118 upon which the cartridge 66 seats, an indexing pin 120 for locating the cartridge 66, and support buffers 122. As can be seen, the cartridge 66 are supported with their bottom supports 104 inclined. The storage platform 60 may be slid outwardly through the side closure 34 of the tool storage assembly 32 to facilitate exchange of cartridges 66 by disengaging the support platform 60 from the stops 70 by means of the release lever 124.
The relative motion of the tool carrier 56 on its carriage 72 and of the storage platform 60 is diagrammatically illustrated in FIG. 8. The position RP represents a reference position only for the right hand assembly as seen from the work station. In position 1 (P1), the tool carrier 56 has been moved in the X-axis to its leftward position in alignment with the right row of cartridges (not shown), and it is in its lowered position on the vertical rails 80 in the Z-axis to engage or deposit a cartridge 66 on the storage platform 60. However, as is also shown, the platform 60 is also movable in the X-axis to align the other row of cartridges therewith.
Position 2 (P2) is the bypass position of the carrier 56 on the rails 52 (not shown) wherein this carrier 56 is moved in the X-axis to the right hand position on the cross slide 78 so that it is spaced to the side of the rotary tool drive assembly 28.
Position 3-4 (P3-P4) is the changing position where it has been moved along the X-axis (W-direction) into alignment with the rotary tool drive assembly, but in P-3 it is spaced outwardly therefrom and P4 represents the tool change position in which it has been moved in the Y-axis into axial alignment with the rotary tool drive assembly 28 for deposit of the tools in the cartridge 66 which it is carrying of for removal of the tools therefrom.
The movement of the carriage 72 is diagrammatically illustrated in FIG. 9 wherein the two carriages 72 are shown as moved outwardly of the tool storage assembly 32 on their rails 52 to a position adjacent but spaced from the overhead arm 14. Neither is aligned with the rotary tool drive assembly 28 and each is movable on its rail in the X-axis away from the other to a non-interferring position and to a position towards the other into alignment with the assembly 20, and it is movable further in the Y-axis along the rails 52 to be in vertical alignment with the tool assembly 28.
In FIG. 10, the operation of the two closure elements 126, 128 of the protective closure is illustrated. The closure elements 126, 128 are generally L-shaped to provide a long leg which is pivotably mounted on the side of the arm 14 and short legs which are disposed outwardly of the rotary tool drive assembly 28 and riveting assembly 30. The closure elements 126, 128 are pivoted from the safety or closed position shown in full line to the full open position shown in phantom line by pneumatic drive cylinders (not shown) to permit exchange of tools in the rotary drive assembly 28.
Turning next to FIG. 11, the principal elements of the rotary tool drive assembly 28 are illustrated. The slide carriage 130 which contains the rotary drive spindle and tool clamping mechanism (not shown) is vertically movable on the rotary spindle 132 by the belt drive 134 of the drive motor 136. The presser foot 138 is seated in the carrier or support 140 which is movable vertically by the piston 142 which is driven by the hydraulic drive 144. The foot 138 will firmly clamp the workpiece stack (not shown) about the rotary tool bit 146.
In FIG. 12, the principal elements of the riveting assembly 30 are illustrated. In the bed 12 of the frame 10 is the lower rivet tooling comprising the punch guide 148 in which is disposed the lower rivet pin 150 which is seated on the lower rivet block 152. In the arm 14 is the upper rivet tooling which include the head 154 having a central passage 156 into which rivets (not shown) are delivered by the supply tube 158. The upper rivet pin 160 bears against the upper rivet block 162 and is reciprocatable thereby in the passage 156 by a hydraulic drive (not shown). The presser foot 164 is movable in the housing 166 by hydraulic fluid to firmly clamp the workpieces during the riveting operation.
The operations performed by the machine on a workpiece are diagrammatically illustrated in FIGS. 13A-13E. In FIG. 13A, the stack of workpieces 168 have been placed upon a base plate 170 and clamped together in the machine guidance system (not shown). A drill bit 172 in the rotary drive assembly (not shown) drills a series of holes 173 through the stack of workpieces 168 and into the base plate 170 at various points about the workpiece stack.
In FIG. 13B, rivets 166 are inserted into the holes and upset by the riveting assembly 30 to secure the stack of workpieces 160 firmly in assembly upon the base plate 162.
In FIGS. 13C and 13D, a milling cutter 176 in the rotary tool drive assembly (not shown) is milling a cutout 178 the entire stack of workpieces 168 and also penetrates into the base plate 170 a distance X.
In FIG. 13E, the rivets 174 have been drilled out of the stack of workpieces 168 so that they can be disassembled from each other and from the base plate 170.
In operation of the apparatus of the present invention, cartridges 66 containing the various drill bits, reaming bits and other rotary tools to be used in machining a particular group of workpieces is selected. These cartridges are then placed in a predetermined order in rows on the platform 60 of the tool storage assembly 32. The information concerning the tools and their orientation within the rows on the storage platform 60 is introduced into the computer memory through the computer console 36.
A stack of sheet metal workpieces 168 is assembled upon a sheet metal base plate 70 and clamped thereon. The clamped stack is moved on the worktables 16, 18 into engagement with the guidance system 24 and clamped therein.
Information concerning the contours and tools to be used for cutting the various contours in the stack of workpieces is entered into the computer memory. Also entered is information concerning the placement of holes in which rivets are to be secured to secure the stack of metal workpieces to the base plate as the metal is being cut thereabout.
The information entered into the computer is then processed by the computer program to select a cartridge 66 containing the appropriate size drill bit for drilling the holes in which the rivets are to be seated, and a tool carrier 56 is moved on its carriage 72 into vertical alignment therewith. The tool carrier 56 is then moved downwardly on the vertical rails 80 to engage between its jaws 86 the plate 106 on the cartridge 66. The carrier 56 is moved upwardly and then forwardly along its rail 52 to a position adjacent the overhead arm 14, and the carrier 56 moves sideways on the cross slide 78 into Y-axis alignment with the rotary tool drive assembly 28. The closure elements 126, 128 are opened and the carrier 50 is moved forwardly into vertical axial alignment with the rotary drive assembly 28 which has its slide carrier 130 in an upper position. The slide carrier 130 is moved downwardly causing the arbor of the drill bit to move thereinto and to be engaged therewithin, and the stripper plate in the carrier 56 is engaged in the bed 12. The carrier 56 is moved outwardly in the Y-axis leaving the tools in the rotary drive assembly 28. The closure elements 126, 128 are moved into their closed position, and the carrier 56 with the now empty cartridge 66 moves on its cross slide 78 into a position to one side.
In the meantime, the computer control has caused another tool carrier 56 to pick up a cartridge 66 containing the next tool required for the machining program, and the carriage 66 has moved the tool carrier 56 containing the second tool to a standby position to the opposite side of the overhead arm 14.
The rotary tool drive assembly 28 is actuated by the computer and a series of holes are drilled in the clamped and assembled stack, with the rotary tool drive assembly 28 being elevated after each drilling operation to permit the stack to be moved in the X and Y axes by the guidance assembly 24.
After all of the holes have been drilled, the guidance assembly 24 now moves the assembled stack of workpieces relative to the riveting assembly 30 wherein rivets are inserted into each of the drilled holes and deformed to firmly secure the stack of workpieces to the base plate against relative movement.
When this operation is completed, the closure elements 118, 120 open, the first carrier 56 moves into alignment with the rotary tool drive assembly 28 to collect the drill bit and its stripper plate, and thereafter it moves outwardly of the rotary tool drive assembly area and into a position spaced from the other tool carrier 56. The second tool carrier 56 containing the next tool is now moved sideways on its cross slide 78 and then inwardly into vertical alignment with the rotary tool drive assembly 28 so that its tooling is now deposited therein, after which the carrier 56 is moved outwardly and into a standby position.
The closure elements 126, 128 are pivoted into the closed position and the machining operation utilizing this tool is conducted. At the same time, the carrier 56 containing the cartridge 66 with the drill bit is moved back to the tool storage assembly 32 and the cartridge deposited in its original position. This carrier 56 may now be moved into a position to pick up the next tool required, and it is moved into a standby position adjacent the overhead arm 14.
This process continues until all of the desired drilling and milling or routing operations have been completed.
The final operation involves the insertion of a drill bit of the original diameter (or slightly larger if so desired) into the rotary tool drive assembly 28 and the drilling of the rivets from the stack which had been used to maintain the workpieces in assembly on the base plate during the various operations. The stack of workpieces and the base plate are then moved outwardly on the worktables 16, 18 to a discharge position and a new stack is ready to be positioned in the machine.
It will be appreciated that the machine of the present invention enables rapid, numerically controlled drilling and routing of aluminum and other sheet metal stock. The riveted stack is readily moved relative to the principal workstation with a degree of accuracy because of the firm engagement of the workpieces, and the parts being produced therefrom are secured to the base plate.
Tools may be rapidly substituted in the rotary tool drive assembly by the pair of tool carriers. One tool carrier available to extract tools from the rotary tool drive assembly while the other carrier is returning to the storage assembly with the tool from the previous operation and obtaining the tooling for the next operation. The remote tool storage assembly and tool changer assembly enables great versatility in tool selection and use and it permits substitution of special tools in the tool storage assembly while the machining is in process.
The motion of the stack of workpieces and of the carriers is precisely controlled by the guidance system for the workpieces, and by the hydraulic, pneumatic and electric drive systems utilized for the tool changer assembly.
Thus, it can be seen from the foregoing detailed description and drawings that the machine tool of the present invention enables the drilling, riveting and machining a multiplicity of stacked workpieces with automatic and rapid exchange of tools in the rotary tool drive assembly. Only two work stations are required to simplify the programming of the X-Y guidance system, and the tools may be rapidly exchanged with the next tool waiting in a position to be rapidly inserted into the mechanism after the first tool is removed.
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A machine for the simultaneous maching of a stack of plate-like workpieces has a frame with an overhead arm portion, a worktable below the arm portion, and a workpiece guidance assembly for moving the workpiece stack on the worktable. A rotary tool drive assembly and a riveting assembly are provided in the arm portion, and a tool storage assembly is spaced from the arm. A tool changer assembly has a pair of carrier rails extending from the tool storage assembly to adjacent the rotary tool drive assembly, and they are spaced to opposite sides thereof. A pair of tool carriers are reciprocatable on the rails for transporting tools between the tool storage assembly and the rotary tool drive assembly to effect insertion into and removal from said tool assembly of such tools. The carriers are vertically and horizontally movable relative to the rails to engage tools stored in the tool storage means and to cooperate with the rotary tool drive assembly to effect insertion of tools thereinto and removal of tools therefrom. A computer is operative to control the riveting and rotary tool drive assemblies and the tool changer and workpiece guidance assemblies.
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FIELD OF THE INVENTION
[0001] The present invention relates to the use of solar energy to desalinate sea water.
BACKGROUND OF THE INVENTION
[0002] Global fresh water shortages are affecting not only people's health, but regional economies and politics. Nearly two million children die annually from lack of access to fresh drinking water and it is estimated that by 2025 almost two billion people will live in areas where water is scarce. Although the Earth's seawater is abundant, freshwater represents less than 3% of the Earth's total water. Several processes are available to filter seawater in order to obtain freshwater. In one such process salt water is forced through a semi-permeable filter (e.g., a polymer membrane), which results in freshwater exiting the filter, leaving behind the salt and impurities. This process is called reverse osmosis, and it requires significant energy. Reverse osmosis is used by large-scale desalination facilities around the world that rely on nuclear power to provide the energy.
[0003] Solar energy is usually abundant in climates that are very dry and lack water. Therefore, using the sun's energy to effect desalination would be very efficient.
[0004] Most materials expand when they are heated and contract when they are cooled. However, there are materials that do the opposite and contract in certain directions as they heated and expand when they are cooled. These are called negative thermal expansion materials and include such materials as graphene, beta-quarts and some zeolites. During daylight the sun can heat most materials causing them to expand and at night when the temperatures are lower they contract. The opposite occurs with negative thermal expansion materials. With the heating during the day and the cooling at night the types of materials will continuously cycle between expanding and contracting. Expanding or contracting materials can also be cooled by a variety of methods for example artificial shade provided by canopies or cooling fluids. When materials are cooled artificially they increase the rate of the expanding or contracting cycle that now does not have to depend on only the natural cooling during nighttime.
[0005] When two metals having dissimilar thermal expansion coefficients are bound together, they result in a bi-metal strip that bends in one direction with heat and straightens or bends in the other direction as it cools. The bending of strips of brass and steel are used to measure temperature in thermostats.
SUMMARY OF THE INVENTION
[0006] The present invention relates to the use of solar energy to heat bi-metals and other materials with high absolute or differential heat expansion coefficients that are coupled to pistons or impellers that in turn are used to force sea water through semipermeable (filtration) membranes to achieve desalinization.
[0007] In accordance with the invention a piston or impeller is moved by a mechanical coupling connected to a material that expands (or contracts) when exposed to radiant heat from sunlight. Various materials, metals and alloys have different expansion rates depending on their internal properties. With this invention solar energy is used to heat a conventional material structure resulting in an expansion of the structure. The expanding structure results in movement. This movement can be coupled to one or more pistons (or impellers) that are used to pump fresh or salt water as well as pressurize a container of saltwater or contaminated water in order to push the saltwater or contaminated water through a semipermeable membrane to desalinate or clean it.
[0008] In the evening the metal cools and the expansion of the metal is replaced with a contraction. During this period the desalination can be stopped. However, in an alternative design the contracting metal also pushes salt water through a second membrane.
[0009] The invention can be used for desalination of saltwater as well as filtration of any type of fluid. In addition the same process of moving pistons or impellers by thermal expansion of metals or other materials by using solar energy can be used to pump saltwater and fresh water to and from the desalination plant. Furthermore, the use of this process can be the basis of pumps used to move any type of liquid or gas. For example, oil refineries may use solar pumps for moving crude oil or refined petroleum products. In addition the mechanical movement necessary to power a generator that procures electricity can be provided by the expansion and contraction of materials with high thermal expansion rates and sunlight. In order to produce sufficient movement the actual motion may need to be amplified, e.g., with a gear chain.
[0010] When the present invention is used with single structure metals, the expansion and contraction is along the axis of the metal. However, an additional feature of the invention is to use bimetals or a series of metals that have different coefficients of thermal expansion. If such metals are bonded together, when they expand at different rates, the structure tends to bend away from the axis. This bending is an indication of temperature when bi-metals are used in a thermostat.
[0011] The deformation of materials by positive or negative thermal expansion along the axis of the metal or by differential thermal expansion at an angle provides a mechanical force. This force can be connected to pistons or impellers and used to ultimately pump fresh or salt water through pipes and/or force the fluid through a filter.
[0012] The metals will deform during the day when sunlight is abundant and at night the metals will cool and returned to their original shape. The movement of pistons is coupled to the (movement) expansion of the metals during heating and (movement) contraction of the metals during cooling. This provides a continuous cycle of pumping water through filters.
[0013] Cooling is required to contract materials that expand when heated (or in special cases expand materials that enlarge during cooling). The cooling can be provided by lack of sunlight at night or an artificial shade provided by a movable canopy. In addition cooling can be provided by fluids that are pumped on to or around the heated elements. For example, heated, expanded bimetal discs can be cooled by fluid, which will result in the contraction of the bimetal discs at a faster rate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing and other objects and advantage of the present invention will become more readily apparent upon reference to the following specification and annexed drawings in which:
[0015] FIG. 1A is an elevation view of a solar desalinization system according to the present invention with a piston against a container wall and bimetal discs contracted in the cold position, FIG. 1B is a view with the piston pushed all the way into the chamber next to a filter and with the bimetal discs expanded in the heated position, and FIG. 1C is a view similar to that of FIG. 1A , but with the bimetal discs replaced with an axially expandable thermal expansion material structure;
[0016] FIG. 2 is an elevation view of an alternative arrangement of the solar desalinization system with a second filter so that desalinization occurs both when the piston is pushed all the way in and when it is withdrawn;
[0017] FIG. 3 is an elevation view of a solar pump according to the present invention, which has the structure of FIG. 1 , but without the filter so that it operates simply as a pump and not a desalinization system;
[0018] FIG. 4 is an elevation view of a solar pump as shown in FIG. 3 , but with a channel to divert fluid from chamber to cool the expanded bimetal discs;
[0019] FIG. 5 is a plan view of a solar pump wherein a single set of bimetallic discs drives a plurality of pumps;
[0020] FIG. 6 is a perspective view showing an arrangement in which the linear movement of heated and cooled bi-metallic discs is converted into rotary movement to drive an impeller;
[0021] FIG. 7 is a perspective view showing an arrangement in which rotary motion as a result of the linear movement generates electricity;
[0022] FIG. 8 illustrates an alternative arrangement for the solar desalinization system of FIG. 1 wherein the filter is in the form of a semipermeable cylinder; and
[0023] FIG. 9 shows an arrangement in which linear motion of the bi-metallic structure results in the generation of electricity.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIG. 1 shows an example of a bimetal configuration that is constructed from a series of bimetal discs 16 , 18 , 20 , and 21 . The bimetal discs are made of two metals 4 and 5 that have substantially different thermal expansion rates. Although the diagram illustrates bimetal discs, any shape that maximizes movement in the linear or rotational direction can be used in the bimetal configuration. As an alternative, a single metal bar with a high coefficient of expansion can be used in place of the discs, but it would likely have a much smaller and slower displacement. A metallic structure thermal expansion material 14 ′ is shown in FIG. 1C substituted for the bi-metallic discs. The tapered nature of the structure caused the pointed end to move more in the axial direction than would a straight bar.
[0025] The bimetal discs are connected to each other and to a piston 12 by shaft 14 . When valve 25 is open fluid can enter a portion 30 of the interior of chamber 3 through pipe 10 . After the portion 30 of the chamber is filled with fluid, valve 25 can be closed and the bimetal discs 16 , 18 , 20 , and 21 , can be exposed to sunlight and expand, thereby pushing shaft 14 and piston 12 to the left in FIG. 1A . As piston 12 is moving it is pushing fluid through a semipermeable membrane 6 . As this occurs, valve 24 must be open in order to allow filtered fluid to exit through pipe 9 . The expansion of the discs and movement of the piston are relatively slow, but they can have great force. If the structures in FIG. 1 are relatively large, even with the slow movement of the piston, a large quantity of salt water can be desalinated. FIG. 1B shows the discs in their fully expanded condition and with the piston 12 pushed against the membrane 6 .
[0026] FIG. 1 shows one possible configuration with the semipermeable membrane 6 being removable from chamber 3 . As a result, semi permeable membrane 6 can be replaced with a new membrane when required. However any possible configuration of having a piston or pistons pushed by bi-metals can be implemented. For example as shown in FIG. 8 , bimetal structures can push a piston 12 ′ into a cylindrical permeable membrane 6 ″ where the entire cylinder is made of semipermeable membrane. The cylindrical semi permeable membrane can then be located in an appropriate housing or chamber 3 ′. With this arrangement a large surface of the membrane is exposed and used in the desalinization process. In particular, salt water can enter the interior of the cylinder 6 ″ through pipe 10 ″ as piston 12 ″ is withdrawn to the right in FIG. 8 . After being fully retracted, a valve on pipe 10 ″ is closed and the piston is pushed into the cylinder due to some form of thermal expansion. As this occurs, the salt water is forced through the cylinder in all directions. The fresh or filter water exits the housing 3 ′ through pipe 9 ″.
[0027] Although FIG. 1 shows a pump using at least one piston to pump fluid or gas, the thermal expansion and movement of shaft 14 can also be coupled to an impeller type of mechanism (or any mechanism that is designed to move fluids or gases and requires a mechanical force) as shown in FIG. 6 , and is not limited to moving fluids or gases by pistons. For the impeller to operate a mechanism is required that converts linear movement into rotary movement. FIG. 6 shows such an arrangement using a rack-and-pinion mechanism to generate the rotary motion. As the shaft 14 moves, the teeth 15 on the rack move. This movement causes pinion 17 to turn, which results in the turning of a shaft 19 that drives impeller 23 . The rotating blades of the impeller 23 can provide the fluid to the portion 30 of the chamber 3 shown in FIG. 1 . The force of this fluid can cause it to move against and through the membrane 6 in the chamber 3 , even without the aid of the moving piston 12 .
[0028] FIG. 1B shows the bimetal discs 16 , 18 , 20 , and 21 , expanded by heat from sunlight so that shaft 14 and piston 12 are pushed all the way into container 3 . This results in the fluid contents being forced through the semi permeable membrane 6 and filtered fluid passing out of open valve 24 and pipe 9 . As daylight ends the discs begin to cool and contract. At that point the desalinization could stop for the day. However, if chamber 3 is provided with another membrane 6 ′ as shown in FIG. 2 , the contraction of the discs and movement of the piston back to its original position could force fluid through it into a portion 90 within chamber 3 . This could create fresh water that could enter tube 9 ′ if valve 24 ′ is opened and thus continue the process at night. In such a case the fluid enters a region 60 which is behind the piston. Note that the portion 30 of the chamber has been reduced to the area between the front of the piston and the membrane 6 .
[0029] With the arrangement in FIG. 2 , a valve 25 ′ is opened as the piston moves to the left in FIG. 2 to fill the portion 60 with salt water. As the piston moves back, that valve is closed and valve 24 ′ is opened to remove the fresh water from portion 90 . At the same time valve 25 is opened to allow salt water to enter the portion 30 at the front of the piston as it moves to the right. The valve 24 would then be closed.
[0030] It should be noted that with this arrangement the shaft 14 passes through the membrane 6 ′. This needs to occur through a water tight passage 32 in order to prevent the mixing of the salt and fresh water.
[0031] FIG. 3 shows a bimetal configuration of a pump that can be used to pump fluids or gases. Note that as compared to FIGS. 1 and 2 , the membrane 6 has been removed. In FIG. 3 , chamber 3 is filled with a fluid or a gas entering through pipe 10 when valve 25 is open and valve 24 is closed. The fluid or gas can now be pushed out of the chamber 3 when valve 25 is closed through open valve 24 and pipe 9 , when the bimetal discs are exposed to sunlight. The expansion of the bimetal discs and movement of shaft 14 and piston 12 will push out the gas or fluid from the portion 30 of the chamber 3 through valve 24 into pipe 9 .
[0032] When all the fluids or gas are pushed out of portion 30 in container 3 , the bimetal discs can be cooled and shaft 14 and piston 12 can then pull gases or fluids from pipe 10 when valve 25 is open and valve 24 is closed, thus refilling the portion 30 with fluid or gas. This repetitive cycle results in a pumping action for fluids and gases. Valve 25 is closed when portion 30 is filled and valve 24 can be opened and the bimetal disc can be exposed to heat to pump out the contents.
[0033] FIG. 3 shows a pump using a single piston to pump fluid or gas. However, a single set discs driving shaft 14 can be used to power a series of parallel pumps 3 A, 3 B, and 3 C as shown in FIG. 5 . In addition the multiple pumps can have a series configuration.
[0034] The pump described in FIG. 3 (non-filtering) can be used to pump fluid (saltwater) to another filtering pump such as that shown in FIG. 3 . Also, the pump can be sued to distribute fresh or filtered water from chamber 3 to where it is needed.
[0035] In addition to providing fluid (that requires filtration) to the filtering pump, a pump described and shown in FIG. 3 can be used to provide cooling fluid to a filtering pump that will cool the expanded elements and bring them to the contracted position.
[0036] The filtering pump in FIG. 2 has the bimetals expanded and the fluids pushed out of portion 30 in container 3 . This means that the bimetal discs need to be cooled in order to retract shaft 14 and piston 12 . The cooling can be done by decreasing the sunlight at night or artificially shading the bimetal discs or using fluid to cool the bimetal discs. Fluid used to cool the bimetal discs can be provided by the pump described and shown in FIG. 3 .
[0037] FIG. 4 illustrates such a cooling mechanism as an integral part of the pump. Piston 12 is shown against the wall of container 3 and in position to push the fluid or gas in portion 30 out of container 3 when the bimetal discs are expanded by exposure to sunlight. As the bimetal discs are approaching maximum expansion, valve 55 can be open so fluid can enter pipe 50 and pass into chamber 65 . Chamber 65 can not only act as a cooling fluid provider for the discs, but also as a movable shade for the discs. Thus the fluid released from chamber 65 and the shade it provides can cool down the bimetal discs. However, fluid can be provided only while the piston is still moving in the heat expansion direction. As contraction begins as a result of the fluid and shade from chamber 65 , shaft 14 and piston 12 will move towards the bimetal discs and as a result piston 12 will stop providing fluid to chamber 65 and will start drawing fluid or gas from pipe 10 when valve 25 is open and valves 24 and 55 are closed. If the shaft 14 moves fast enough that the piston is near the end of its travel away from the discs during only a part of the day and the contraction is due to the fluid and shade from chamber 65 , as opposed to sunset, the pumping cycle can then begin again by exposing the bimetal discs to the sun again so they expand. Thus a pumping cycle that is more frequent than the sun cycle is possible.
[0038] Although FIGS. 1A, 1B, 2, 3, 4 and 5 , illustrate expansion due to bimetals, any type of material that has a high thermal expansion rate, whether due to heating or cooling, can be used to power shaft 14 and piston 12 in order to filter or pump fluids and gases. See for example FIG. 1C .
[0039] The amount of sunlight (and heat) provided to expanding materials can be amplified by using reflective surfaces, e.g., reflector 28 in FIG. 4 , that focus and concentrate sunlight on materials (e.g., the discs) that expand when heated. Parabolic reflective surfaces on structure 28 focus sunlight on the discs to maximize the heat transfer that expands the discs. If structure 28 is made movable, it can move the focal point on the discs during part of the cycle and can move the focused beam away from the discs during a cooling cycle, which would result in efficiently cycling of the expansion and contraction of the materials that provide movement to the solar pump.
[0040] Electrical generators can produce electricity by converting mechanical energy into electrical energy. The source of mechanical energy for an electric generator can be the motion of a shaft or connecting rod that is connected to a thermal expansive structure or bimetal structure designed to expand when heated by sunlight as shown in FIG. 7 . The movement resulting from expansion ultimately moves the shaft or connecting rod 14 that provides the mechanical energy required by electric generators to produce electricity. However, in order to generate electricity, typically a faster speed is required than the expansion speed of the present invention. Also, typically a rotary motion is needed, but linear generators as shown in FIG. 9 can also be used.
[0041] As shown in FIG. 7 a higher speed rotary motion is accomplished by a rack-and-pinion arrangement 35 , which is similar to that in FIG. 6 . However, the pinion 17 ′ in this arrangement has a step up gear ratio so that the slow movement of the shaft 14 is converted into a much faster rotation of shaft 19 ′. The shaft 19 ′ drives an electrical generator 37 that produces electricity. This electricity can be used to power the opening and closing of values in the desalinization plant or if there is excess electricity, it can be provided to the power grid.
[0042] In FIG. 9 a linear electrical generator is shown. It includes a tightly wound coil 40 and a shaft 41 with a series of magnets. As the magnets are moved through the coil, electricity is generated in the coils. In order to move the shaft 41 , the bi-metallic discs 16 , 18 , 20 and 21 are connected to shaft 14 as shown in FIG. 1 . However, in generating electricity, it is helpful to have more speed than is produced by the discs. The extra speed is provided by a transmission 43 that amplifies the rate of motion of shaft 14 and applies it to shaft 41 .
[0043] The elements of the embodiments described above can be combined to provide further embodiments. These and other changes can be made to the system in light of the above detailed description. While the invention has been particularly shown and described herein, with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
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A pump uses solar energy to heat bimetals and other materials with high expansion coefficients to create movement that is coupled to pistons or impellers resulting in a fluid pumping action. The moving pistons or impellers are used to push salt water (or any fluid) through a membrane for filtration. Furthermore, the mechanical movement, powered by solar energy can be used for a variety of applications including pumps to move liquids or gases.
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BACKGROUND OF THE INVENTION
The invention relates to a gear pump for feeding of fluids, in which the pump includes gears arranged axially parallel to each other and meshing in pairs within a housing having a peripheral wall. One gear is axially fixed to the housing while the other is movable in the axial direction.
Gear pumps of this type are employed for stationary as well as for mobil applications. The known advantages mainly consist in the fact that high and super high pressures may be achieved, thereby allowing for relatively exact volumetric metering.
It has become known in the relevant art to shift gears which are meshing with each other, in an axial direction relative to each other, in order to change the amount of pumped fluid during operation. This concept is disclosed in U.S. Pat. No. 5,184,947 wherein a gear which is axially non-shiftable is journalled in a housing. A second gear which meshes with the first gear, is supported by a slide block, which is shiftable relative to the axis of the first gear.
German Patent No. OS-41 21 074 A1 describes an external gear pump for a continuously variable flow of fluid. This patent discloses two gears which are shiftable relative to each other. The driven gear is journalled in a housing, whereas the idle gear may be shifted depending on the pressure differential of the fluid at the pump.
It is the disadvantage of all these known devices that the sealing of the pumping chamber is not satisfactory. The sealing devices are subject to very substantial pressures and therefore to a high wear which limits the lifetime of the gear pump.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a gear pump according to the above description which meets the main requirement of an easy and rapid change of the volume of pumped fluid during operation, while at the same time, subjecting the sealing devices to much less wear compared to known gear pumps, and thereby keeping the costs of manufacture relatively low.
The present invention, in one form, is a fluid gear pump or motor. The fluid gear pump or motor comprises a casing having a peripheral wall with the peripheral wall having an inner surface. A pair of gears, a fixed gear and a movable gear, are mounted inside of the casing. The fixed gear has two ends, a fixed end and a free end, with the fixed end being rotatably mounted in the casing. The movable gear, which has a first and second end, is axially parallel to, and meshes with the fixed gear.
Also within the casing are first and second end walls which rotatably receive the first and second ends of the movable gear. These two end walls are in slidable sealing contact with the interior surface of the peripheral wall of the casing. Aside from the movable gear, the two end walls are also bridged by a wall, which has an interior wall surface. The first and second walls and the bridging wall together form a carriage which is slidable within the casing. The interior wall surface together with the axially fixed gear and the axially movable gear form a first delivery gap and a second delivery gap which extend across part of the circumference of the axially fixed gear and the axially movable gear. Each delivery gap has an entry area provided with a low-pressure space having an inlet and an outlet area provided with a high pressure space having an outlet.
A third end wall, also within the casing rotatably receives the free end of the fixed gear. This third end wall bears under seal on the interior wall surface of the bridging wall.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 depicts a longitudinal sectional view of a gear pump comprising two gears;
FIGS. 2-5 are cross-sectional views in the planes A--A, B--B, C--C and in the offset plane D--D;
FIG. 6 depicts an enlarged perspective view of the non-shiftable gear, comprising details of a shiftable end wall as well as the corresponding sealing devices;
FIGS. 7.1, 7.2 and 7.3 depict the pump at three different phases of operation; and
FIG. 8 depicts a further embodiment of a gear pump according to the invention, comprising two gears which are axially fixed relative to each other as well as a gear which is shiftable relative to the said first two gears.
DETAILED DESCRIPTION OF THE INVENTION
The gear pump according to FIGS. 1-6 comprises two gears 1 and 2. These are arranged with their axis parallel to each other and meshing with each other on a portion of their length. There is provided a housing 3, comprising peripheral walls 3.1 and 3.2 as well as end walls 3.3 and 3.4. One of the two gears, gear 2, is axially non-shiftable. At the right-hand end thereof it is journalled in end wall 3.4, and at its left-hand end it is journalled in an intermediate wall 6. The intermediate wall 6 and the peripheral wall 3.2 of the housing form one single part, which in the present case is made of cast iron. The other one of the two gears, gear 1, is shiftable in the axial direction, and accordingly relative to gear 2 and to housing 3. It is journalled in end walls 7, 8, which are both shiftable with gear 1. Additionally, the shiftable walls 7, 8 are fixedly connected with each other by a bridge 9. The shiftable walls 7, 8, as well as bridge 9, form an axially shiftable slide. Two chambers, one between the left-sided end wall 3.3 of the housing and the shiftable end wall 7, and the other between the right-sided end wall 3.4 of the housing and the shiftable end wall 8, are provided with inlets 10, 11 for the entrance, respectively, or exit of a control medium.
From FIG. 2 it may be seen that the two gears 1, 2 mesh with each other. Furthermore, they are, in a very distinct way, embraced by the peripheral wall 3.2 of the housing, on the one hand, and by the bridge 9, on the other hand. As may be seen from FIG. 2, the inner surface of the peripheral wall 3.2 forms, together with gear 1 along a portion of the circumference thereof, a feeding gap 15. The inner surface of bridge 9, to the contrary, forms with gear 2, along a portion of the circumference thereof, a feeding gap 16. As may be seen, the widths of the feeding gaps 15, 16 decrease in the direction of rotation of the gears 1, 2. An inlet area 17 for the fluid to be pumped includes an inlet 17.1, and an outlet area 18 includes an outlet 18.1. As may further be seen from FIG. 1, the inlet and outlet areas 17, 18 in connection with the inner surfaces of the peripheral wall 3.2 of the housing and of the bridge 9 as well as of the circumferences of the two gears 1 and 2 are limited. As may be seen from FIG. 1, the right-hand surface of the intermediate wall 6 and the left-hand surface of the shiftable end wall 8 serve to limit the amount of axial movement allowed by movable gear 1. These two last named surfaces at the same time define the pumping chamber of the gear pump.
FIG. 6 shows that the shiftable intermediate wall 8 not only serves to confine and seal the pumping chamber, but also provides a bearing for gear 2. More in detail, FIG. 6 shows wall 8, a radial bearing 8.1 supported by the same wall, a seal 8.2 for sealing of the contour of the teeth against the radial bearing 8.1, a shaft seal 8.3 as well as a seal 8.4 for sealing of the shiftable wall 8 against the peripheral wall 3.2 of the housing 3. Also, a portion of bridge 9 as well as a cover 8.5 of the slide may be seen.
Housing 3 comprises three chambers 20, 21, 22. One of these chambers, chamber 21, is located next to bridge 9. It is advantageous to have chambers 21 and 22 under pressure. Thereby, walls 6 and 8 and the surrounding seals 8.2, 8.3 and 8.4 are subjected to pressure from the outside, which relieves all seals between the fixed and the movable parts.
It is advantageous to provide a fluid connection between chambers 21 and 22, such that one of these chambers may feed the other one.
The method of operation of this first embodiment of a gear pump according to the invention is shown in FIG. 7, whereby the various working positions are shown in FIGS. 7.1, 7.2 and 7.3.
According to the embodiment of FIG. 7.1, the slide including gear 1 has been moved into an intermediate position, whereby the axial degree of overlapping of the two gears 1, 2 assumes an intermediate value. In this state, the pump volume has a medium value.
With the working position shown in FIG. 7.2, the degree of overlapping of the two gears 1, 2 is as great as is possible with regard to the design of the pump. The slide and gear 1 are both are shifted as far as possible to the right. The degree of overlapping is at a maximum value and accordingly, the pumped volume is at its maximum value.
In the working position, according to FIG. 7.3, the degree of overlapping is at about zero, and accordingly so is the pumped volume.
The control of the slide will be made through the above mentioned connections 10 and 11 by means of a suitable pressurized control medium. The slide is able to shift continuously, and may be maintained in any desired position. It will be seen that a continuous adjustment of the pumped amount is possible during operation.
The pump may be adjusted by hydrostatic pressure, either generated externally, or by its own, in the latter case only during operation. In order to have the adjustment pressure available at any time, a pressure reservoir could be provided. Such a reservoir only needs minimum dimensions and may by located between the peripheral walls 3.1, 3.2 on the one hand, and bridge 9 on the other hand, if desired.
The second embodiment of a gear pump according to the invention, shown in FIG. 8, is different from the first embodiment in that there are provided three gears, including a lower, axially shiftable gear 1 as well as two upper, axially fixed gears 2.1, 2.2, which are arranged co-axially relative to each other. Here again, a housing 3 is shown comprising peripheral walls 3.1, 3.2, end walls 3.3 and 3.4 as well as all essential further components of the first embodiment.
It is an advantage of the three-gear-embodiment that it comprises two working chambers. The width of the working chambers is indicated by reference numeral a 1 and a 2 . The working chambers are confined by outer shiftable end walls 7, 8 of the slide as well as by a fixed intermediate wall 6.
As may best be seen from the longitudinal sections, the bottom of the tooth gap of each tooth at the end of the working chamber is somewhat lowered radially and inwardly, such that it decreases against the end surface of the respective tooth. This allows for the proper removal of excess oil into low-pressure area 17.
It should be clear that the term "gear" should not be interpreted too narrowly. The drawings, for example, show gears of substantial axial extension, whereby the ratio between the axial length and the diameter is relatively great, such as 2:1. Instead, the invention may also be applied with gears which have a relatively small axial dimension, and therefore a relatively low ratio between the axial dimension and their diameters.
In addition, it should be clear that the invention is not applicable to pumps only, but also to hydrostatic motors.
While this invention has been described as having a preferred design, 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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Gear pump or motor to deliver fluid medium or use fluid medium as power source, respectively. The pump or motor has at least two gears contained within a housing. At least one gear is in a fixed position while the other gear is in slidable engagement with the fixed gear. In the pump configuration, fluid is introduced into the housing on one side of the engaged gears and is drawn through decreasingly wide passages by the rotating gears. The fluid thereby passes to the other side of the gears and exits the pump at a greater pressure. A control medium is used to control the position of the slidable gear. The greater the overlap between the gears the greater the volume of pumped fluid.
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BACKGROUND OF THE INVENTION
The field of the invention is that of heat exchangers, and more particularly, heat exchangers for use in domestic furnaces.
In one prior art form of a conventional domestic furnace, air to be heated (room air) is circulated around a serpentine heat exchanger for heat transfer to the conditioned room air. The heat exchanger defines a passageway for the flow of hot combustion gases conventionally produced by burning a fuel such as oil, gas, etc. The hot products of combustion pass through the heat exchanger thereby transferring heat to the conditioned room air, which is exhausted through a suitable flue.
To facilitate the heat transfer, heat exchangers preferably cause a turbulent flow within the fluid streams which exchange heat. Turbulent flow is achieved by superimposing an unsteady fluctuating velocity distribution on a steady mean flow pattern. By providing such a steady mean flow pattern, i.e. an average rate of flow, the furnace can reliably maintain air intake and exhaust. By superimposing an unsteady fluctuating velocity distribution, i.e. shifting subcurrents, on the steady flow pattern, the fluid stream transfers heat through the interface media of the walls of the heat exchanger. Providing a sufficiently turbulent flow assures that the fluid streams interact properly with the interface media for the efficient exchange of heat. However, turbulence also creates stress on the heat exchanger structure. Thus, it is desirable to provide a structurally secure heat exchanger which provides a sufficiently turbulent flow to assure proper functioning of the heat exchanger.
Heat exchangers are classified by the relative direction of the fluid streams which exchange heat. With aligned fluid flow channels, the streams run either parallel or counterflow. Streams with a parallel flow orientation are those which flow in relatively the same direction. Streams with a counterflow orientation travel in relatively opposite directions. With the fluid flow channels positioned relatively transversely, the streams flow with a cross flow orientation. Counterflow represents the most efficient method of transferring heat within a heat exchanger since it assures the greatest temperature differential between the heat exchanging fluid streams.
To most efficiently utilize a furnace, the heat transfer from the combustion products to the conditioned room air is maximized. A serpentine heat exchanger is conventionally used to continuously increase the temperature of the conditioned room air as it flows over the heat transfer surfaces of the heat exchanger. When disposed in a counterflow orientation, conventional heat exchangers maximize their heat transfer efficiency, although certain installations require a more uniform, albeit somewhat less efficient, distribution of heat transfer.
U.S. Pat. No. 4,739,746 (Tomlinson) describes a furnace having a serpentine heat exchanger for selectively providing either a parallel or counterflow heat transfer arrangement. Although the serpentine heat exchanger of the Tomlinson patent provides improved selective functioning, the increasing cost of fuel for furnaces creates a need for heat exchangers which have greater efficiencies in order to minimize heating costs. However, conventional designs do not effectively employ the full advantage of the heat transfer surfaces. Thus what is needed is a heat exchanger which fully utilizes the potential heat transfer surfaces of the heat exchanger.
SUMMARY OF THE INVENTION
The present invention is an improved serpentine heat exchanger. The passageway of the serpentine heat exchanger has a contour which provides improved heat transfer characteristics. Specifically, elongated ribs and column-like dimples extending within the passageway direct flow onto heat transfer surfaces to increase the efficiency of heat transfer. The heat exchanger is securely crimped together at its edges, while eyelets located located in the interior of the passageway secure together plates and preserve the integrity of the passageway.
Also, the serpentine heat exchanger has a contour which provides counterflow heat transfer segments within the passageway. To minimize combustion problems, the first segment of the serpentine passageway is initially straight and has a cross flow orientation with respect to the flow of room air. After the initial segment, the passageway bends and the remaining segments have a parallel or counterflow orientation. The orientation of the present invention provides a greater heat transfer efficiency, having segments with true counterflow heat exchange.
The present invention, in one form, is a heat exchanger for a domestic furnace. In a furnace having a burner for providing hot products of combustion, and a blower for circulating conditioned air, the heat exchanger transfers heat from the products of combustion to the conditioned air using two clamshell plates assembled together which define a serpentine passageway. The plates are interconnected at their edges by crimping, except at the portals of the passageway. Depressions in the plate form the passageway and, near the second portal, elongated ribs extend from the plate into the passageway to generate a turbulent fluid flow.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a top plan view of a heat exchanger clamshell plate of the present invention;
FIG. 2 is a perspective view of the heat exchanger clamshell plate of FIG. 1;
FIG. 3 is a cross sectional view of an assembled heat exchanger taken along lines 3--3 of FIG. 1;
FIG. 4 is a cross sectional view of an assembled heat exchanger taken along lines 4--4 of FIG. 1;
FIG. 5 is a front view in partial cut-away of a bank of heat exchangers according to the present invention;
FIG. 6 is an enlarged front sectional view of a passageway portal of an assembled heat exchanger;
FIG. 7 is a cross sectional view of the passageway portal taken along lines 7--7 of FIG. 6;
FIG. 8 is an enlarged fragmentary view of one plate which forms the passageway portal taken in region 8 of FIG. 1;
FIG. 9 is a sectional view of the crimped edges of two heat exchanger clamshell plates; and
FIGS. 10 and 11 are schematic diagrams of air flow within the serpentine passageway without ribs and with ribs, respectively.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention, in forms thereof, and such exemplifications are not to be construed as limiting the scope of the disclosure or the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The shape of the passageway of the present invention is shown in FIG. 1. Serpentine heat exchanger clamshell plate 10 has a depression 11 which, in combination with a depression of a matching plate, defines inlet portal 12, exhaust portal 14, and passageway 16 that connects portals 12 and 14.
Passageway 16 is comprised of various segments, including inlet channel 18, parallel flow channel 20, counterflow channel 22, and turbulence channel 24. Inlet channel 18 extends straight from inlet portal 12 along lower edge 26 to bend 28 near peripheral edge 30. At bend 28, passageway 16 continues through parallel flow channel 20 which extends upwardly along peripheral edge 30. Parallel channel 20 extends up to upper edge 32, where it forms part of U-turn 34. Counterflow channel 22 extends from U-turn 34 to U-turn 36, from upper edge 32 downwardly towards inlet channel 18. Completing passageway 16 from U-turn 36 to exhaust portal 14 is turbulence channel 24, which contains both ribs 38 and dimples 40. Thus, parallel channel 20, counterflow channel 22 and turbulence channel 24 define an "S" shaped passageway for products of combustion ending in exhaust portal 14. Inlet channel 18 connects inlet portal 12 with one end of the "S" at bend 28.
The serpentine heat exchanger is used within a furnace, with its portals 12 and 14 connected to the heating system. For example, one configuration of such a furnace has a burner placed within inlet channel 18; near exhaust portal 14 a blower induces a draft within passageway 16 so that the burner is assured of a fresh flow of combustion gases. To circulate conditioned air within the building being heated, another blower causes conditioned air to flow over the exterior of the serpentine heat exchanger.
As disposed within a furnace, room air passes over plate 10 in a direction from lower edge 26 to upper edge 32. Assuming the products of combustion flow from inlet portal 12 to exhaust portal 14, products of combustion flowing through inlet channel 18 have a cross flow orientation relative to the conditioned room air. Subsequent flow through parallel flow channel 20 and counterflow channel 22 has a parallel flow and counterflow orientation, respectively, relative to the room air flow. In turbulence channel 24, the flow of the products of combustion is generally parallel to the room air flow, but the addition of ribs 38 and dimples 40 disrupts the uniformity of the fluid flow and causes the flow to be turbulent rather than laminar. Turbulent flow results in more efficient heat transfer to the room air.
Alternately, if exhaust portal 14 is positioned below inlet portal 12, and conditioned air then passes over plate 10 in a direction from edge 32 to edge 26, channels 20 and 24 have a counterflow orientation, while channel 22 has a parallel flow orientation.
The interior surfaces of the channels which comprise passageway 16 have a rounded rectangular cross sectional area, as can be seen in FIGS. 3 and 4. As shown in FIG. 5, the height of passageway 16 within assembly 80 is greater near inlet portal 12 than near exhaust portal 14. This decreasing depth without a corresponding increase in width produces a venturi effect in counterflow channel 22 and more so in turbulence channel 24. Thus, the increased flow velocity which occurs in counterflow channel 22 and turbulence channel 24 aids in increasing the efficiency of heat transfer in the heat exchanger.
Ribs 38 help create turbulence to facilitate heat transfer, as each rib 38 is comprised of an elongated indentation extending into passageway 16 (see FIG. 4). In the preferred embodiment of the present invention, three ribs 38 are positioned within turbulence channel 24. On each plate 10, ribs 38 extend from turbulence channel 24 to near the plane defined by the interior surfaces of plate 10. Matching ribs 38 from matching plates 10 have only a marginal space between their ends, and can directly abut to form a wall-like obstruction to air flow. Ribs 38 are arranged to be generally vertically parallel to each other and spaced apart by a relatively short distance or in an abutting position, middle rib 38b having a top end 42 horizontally aligned with a bottom end 44 of outer rib 38a, and a bottom end 46 of rib 38b horizontally aligned with top end 48 of inner rib 38c. With this configuration of ribs 38, the channel 24 between counterflow channel 22 and exhaust portal 14 is partially obstructed, which promotes turbulence. Thus, products of combustion traversing turbulence channel 24 must circulate around ribs 38, diverting those products of combustion onto heat transfer surfaces which improves the heat transfer efficiency.
Also, dimples 40 extend into passageway 16, to compound the turbulence caused by ribs 38. Each annular dimple extension 50 extends and nearly meets a corresponding annular dimple extension 50 of its matching plate. The ends of dimple extensions 50 are connected together by eyelets 52 formed directly in plates 10 as further explained hereinafter. Being cylindrical in shape and securely connected together, matching dimple extensions 50 form column like obstructions within passageway 16. The column like obstructions of passageway 16 cause additional turbulence, while the secure fastening of eyelets 52 serves to preserve the structural integrity of the serpentine heat exchanger.
Passageway 16 terminates at inlet and exhaust portals 12 and 14, respectively, which are shown in greater detail in FIGS. 6, 7 and 8. Upper plate segment 54 and lower plate segment 56 join at crimping locations 58 to form portal 12, which represents the structure of either portal 12 or 14 in FIGS. 7 and 8. Wrapped around portal 12 to secure it is lip 62 which facilitates connection to a furnace. As seen in FIG. 7, the portal edges 55 and 57 of plate segments 54 and 56, respectively, flange outwardly from portal 12. Also, portal 12 extends beyond connecting edge 64 (FIGS. 1, 7, and 8).
The plates of the serpentine heat exchanger are connected together by eyelets 52 within the edges of plate 10 and by crimping along the edges of plate 10. Eyelets 52 can be seen in perspective in FIG. 2, and in a sectional view in FIG. 3. Each eyelet 52 comprises interior edge portions of plate 10, matching receiving holes and collars from matched plates 10. One of the matched plates has a pierced receiving hole 52a and the other has an extrudent upwardly projecting collar 52b. Collar 52b initially has an outer diameter less than the inner diameter of hole 52a and thus extends through its matching receiving hole 52a; then collar 52b is peened or hemmed over the edges of hole 52a to fasten collar 52b about hole 52a. Thus, interior points of plate 10 are connected to a corresponding plate without welding or other forms of coupling which are more subject to breakage due to thermal stresses.
Along edges 26, 30, 32, and 64, matching plates which form the serpentine heat exchanger are bent and crimped together to provide a secure seal. FIG. 9 shows a sectional view of a top plate 66 and a bottom plate 68 joined together by crimping at an edge. The end of top plate 66 extends outwardly and bends downwardly to project from the crimping edge 71. The bend near the end of top plate 66 is, in the preferred embodiment, approximately 45°. Bottom plate 68 is wrapped around top plate 66, and a gap 70 exists between plates 66 and 68 where bottom plate 68 wraps over top plate 66. Gap 70 allows the metal of top plate 66 to expand without adversely effecting the coupling, so top plate 66 does not press against bottom plate 68. Thus, changing temperature conditions which cause top plate 66 to expand do not cause it to alter the position of bottom plate 68.
Also in the preferred embodiment, after wrapping bottom plate 68 over top plate 66, a perforation crimping is applied on top surface 72 of wrapped around portion or fold 73 of bottom plate 68. The gap 70 (FIG. 9) and the perforated crimping edge 71 (FIG. 1) on top surface 72 form a gusset 74 which maintains a seal between the two metal plates. The gussets 74, preferably evently spaced, actually stretch the plate material to make the juncture tight from one end to the other, which also helps to maintain a seal. This bending and crimping helps to break the material and make a good end seal.
A number of serpentine heat exchangers may be combined to form a serpentine heat exchanger bank 76, as shown in FIG. 5. Case 78 houses a plurality of heat exchanger assemblies 80, with FIG. 5 depicting two assemblies 80 within case 78. Lip 62 may be formed as part of case 78, integrally forming couplings to a furnace. A furnace compatible with serpentine heat exchanger bank 76 is described in U.S. Pat. No. 4,739,746, which is incorporated herein by reference. When installed in a furnace, the inlet portals 12 of assemblies 80 are connected to burners while exhaust portals 14 are coupled to a blower. Products of combustion pass through passageways 16 within assemblies 80, while room air circulates around assemblies 80 within case 78.
The plates 10 of the heat exchanger assemblies 80 may be comprised of corrosion resistant metallic materials, such as aluminized steel, 409 stainless steel, or a coated metal material. In the preferred embodiment, stainless steel is used.
While this invention has been described as having a preferred design, it can be further modified within the teachings of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention following its general principles. This application is also intended to cover departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and fall within the limits of the appended claims.
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The present invention is an improved serpentine heat exchanger. Two metal sheets are crimped together, sealed at their abutting edges. The sheets have matching depressions which from a serpentine air passageway. Within the passageway are elongated ribs and column like dimples which serve as obstruction to the air flow, directing fluid flow over under-utilized portions of the passageway and generating turbulent fluid flow near heat transfer surfaces.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application 61/270,395 filed with the USPTO on Jul. 9, 2009. The Inventors have filed related applications regarding floating storage tank roofs as disclosed in PCT Applications PCT/CA2009/000388, filed on Mar. 24, 2009 and PCT/IB2009/05411 filed on Sep. 21, 2009.
FIELD OF THE INVENTION
[0002] This invention relates to the wireless monitoring of linear heat detection systems deployed on the roofs of large storage tanks, including tanks used for storing liquid petroleum products or other chemicals. The invention comprises two units that communicate using wireless means: a self-powered Remote Unit that connects to the linear heat detector and a Communication Unit that is linked to the Fire Control Panel. The invention provides a wireless link between the monitoring system and the linear heat detector and thereby supersedes the conventional wired connection between the linear heat detectors and the Fire Control Panel. The Communication Unit can be connected to a Fire Control Panel using wired or wireless means. The proposed invention can be used for routine status monitoring or for notifying plant operators in the event of alarm conditions. The invention is suitable for encapsulation and use in harsh environments.
BACKGROUND OF THE INVENTION
[0003] Large storage tanks are often cylindrical and have a circular floating roof. The roof floats on the surface of the liquid, thereby decreasing the vapor space inside of the tank. A floating roof may be required for reasons of safety or for pollution reduction. The floating roof has a seal between its outer edge and the wall of the tank that helps to prevent the escape of the contained liquid or vapors from that liquid. This seal moves up and down with the roof as the liquid level changes.
[0004] There are two broad types of storage tanks that utilize floating roofs: tanks having an exposed floating roof and tanks having a fixed roof covering the floating roof. An advantage of the covered tank is that it protects the floating roof from undesirable effects from the external environment, such as rain or birds. A disadvantage of the covered tank is that volatile, explosive, corrosive, or toxic gasses or liquids can accumulate between the floating roof and the fixed roof.
[0005] When the contained liquid or its vapors are flammable, a substantial fire hazard can exist at the roof of the tank. The fuel for such a fire can be from the escape of liquid or vapor from the storage tank. The industry is therefore quite interested in monitoring systems that can be used to improve safety by identifying fires or any excessive heating conditions that may lead to fire.
[0006] The linear heat detector (LHD) is an existing technology that is typically realized using one of two configurations. With the first configuration, referred to as a “digital” LHD, a cable containing two wires is installed around the circumference of the tank between the primary seal and the outer seal of the tank. The digital LHD cable comprises two insulated steel conductors, which may be copper-coated. The insulated conductors are twisted in a helical configuration resulting in a residual spring-like stress in the cable. If the ambient temperature reaches the melting point of the insulating material, the conductors push their way through the insulation, thereby contacting one another and short-circuiting the two conductors. This short-circuit condition is detected by measuring the current flow through the LHD, thereby raising an alarm condition. When such a short-circuit condition occurs, it is necessary to replace the affected part of the LHD to restore normal operation.
[0007] The second LHD configuration, known as “analog” LHD, uses four wires: one pair of copper wires carries a reference current through the LHD loop. The second pair of wires is coated with a negative-temperature-coefficient (NTC) insulation. Elevated temperatures are detected by comparing the reference current to the current in the NTC-insulated loop. This approach has the advantage of supporting the estimation of loop temperature. This NTC-based system will continue to operate normally if an elevated temperature is subsequently reduced, provided that the elevated temperature was not high enough to permanently damage the cable.
[0008] In the current state-of-the-art, a lengthy umbilical cable is used to connect the LHD on the floating tank roof to the monitoring system connection that is located near the top of the tank. This umbilical cable is subjected to stresses from self-weight and stresses during tank movement or adverse weather conditions. It may subsequently fail, resulting in a loss of monitoring capability and necessitating costly repairs.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention provides a new wireless apparatus for connecting the LHD to the Fire Control Panel, thereby obsolescing the unreliable umbilical cable that is currently used. The invention also includes methods for reducing power consumption and for more accurately locating the fault in the cable that is causing an alarm condition.
[0010] The invention is comprised of a Remote Unit and a Communication Unit. The Remote Unit is wired to the LHD and generates the signals that are used to detect the condition of the LHD. The Remote Unit is located on the tank roof. It monitors the signals in the LHD and generates alarm conditions or status messages that are sent to the Communication Unit. The Communication Unit is typically located near the top of the cylindrical wall of the tank. It relays alarm or status messages to Fire Control Panel. The connection from the Communication Unit to the Fire Control Panel can be wired, for example, using a 20 mA current loop. Alternatively, the connection from the Communication Unit to the Fire Control Panel can be wireless, for example, using an existing wireless technology such as the SK2000 wireless device that is available from Saval NV.
[0011] Fire Control Panels are well-known in the current state-of-the-art and the Fire Control Panel is not discussed further.
[0012] The Remote Unit is self-powered, typically using batteries, solar cells, or a combination thereof. It consequently removes any requirement for wiring to the roof of the tank for the purpose of deploying a LHD system on the tank roof. The Remote Unit contains a microprocessor or microcontroller that is used for control signal generation and monitoring of the LHD, for assembling messages and transmitting them to the Communication Unit, and for interpreting messages from the Communication Unit. Since the only wired connection on the Remote Unit is to the LHD, the Remote Unit is well-suited for encapsulation and use in harsh environments.
[0013] There is no known existing apparatus that is similar to the current invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 : Functional Block Diagram of the Proposed Apparatus
[0015] FIG. 2 : Functional Block Diagram of the Remote Unit
[0016] FIG. 3 : Pictorial Drawing of the Remote Unit
DETAILED DESCRIPTION OF THE INVENTION
[0017] With reference to the block diagram in FIG. 1 , the invention comprises a Communication Unit 1 and a Remote Unit 2 that communicate via wireless means using antennas 3 . The configuration of the antennas 3 is not a facet of this invention.
[0018] The Communication Unit 1 is connected to the Fire Control Panel using a Communication Link 4 that is compatible with the Fire Control Panel. As examples, this Communication Link 4 could be a wired connection, such as a 20 mA current loop or an asynchronous serial link, or it could be a wireless connection such as the Saval SK2000. The Communication Unit 1 is typically deployed near the top of the wall of the storage tank.
[0019] The LHD 5 is wired to the Remote Unit 2 , using either a two-wire or a four-wire connection, depending, respectively, on whether a “digital” LHD or an “analog” LHD is required. The invention can be readily configured for use with either type of LHD. The Remote Unit 2 is typically deployed on the floating roof of the storage tank.
[0020] With reference to the functional block diagram in FIG. 2 , said Remote Unit minimally comprises a Power Module 9 and the following core functional modules: a Microcontroller 7 ; a Communications Module 6 ; and an Interface 8 to the LHD 5 . Said Interface 8 may be integrated into the Microcontroller 7 .
[0021] With reference to FIG. 2 , the lines drawn with arrows between the Microcontroller 7 , the Communications Module 6 , and the Interface 8 indicate communication links; the solid lines from the Power Module 9 indicate power connections; and the solid line to the LHD 5 indicates a wired connection. Said communication links are shown as being bidirectional but unidirectional connections are also permissible. The communication link for the power module is optional.
[0022] Since the Microcontroller 7 is capable of both generating and analyzing signals, it can be used to enhance the detection capabilities of the LHD. Therefore, it can support measurement techniques that are in addition to the measurement of current and voltage in the LHD that is prevalent in the current state-of-the-art. In the proposed invention, time-domain reflectometry (TDR) can be supported by the Microcontroller software. With TDR, a signal comprising a short pulse or chirp is sent into the LHD via the Interface 8 . The Microcontroller then measures the response from the LHD using an analog-to-digital converter. Using well-known techniques, the Microcontroller can then compute the distance to the fault or short-circuit in the LHD. Using TDR results in a more accurate estimate of the location of the fault than using conventional resistance-based measurements.
[0023] The Microcontroller 7 can also be used to help conserve power. In conventional LHD systems, a current source is applied continuously to the LHD, thereby continuously consuming power. In the proposed invention, power can be conserved either by periodically applying current to the LHD or by periodically applying the aforementioned TDR technique. For said periodic application of current, the current must be applied to the LHD for a sufficient period of time, known as the settling time, for the transient response of the LHD to decay to a level where the voltage or current in the LHD can be reliably measured. Since the LHD acts as a linear electrical transmission line, the settling time for the LHD can be easily predicted.
[0024] Further, the Remote Unit can operate using low voltages and low power on its connection to the LHD, thereby conserving power and reducing the risk of sparks that could ignite flammable vapors.
[0025] The wire interface on Remote Unit that is described in this application is programmable, thereby making it suitable for use with other current-loop sensors or voltage-level sensors.
[0026] The Remote Unit is powered by a Power Module employing batteries, photovoltaic cells, radio-frequency power transmission, optical power transmission, or any combination thereof. The Communication Unit can be line powered, use batteries, use photovoltaic cells, or any combination thereof.
[0027] To prevent improper operation due to the proximity of other Communication Units or Remote Units, each Remote Unit or Communication Unit can be uniquely identified by one or more identification numbers: an electronic identification number that is set up during system configuration or a unique electronic identification number that is set up before system configuration. The identification number need not be globally unique: it can be unique to a particular deployment.
[0028] In the current embodiment, the Communication Unit is comprised of a Freescale MC13224 that contains a radio-frequency communications module for wirelessly communicating with the Remote Units; and a 20 mA current loop interface for connecting to an existing Fire Control Panel. The Communication Unit is used to relay information to or from a Remote Unit and to or from a Fire Control Panel.
[0029] In the current embodiment, power for the Communication Unit is scavenged from its interface to the 20 mA current loop. Said current loop, which is powered by the Fire Control Panel, can easily supply the power requirements of the Communication Unit without any disruption to its normal operation.
[0030] The microprocessor is programmable and can have software for computing alarm conditions from signals gathered from the LHD. Optionally, the microprocessor can be re-programmed in the field by wired or wireless means.
[0031] For either the Communication Unit or the Remote Unit, the microcontroller and the communications module may be integrated into a single device such as the Freescale MC13224.
[0032] With reference to FIG. 3 , the Remote Unit is preferentially encapsulated for use in harsh environments, including but not limited to chemical plants, petrochemical plants, and marine environments. The alternative to encapsulation is mechanical sealing systems, such as enclosures sealed with gaskets. As illustrated in FIG. 3 , the two or four wires that are used to connect to the LHD preferentially extend from the Remote Unit so that the Remote Unit and the LHD can be interconnected using a standard junction box. Preferentially, the Remote Unit is immersible.
[0033] In the current embodiment of the Remote Unit, the core functional modules displayed in FIG. 2 are implemented using a Freescale MC13224.
[0034] Communications among the system components (the Remote Unit, the Communication Unit, and the Fire Control Panel) may be initiated using one or more of the methods described in the following three paragraphs. In all cases, communications between any Remote Unit and the Fire Control Panel must pass through a Communication Unit.
[0035] The Fire Control Panel can send a request to a Remote Unit. The Remote Unit will subsequently reply with the requested information. This type of communications is referred to as polling.
[0036] The Remote Unit can send periodic status messages to the Fire Control Panel. These periodic messages can contain information about the LHD; alarm status; and/or information regarding the state of the Remote Unit, such as battery condition. This type of communications is referred to as periodic.
[0037] The Remote Unit can send messages to the Fire Control Panel in the event that that an alarm condition has been detected by the Remote Unit. This type of communication is referred to as event-driven.
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An fire monitoring apparatus for large storage tanks of combustible fluids permits wireless communication between a Linear Heat Detector system and a Fire Control system. The system comprises a Communication Unit and a Remote Unit. The Communication Unit relays status and control signals between the Fire Control system and the Remote Unit. The communication between the Communication Unit and the Remote Unit is wireless. The Remote Unit is self-powered using solar cells, batteries, or a combination thereof.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention concerns the manufacture of optical fibers, particularly bend insensitive multimode fibers.
[0003] 2. Discussion of the Known Art
[0004] Patent Application Pub. No. US 2009/0060437 (Mar. 5, 2009) discloses a bend insensitive, single mode fiber having a relatively low bend loss at a bend radius of about 4 to 15 mm. The disclosed fiber has a core and a cladding region for propagating light in a fundamental transverse mode. The cladding region includes (i) an outer cladding having a refractive index less than that of the core region, (ii) an annular pedestal region having a refractive index higher than that of the outer cladding and comparable to that of the core, (iii) an annular inner trench region disposed between the core and the pedestal region, the inner trench region having a refractive index less than that of the outer cladding, and (iv) an annular outer trench region disposed between the pedestal region and the outer cladding, the outer trench region having a refractive index less than that of the outer cladding. All relevant portions of the '437 Publication are incorporated by reference.
[0005] Typical bend insensitive multimode fibers (BIMMF) have a refractive index profile in which the fiber cladding contains a trench region or layer of depressed index glass. Such index profiles are disclosed in, e.g., U.S. Pat. No. 8,073,301 (Dec. 6, 2011)(see FIG. 2 and related text), and U.S. patent application Ser. No. 13/252,964 which was published as US 2012/0183267 on Jul. 19, 2012, all of which are incorporated by reference.
[0006] FIG. 1 is an example of a refractive index difference profile of a BIMMF, relative to a pure fused quartz overclad (or substrate) tube 14 in a preform from which the fiber is drawn. A trench region 12 in FIG. 1 is typically obtained by depositing a depressed index glass on the inside diameter of the overclad tube 14 , using either a modified chemical vapor deposition (MCVD) or a plasma chemical vapor deposition (PCVD) process. See, U.S. Pat. No. 7,903,918 (Mar. 8, 2011) which is incorporated by reference.
[0007] A glass core rod 16 is then inserted axially inside the overclad tube 14 to make the fiber preform, and the preform is heated vertically inside a furnace until the overclad tube 14 softens and collapses on the core rod 16 to form a drop at the bottom of the preform. The BIMMF is then drawn from the drop. It will be appreciated that among other drawbacks, the trench deposition process is very costly, ties up a lot of deposition capacity, and the resulting fiber is subject to yield loss related to axial trends in the deposited glass.
SUMMARY OF THE INVENTION
[0008] According to the invention, a method of assembling a preform for a bend-insensitive multimode optical fiber (BIMMF), includes providing a multimode core rod, a glass over-cladding tube, and a trench tube of down-doped quartz glass with a depressed refractive index sufficient to obtain a desired trench depth in a refractive index (RI) profile of a drawn fiber. The core rod is placed coaxially inside the trench tube, and the trench tube and the core rod are placed coaxially inside the over-cladding tube to define the preform.
[0009] A top end of the trench tube is formed to contact an adjacent part of either the core rod or the over-cladding tube so that the trench tube is suspended to hang from the adjacent part when the preform is vertically oriented, and a bottom end of the trench tube is restrained from sinking into a lower portion of the preform when the preform is heated to collapse.
[0010] For a better understanding of the invention, reference is made to the following description taken in conjunction with the accompanying drawing and the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
[0011] In the drawing:
[0012] FIG. 1 is a refractive index difference profile of a bend insensitive multimode optical fiber (BIMMF) relative to a quartz overclad tube of a typical preform from which the fiber is drawn, according to the prior art;
[0013] FIG. 2 shows sectional views of a BIMMF preform in planes perpendicular and parallel to the axis of the preform, according to the invention;
[0014] FIG. 3 is a sectional view of an upper portion of a BIMMF preform in a plane parallel to the preform axis, according to a first embodiment of the invention;
[0015] FIG. 4 is a sectional view of a preform trench tube, an open end of which is heated by a torch to be reshaped;
[0016] FIG. 5 is a sectional view of an upper portion of a BIMMF preform in a plane parallel to the preform axis, according to a second embodiment of the invention;
[0017] FIG. 6 is a sectional view of a preform trench tube and an inserted core rod, wherein an open end of the tube is heated to be reshaped;
[0018] FIG. 7 is a sectional view similar to FIG. 6 , including a pedestal for elevating the trench tube relative to the core rod prior to heating the open end of the tube;
[0019] FIG. 8 is a table showing average bend loss of a number of BIMMFs produced using a preform according to the invention; and
[0020] FIG. 9 is a refractive index difference profile of a bend insensitive multimode optical fiber (BIMMF) relative to an overclad tube in a preform from which the fiber was drawn, according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 2 shows sectional views of a cylindrical BIMMF preform 20 made according to the invention. The view at the top of FIG. 2 is taken in a plane transverse to the axis A of the preform 20 , and the view at the bottom of FIG. 2 is shown parallel to the preform axis A. A tube 22 of down-doped or low-index glass (e.g., quartz) is supported inside the preform 20 so that the tube 22 is disposed coaxially with an inner core rod 24 , and with a surrounding glass overclad tube 26 made of, e.g., pure fused quartz. The down-doped glass tube 22 is referred to herein as a “trench” tube.
[0022] When the preform 20 is suspended vertically and lowered into a furnace or other heated region, the trench tube 22 and the surrounding overclad tube 26 collapses over the core rod 24 , and a glass drop forms at the bottom of the collapsed preform 20 . A BIMMF is then drawn from the bottom of the preform 20 in a known manner. The refractive index (RI) profile through the cladding of the drawn fiber has a trench region such as, e.g., the trench region 12 in FIG. 1 , which region is formed by the collapsed trench tube 22 and enables the drawn fiber to be bend insensitive. Once the preform 20 has been collapsed, it can be withdrawn from the furnace in the collapsed state, allowed to cool, and heated again at a later time to draw more fiber.
[0023] Heating and collapsing the down-doped trench tube 22 and the surrounding overclad tube 26 simultaneously over the core rod 24 was found to be preferable to other possible solutions such as first collapsing the trench tube 22 horizontally on the core rod 24 , and then collapsing the overclad tube 26 on the outer circumference of the trench tube 22 in a vertical furnace during the fiber draw process. The trench tube 22 will generally have a lower softening point than either of the core rod 24 or the overclad tube 26 . If the trench tube 22 is simply dropped into the preform assembly to rest on its lower end, it was found to sink into the lower end of the preform during the fiber draw process, thus causing the trench region 12 in the fiber cladding to have an increased width and additional axial variability. To avoid this problem, it has been found that prior to heating, the trench tube 22 should be physically supported at its upper end so as to hang vertically inside the preform 20 . In accordance with the invention, this is accomplished in either one of two ways:
[0024] A. See FIG. 3 . A top end 30 of the trench tube 22 is heated and flared radially outward or conically, so that the top end 30 of the tube abuts an inner circumferential edge 32 on the top end of the overclad tube 26 in the vicinity of a weld 34 between the overclad tube 26 and an associated tubular handle 36 . Thus, the trench tube 22 is positively supported by the top end of the overclad tube 26 to hang vertically and coaxially inside the overclad tube to assemble the preform 20 . Alternatively, a number of radially outward, circumferentially spaced protuberances can be formed at the top end of the trench tube 22 so that the protuberances abut the inner circumferential edge 32 of the overclad tube 26 , allowing the trench tube 22 to be suspended and to hang vertically inside the overclad tube 26 .
[0025] If a hydrogen-oxygen torch is used to heat the top end 30 of the trench tube 22 when flaring the top end outward, moisture and air particles may accumulate within the trench tube 22 . This condensation can flow inside the trench tube 22 and contaminate the inside surface, causing, among other issues, prooftest breaks and voids in the drawn optical fiber if the trench tube 22 is not washed promptly after following the above steps. It was found that such contamination can be avoided by flowing a clean and filtered gas (e.g., Nitrogen) through the tube 22 during the heating process.
[0026] Specifically, as shown in FIG. 4 , a stopper or seal such as a cork 40 is inserted in the open end of the trench tube 22 opposite to the end that is being heated to be flared, and clean gas is introduced through an axial passage 42 in the cork via a nozzle. As the gas flow exits the heated end of the trench tube 22 , the flow prevents moisture and contamination from entering inside the tube.
[0027] B. See FIG. 5 . Alternatively, the top end 30 of the trench tube 22 is formed to have an hourglass or necked-in shape, or with circumferentially spaced radially inward indentations or dimples, so that the top end of the tube abuts and is suspended to hang from a peripheral top edge 50 of the core rod 24 , near a weld 52 between the core rod and a rod handle 54 after the tube passes over the handle 54 . (The outside diameter of the handle 54 is typically less than that of the core rod 24 ). The trench tube 22 is thus firmly supported by the top edge 50 of the core rod 24 so as to hang vertically and coaxially inside the surrounding overclad tube 26 . This process avoids a need to weld the trench tube 22 to any part of the core rod 24 or to the rod handle 54 . And when the core rod 24 is raised by the handle 54 , the trench tube 22 remains suspended from the top edge 50 of the rod.
[0028] If a hydrogen-oxygen torch is used to heat the top end 30 of the trench tube 22 prior to necking in the top end, or to forming the indentations in the top end, contamination of the inside surface of the tube can be avoided by making the trench tube at least 5 cm longer than the core rod 24 . See FIG. 6 . In this manner, the open top end of the trench tube 22 extends past the region of the tube to be heated, and the torch flame is not in the vicinity of the open top end 30 . While there may be some local contamination on the outside surface of the tube 22 where the torch is applied, no condensation will accumulate on the inside surface of the tube. Method B is preferable to method A since it does not require gas flow apparatus or subsequent tube washing to eliminate concerns over contamination.
[0029] Further, in method B, it was found that if the necked-in or dimpled region of the trench tube 22 pinches directly against an area of the rod handle 54 that has residual stress, then the handle 54 may become weakened to crack either immediately or within hours after forming the dimpled region. If so, the core rod 24 could fall out of the open bottom end of the preform 20 . Since there is typically a stress region in the rod handle 54 close to the weld 52 between the handle and the core rod 24 , such stress can be relieved for example, by the use of a known slow annealing process prior to forming the necked in or dimpled region at the top end 30 of the trench tube. A faster solution that avoids such annealing was devised, wherein the trench tube 22 is temporarily raised relative to the core rod 24 while the necked in or dimpled region is formed in the top end of the tube.
[0030] Specifically, as shown in FIG. 7 , a pedestal 70 is used to elevate the trench tube 22 axially by a certain offset distance D relative to the core rod 24 . When the tube is heated by a torch to be necked in or dimpled inwardly at its top end 30 , the tube constricts or pinches against a region along the rod handle 54 that does not have stress regions. Thus, the strength of the handle 54 is not compromised. The pedestal 70 is removed and the trench tube 22 is lowered relative to the core rod 24 so that the tube then hangs from the top edge of the core rod 24 as described previously. While the necked in or inwardly dimpled region may be formed at the top end 30 of the tube before the core rod and rod handle are placed inside the tube, the pedestal technique in FIG. 7 overcomes situations where the rod handle 54 has a large diameter ball at its top end for supporting the handle and the rod 24 inside the overclad tube 26 . In such cases, the ball could prevent the necked in region of the trench tube 22 from being moved downward along the handle to rest atop the core rod 24 , thus requiring the trench tube to be moved upward from the bottom end of the core rod before the necked in region can be formed at the top end 30 of the trench tube.
[0031] Both of the methods A and B require that clearance gaps G shown in FIGS. 3 & 5 provided between the trench tube 22 and the inner core rod 24 , and between the trench tube and the surrounding overclad tube 26 , be kept as small as possible to minimize or avoid any radial asymmetry during a collapsing process. The gaps G are preferably as small as possible while allowing enough clearance for the core rod 24 to pass axially inside the trench tube 22 . For example, the inside diameter of the trench tube 22 may be 1 mm to 2 mm larger than the outside diameter of the core rod.
[0032] It has also been discovered that both methods A and B work particularly well when the trench portion in the in the refractive index (RI) profile of the drawn fiber (e.g., portion 12 in FIG. 1 ) is situated relatively far from the RI profile of the fiber core.
Example
[0033] Manufacturing a 50 μm bend insensitive multimode fiber
[0034] A preform 20 was assembled via the method of FIG. 5 (Method B) using the following components:
Core Rod 24 Diameter=24.5 mm Core Rod 24 Length=1175 mm Trench Tube 22 Inner Diameter=26.54 mm Trench Tube 22 Outer Diameter=29.51 mm Trench Tube 22 Length=1280 mm Trench Tube 22 Delta Refractive Index (relative to pure quartz)=−0.0056 Overclad Tube 26 Inner Diameter=31.43 mm Overclad Tube 26 Outer Diameter=47.77 mm Overclad Tube 26 Length=1280 mm
[0044] The assembled preform 20 was heated in a vertical furnace and a number of 50/125 μm bend insensitive multimode fibers were drawn, each having a length of approximately 8.8 km. Bend loss test results for the fibers are shown in FIG. 8 . The data reflects additional loss induced by wrapping the fibers twice around a mandrel of radius 7.5 mm. Bend loss was measured at wavelengths of 850 nm and 1300 nm. Both ends of each fiber were tested and the average loss value is given for each test.
[0045] FIG. 8 shows that 100% of the fiber from the preform 20 passed currently specified bend loss test standards for BIMMFs. This is a significant improvement over prior BIMMF preform assembly and fiber drawing processes, wherein the trench in the RI profile of the drawn fiber tapers at one end, and many fibers fail to meet the specified standards. FIG. 8 also reflects an increased fiber yield with respect to the prior performs and processes, and increased uniformity that results from preventing the trench tube 22 from sinking during fiber draw.
[0046] FIG. 9 is a typical RI difference profile of fibers that were drawn from the preform 20 of the present Example. Note that the profile in FIG. 9 is substantially identical to that in FIG. 1 , thus confirming that the inventive preform and method produce a BIMMF having desired properties.
[0047] As disclosed herein, a bend insensitive multimode optical fiber is manufactured by placing a tube of down-doped quartz glass radially between an inner core rod and a surrounding overclad tube in a preform so that a trench region is formed in the index profile of the cladding of a drawn fiber. The preform is heated vertically in a furnace to collapse on the core rod, and the fiber is then drawn from the preform. Alternatively, once the preform collapses on the core rod, the preform can be withdrawn from the furnace and later re-heated for a fiber draw process. The inventive method provides higher productivity, lower cost, and higher fiber yield than the known prior methods.
[0048] While the foregoing represents preferred embodiments of the present invention, it will be understood by persons skilled in the art that various modifications, additions, and changes may be made without departing from the spirit and scope of the invention. For example, the dimensions and the RI of each component of the preform 20 may differ from the corresponding values given in the above Example, so that certain desired properties in the drawn BIMMF are obtained. Accordingly, the invention includes all such modifications, additions, and changes that are within the scope of the appended claims.
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A method of assembling a preform for a bend-insensitive multimode optical fiber (BIMMF), includes providing a multimode core rod, a glass overclad tube, and a trench tube of down-doped quartz glass with a depressed refractive index sufficient to obtain a desired trench depth in a refractive index (RI) profile of a drawn fiber. The core rod is placed inside the trench tube, and the trench tube and the core rod are placed inside the overclad tube to define the preform. A top end of the trench tube is formed to contact an adjacent part of either the core rod or the overclad tube so that the trench tube is suspended to hang from the adjacent part when the preform is vertically oriented, and a bottom end of the trench tube is restrained from sinking into a lower portion of the preform when the preform is heated to collapse.
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RELATION TO PRIOR APPLICATION
[0001] This is a U.S. non-provisional application relating to and claiming the benefit of U.S. Provisional Patent Application Ser. No. 61/512,453 filed Jul. 28, 2011.
BACKGROUND
[0002] Light emitting diode (LED) lighting systems are becoming more and more popular because of their efficiency and lifespan advantages over more traditional lighting systems such as incandescent, fluorescent and HID lighting systems. An LED light source is easier to control as it is directional. Instead of emitting three hundred sixty degrees as all previous light sources, LEDs emit light in one direction in patterns of ninety to one hundred forty-five degrees. However, all lights including LEDs have undesirable excessive amounts of waste light in certain situations. Waste light is light dispensed where it is not needed or is usable. This is the case with all lights when mounted high as with bay lights. Bay lights disperse some of their light at side angles at heights where it is not usable. It would be advantageous to have a method of controlling light which is normally emitted to the fixtures' sides and redirect it downward, thus minimizing this loss of light and energy. For example, with a twenty-five foot average ceiling height, four hundred watt metal halide fixtures spaced every thirty feet from one another are usually all that is necessary for proper lighting. If the ceiling height is forty-eight feet, usually it requires a six hundred watt or one thousand watt replacement, or a dual head four hundred watt system to replace the individual four hundred watt fixtures so as to obtain the same light to illuminate the same area due to the “waste light” loss. In most cases, fixtures must be set closer to one another for the same reason to create the needed light level.
[0003] With existing lighting marketed for years, such as incandescent, quartz, fluorescent and HID (sodium, mercury, metal halide), optimal control could only be adjusted by utilizing a means of reflectors as all the previous light systems emit light within a three hundred sixty degree circumference and the shape of the bulbs and tubes does not lend to accurate light dispersion. Thus, various fixtures at varying power levels were required for different light heights and distribution coverages. With the more controllable LED technology, newly introduced to commercial lighting, it is possible to provide more accurate light dispersion.
[0004] As LEDs are directional (not three hundred sixty degrees), it is possible to develop the LEDs/LED arrays with lensing molded to the LED emitter itself and, in some cases, small lenses or reflectors can be mounted to the LED board. This is somewhat of a step forward. With these methods, light dispersion is much more controllable, however, it produces the same restriction as earlier reflector systems with previous lights as, once the lens or reflector is mounted to the LED, it is now limited to a certain angle of light output and height.
SUMMARY OF THE INVENTION
[0005] In accordance with one form of this invention there is provided an LED light fixture including a housing adapted to be mounted at predetermined heights above a surface. The housing includes at least one LED emitter. The LED emitter is situated so as to emit light toward the surface. A first lens plate is provided and is removably attached to the housing. There is at least one opening in the first lens plate. A first lens is received in the opening. The opening of the first lens plate is aligned with the LED emitter whereby the first lens controls the angle of light dispersion of the light from the LED emitter and the footprint of the pattern of light which impinges on the surface. Preferably the housing includes a plurality of LED emitters and the lens plate includes a plurality of openings and lenses.
[0006] Preferably, a second lens plate is included having a second lens with a different angle of light dispersion from the first lens. The first lens plate is replaced by the second lens plate when the housing is mounted at a height above the surface which is different from the first predetermined height.
[0007] In accordance with another form of this invention there is provided a method for providing a substantially uniform light pattern from a light fixture having at least one LED emitter for various mounting heights of the fixture. The light fixture further includes a housing and a first lens plate. The first lens plate has at least one opening and a first lens having a first angle of light dispersion is received in the opening. The first lens is adjacent to the LED emitter. The method includes mounting the fixture at a first distance above a surface; energizing the LED emitter wherein light is emitted through the first lens and forms a light pattern on the surface having a predetermined footprint; removing the first lens plate from the light fixture; and replacing the first lens plate with a second lens plate. The second lens plate has at least one opening therein and a second lens having a second angle of light dispersion is received in the opening. The second lens is adjacent to the emitter. The method further includes mounting the fixture at a second predetermined distance above the surface; and energizing the LED emitter wherein light is emitted through the second lens and forms a light pattern on the surface having a footprint substantially equal to the first predetermined footprint.
[0008] In yet another form of this invention there is provided an LED lighting system including a light fixture with a housing. The housing includes an emitter plate having at least one LED emitter mounted thereon. A first lens plate having at least one opening therein is provided. A first lens having a first angle of light dispersion is mounted in the opening in the first lens plate. A second lens plate having at least one opening therein is also provided. A second lens having a second angle of light dispersion is mounted in the opening in the second lens plate. The light fixture is mountable at various heights above a surface. The first lens plate is attached to the housing for a first predetermined height above the surface. The first lens is located adjacent to the LED emitter wherein a light pattern having a predetermined footprint is formed on the surface. The second lens plate is attached to the housing for the second predetermined height above the surface. The second lens is located adjacent to the LED emitter wherein a light pattern having substantially the same predetermined footprint is formed on the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The subject matter which is regarded as the invention is set forth in the claims. The invention, however, may be better understood in reference to the accompanying drawings in which:
[0010] FIG. 1 is a partially exploded perspective view showing one embodiment of the subject invention.
[0011] FIG. 2 is an inverted partial perspective view showing a portion of the embodiment of FIG. 1 in more detail.
[0012] FIG. 3 is a side elevational view of several lenses which may be used with the lens plate of the embodiment of FIG. 1 .
[0013] FIG. 4 is a side elevational view of a portion of the embodiment of FIG. 1 .
[0014] FIG. 5 is a schematic illustration showing the relationship between the angle of light dispersion of various lenses and various fixture heights above a surface.
[0015] FIG. 6 illustrates the overlap of the light patterns on a surface using four fixtures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] This invention enables the control of light patterns using a single light fixture for many applications and for various heights. The fixture includes a removable lens plate which is populated with individual optic or dome lenses which are mounted in line with LED emitters which in turn are mounted on an emitter plate located within the light fixture. The invention enables the lens plate to incorporate multiple lenses, all with the same angle of light dispersion, to accurately control the exact light coverage or footprint as well as the intensity of the light in a specific area at a given height. An identical lens plate can also be utilized with dome type lenses to disperse the light further to the sides which is particularly useful in a low ceiling application since the light intensity is not as critical directly below the fixture in a low mounting position. The lens plate can also be populated with a mix of various lenses, including a mix of optic lenses and dome lenses for other custom applications. This allows for a single fixture to be utilized in a wide array of lighting circumstances. Appropriate optical lenses are commercially available from LED World. Appropriate dome lenses are commercially available from Ximenwerun Technology Corp.
[0017] The lens plate not only allows for a multitude of applications of a single fixture, it also allows for the same fixture to be relocated in various areas at various heights simply by exchanging the lens plate alone without a substantial change in the lighting pattern or light intensity. For example, at a thirty foot height, a ninety-five watt LED bay fixture having sixty degree light dispersion individual optic lenses within a lens plate can replace a four hundred watt metal halide fixture. At a twenty foot height, the LED fixture may best be suited with individual ninety degree light dispersion optic lenses to optimize the light output. Finally at twelve to fifteen foot heights, one could use dome lenses within the lens plate of the LED fixture. In addition, at twelve to fifteen foot heights, a combination of one hundred twenty degree light dispersion optic lenses, mixed with dome lenses, may be the optimal choice to acquire the desired light coverage. Most any degree and spread of light combination or degree of coverage can be achieved easily, with very little time and effort, simply by replacing the lens plate, using any number of individual optic or dome lenses, or any combination thereof, within the lens plate to precisely control the light emission in any area and in any situation by using a single fixture.
[0018] Referring now more particularly to FIG. 1 , there is provided LED light fixture 10 having a housing 12 . Housing 12 includes main housing 13 , mounting plate 14 , and emitter plate 16 . Mounting plate 14 is attached to main housing 13 which attaches to a ceiling (not shown). A plurality of LED emitters 18 and associated heat sinks 34 are mounted on emitter plate 16 . In the embodiment of FIG. 1 , there are six LED emitters. There is a plurality of holes 20 in main housing 13 used for mounting the lower fixture to main housing 13 . Holes 25 are for attaching lens plate 24 to emitter plate 16 through holes via spacers 28 using spacer screws 22 . The mounting screws pass through holes in both the emitter plate 16 and mounting plate 14 . Thus, the mounting plate 14 and emitter plate 16 are secured to the main housing 13 . Lens plate 24 is removably attached to emitter plate 16 by screws 26 . A plurality of stand-off spacers 28 maintains a predetermined distance between lens plate 24 and emitter plate 16 . Lens plate 24 includes six openings 30 therein. Each opening receives lens 32 . Stand-off spacer 28 also maintains a predetermined distance between LED emitter 18 , mounted on heat sink 33 , and optic lens 32 . Preferably this spacing between LED emitter 18 , mounted on heat sink 33 , and lens 32 is five millimeters for optic lenses. Preferably, for a dome type lens such as dome lens 34 shown in FIG. 4 , the LED emitter 18 penetrates to the inside of the dome. Dome lens 34 surrounds LED emitter 18 . As can be seen in FIG. 2 , a shim 36 may be provided and located between the top of spacer 28 and emitter plate 16 to increase the distance between the LED emitter 18 and lens 32 so as to change the angle of light even further. In the preferred embodiment, emitter 18 is attached to heat sink 33 which, in turn, is attached to emitter plate 16 . Emitter 18 may also be attached to a circuit board (not shown). The combination of emitter 16 and heat sink 33 is often referred to as an LED module.
[0019] As previously indicated, lenses having various angles of light dispersion may be used with lens plate 24 depending on the height that the fixture is placed above the surface, such as the ground or the floor of a building. For example, lens 32 may be hollow dome lens 34 which has a light dispersion of more than one hundred eighty degrees and in addition, the inside of the lens is frosted so as to evenly diffuse the light. This hollow dome lens is particularly adapted for use at lower levels. In addition as shown in FIG. 4 , by using a hollow dome lens which has been internally frosted, a limited amount of light disperses upwardly towards the ceiling which eliminates the cave effect.
[0020] Lens 32 may be any of a number of lenses having various light dispersions such as lens 34 , 37 , 38 and 40 shown in FIG. 3 . Lens 37 , which is a solid optical lens, has a light dispersion of ninety degrees and is ideal for heights above the surface of fifteen to twenty feet. Lens 38 is also a solid optical lens and has light dispersion of sixty degrees which makes it ideal for ceiling heights of eighteen feet to thirty-five feet. Lens 40 is also a solid optical lens and has a forty-five degree light dispersion and is ideal for ceiling heights of thirty to fifty feet. The difference in the light dispersion is accomplished by using lenses with different radii of curvature, as well as shim 36 .
[0021] Individual lenses may be replaced on the lens plate 24 to achieve optimum lighting for the surface, such as the floor. However, it is preferred that a lens plate having lenses with the same light dispersion be replaced with a lens plate having lenses with different light dispersions when it is desired to mount the fixture 10 at a different height above a surface. By using removable screws 26 , the replacement of a lens plate is made easy. Thus, by merely replacing a lens plate, the fixture may be used at different heights to provide the same lighting footprint for a given area of a surface such as a floor. This is best illustrated in reference to FIG. 5 .
[0022] FIG. 5 shows fixture 10 which is mounted at various levels above surface 42 , which in this embodiment is a floor. Also in this embodiment, fixture 10 is mounted to a ceiling.
[0023] FIG. 5 shows five angles of light dispersion, 44 , 46 , 48 , 50 and 52 , each representing a lens plate having lenses with a particular light dispersion. Line 44 illustrates use of a lens, such as dome lens 34 , having a light dispersion of more than one hundred eighty degrees mounted twelve feet above the floor 42 ( a ). Line 46 illustrates use of lens 37 having a light dispersion of ninety degrees with an elevation of fifteen feet above the floor. Line 48 represents use of a lens having a seventy degree light dispersion with the fixture being twenty feet above the floor. Line 50 represents a thirty-four degree light dispersion with the fixture mounted forty feet above the floor. Line 52 represents use of a lens having a twenty-two degree light dispersion where the fixture is mounted sixty feet above the floor. All of these lenses and fixture mounting heights provide a fifteen foot footprint of light on the floor. While there is some loss of light intensity at higher levels, the loss is not significant with this method.
[0024] FIG. 6 illustrates the overlap of floor lighting when using four ceiling mounted fixtures 10 located twenty feet apart. Other lighting fixtures in addition to indoor bay lights may be used, such as street lights. A preferred method for providing a substantially uniform lighting pattern from a light fixture for various mounting heights is set forth below.
[0025] The fixture is first mounted a predetermined distance above a surface. The LED emitters are energized so that light is emitted through lenses in the first lens plate and forms a lighted pattern on the surface having a predetermined footprint. The first lens plate is removed from the light fixture and replaced with a second lens plate. The second lens plate is substantially the same as the first plate except that it is populated with lenses having a different angle of light dispersion from the lenses of the first lens plate. The fixture is then mounted a second distance above the surface. The LED emitters are energized so that the light is emitted through the second lens plate and forms a lighted pattern on the surface having a footprint which is substantially equal to the first predetermined footprint.
[0026] While the invention has been described in terms of the above embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims.
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There is provided an LED light fixture including a housing adapted to be mounted a predetermined height above a surface. The housing includes at least one LED emitter situated so as to emit light toward the surface below the housing. A first lens plate is provided and is removably attached to the housing. The first lens plate has a first opening therein and a first lens having a first angle of light dispersion is received in the opening. The opening of the first lens plate is aligned with the LED emitter so that the first lens controls the footprint of the pattern of light from the LED emitter which impinges upon the surface.
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FIELD OF THE INVENTION
[0001] This invention relates to methods for carrying out multiple binding reactions between bio-molecules in an array-format and more specifically to such systems and methods using biosensors and more specifically using optical detection methods such as surface plasmon resonance (SPR).
BACKGROUND OF THE INVENTION
[0002] In the new era of genomics, proteomics and bio-informatics, a vast number of proteins, new drug targets and small molecules are being investigated intensively and in high-throughput fashion. Although the full mapping of the human genome is done, genomics cannot provide a complete understanding of cellular processes which involve functional interactions between proteins and other molecules as well. Therefore, proteomics may be considered as a cutting-edge area of research today, bridging genomics and cell function.
[0003] Current technological methods for analyzing a large number of functional interactions between bio-molecules (especially proteins) include well-plate based screening systems (e.g., ELISA), cell-based assays, soluble reactants screening (e.g., radio immunoassays) and solid-phase assays (e.g., DNA-chips). Today, there is an obvious lack of high throughput technology which enables real-time, label-free monitoring of kinetics of multiple bio-molecular interactions (especially proteins).
[0004] The major current limitation in developing such solid-phase based-assays stems from the complexity and variability of proteins. Proteins, in contrast to DNA molecules which are used in producing DNA-chips, are less stable, and generally must kept hydrated and in an active structure and conformation. Also, proteins are very sensitive to chemical and physical changes (e.g., temperature). Finally, with regard to solid-phase kinetic studies, the amount or capacity of an immobilized protein must be known in order to perform an accurate, full kinetic study.
[0005] As used herein, the term “biosensor” refers to combination of a receptor surface for molecular recognition and a transducer for generating signals indicative of binding to the surface.
[0006] Various related optical methods can be used to measure kinetic binding interactions between bio-molecules. These include, among others, Surface Plasmon Resonance (SPR), total internal reflection fluorescence (TIRF) and evanescent wave elipsometry. It is known in the art to use biosensors and mainly SPR for such purpose. A kinetic binding reaction involves a first molecular species referred to herein as “the probe”. The probe is adsorbed to the sensor surface, and a solution containing a second molecular species, referred to herein as “the target” is then allowed to flow over the probe molecules adsorbed onto the sensor surface. As is known in the art and in commercially available devices, a standard kinetic binding interaction measurement can be described by the following procedure:
(1) Chemical activation of solid-phase surface with a chemical activator (e.g., EDC/NHS); (2) Immobilization of a ‘probe’ molecule on a chemically-activated surface; (3) Washing and blocking of un-occupied activated groups with a blocker such as 1M ethanolamine; (4) Addition of one concentration of a ‘target’ molecule; (5) Washing and regeneration of the ‘probe’ with appropriate regenerating chemicals (e.g., 50 mM NaOH, 0.05% SDS); (6) Addition of another concentration of ‘target’; (7) Repeat stages 4-6, at least five times, each time with a different ‘target’ concentration.
[0008] In one aspect of this invention, the invention provides a method, referred to herein as “One-Shot Kinetics” (OSK). for obtaining one or more kinetic parameters of a binding reaction As shown below, this method allows carrying out a plurality of binding reactions without the need of the regeneration stage which is known to be harmful to the ‘probe’.
[0009] In general, any binding event between probe and target molecules can alter an SPR detection parameter which is than is used to monitor the binding reaction. The change in the detection parameter over time is used to determine a characteristic of the binding reaction, such as an association or dissociation constant rates as well as affinity. It is known to use surface Plasmon resonance (SPR) as the method of detection. SPR devices and methods are very sensitive to changes in an optical property of a probe layer and have proven to be useful in detecting changes in an optical property of a probe layer generated by relatively small stimuli.
[0010] An SPR probe layer may be configured as a multi-analyte “microarray” in which at each of a plurality of discrete regions, “microspots” on the sensor surface a probe material for interaction with a target material is adsorbed. Berger et al., describes a method for preparing a probe array and for presenting targets to the probe array so as to monitor the binding of the targets to the probes (“Surface Plasmon Resonance Multi-Sensing”, Anal. Chem. Vol. 70, February 1998, pp 703-706,.
[0011] PCT publication WO 02/055993, discloses the use of electrostatic fields and chemical cross-linking for binding probes to a sensor surface.
SUMMARY OF THE INVENTION
[0012] The present invention provides a system and method for determining kinetic parameters of one or more binding reactions between one or more probes and one or more targets. The probes and targets may be, for example, peptides, proteins, nucleic acids or polysaccharides. The probes and targets may be of the same species. For example, both of them may be proteins. Alternatively, the probes and targets may be of different species. For example, the probes may be nucleic acids, while the targets are proteins.
[0013] The system of the invention uses any detection method suitable for use in biosensors. More specifically, it uses a detection method based on an evanescent wave phenomenon such as surface plasmon resonance (SPR), critical angle refractometry, total internal reflection fluorescence (TIRF), total internal reflection phosphorescence, total internal reflection light scattering, evanescent wave elipsometry or Brewster angle reflectometry. The detection method makes use of a surface that allows a plurality of binding reactions to be monitored simultaneously. The method comprises adsorbing the probes to the sensor surface at different locations on the surface, for example by means of micro-fluidic methods using a chemical surface activator, or using a localized electric field. Each target is then presented to its respective probe adsorbed to the surface. The binding reactions between each pair of probe and target are monitored simultaneously.
[0014] In its first aspect, the present invention provides a system and method for determination of the kinetic parameters of a binding reaction, referred to herein as “One-Shot Kinetics” (OSK). This method allows carrying out a plurality of binding reactions without the need of the regeneration stage and without the need of repeated experiments which is known to be harmful to the ‘probe’. In this preferred embodiment of the method of the invention, a single probe species is adsorbed to microspots on a surface such as an SPR surface under a plurality of conditions, for example at different concentrations or pH, in order to obtain different probe densities. Some conditions may be repeated in order to obtain density duplicates. A single target species is then presented to the microspots at a plurality of concentrations. A plurality of probe density and target concentration combinations is thus obtained. The pluralities of reactions are monitored simultaneously and signals indicative of the binding reactions are obtained and analyzed so as to produce a kinetic analysis of the binding. The kinetic analysis may comprise of, for example, calculating an association constant or a dissociation constant or affinity constant for the binding of the probe to the target.
[0015] In its second aspect, the invention provides a method, referred to herein as “array-screening”, for simultaneously monitoring a plurality of binding reactions between a plurality of probes and one or more targets so as to obtain analysis of many binding reactions. In one embodiment of this aspect of the invention, a specific probe species is adsorbed to the surface at different one of a plurality of microspots so that each probe in each microspot may be selected independently of the probes on the other microspots. A target species is then presented to the probe in each microspot. Binding of the targets to the probes in the plurality of microspots is monitored simultaneously and signals indicative of the binding reactions are analyzed so as to produce analysis of the binding. The analysis may comprise of, for example, determining the existence of a detectable interaction at each microspot or calculating an equilibrium constant for the binding of the probe to the target at each microspot or determining the kinetics of binding.
[0016] The probes may be localized at different locations on the surface, for example, by means of micro-fluidic methods. The location on the surface may be activated, for example by using a chemical activator, or by applying an electric field, or by exposure to light (photo-activation). In order to achieve, localization, it is known to form a chemical thin layer covering a specific region of the surface, frequently referred as a binding layer. The binding layer may include different functional groups that are chemically activated, either by contact with chemical reagents, by applying an electric field, or by exposure to light (photo-activation).
[0017] Activation by an electric field may be carried out in two principal ways: (A) inducing an electrochemical reaction (reduction or oxidation) of functional groups in the binding layer. (B) applying an electric field so as to attract charged bio-molecules to the surface, and thus enhance the immobilization reaction; thus forming a higher local concentration of the probe molecules at the surface.
[0018] The most common binding layers for protein immobilization contain carboxylic groups. These carboxylic groups are activated by exposing the surface to accepted chemical activators, generally a mixture of EDC (1-ethyl-3-(3-dimethylaminopropyl) carbodiimide) and NHS (N-hydroxysuccinimide)) in an aqueous solution. As a result, active NHS esters are formed. When the activated surface is contacted with a protein solution, the NHS esters react efficiently with nucleophilic groups on the protein backbone, mainly with amino groups to form stable amide bonds. Thus, covalent immobilization of proteins is achieved. Other methods for chemical activation include attachment of a molecule that exhibits a high affinity to the candidate for immobilization, e.g. attachment of avidin or an avidin derivative for immobilization of biotin-labeled molecules.
[0019] The invention also provides a method for preparing a probe array for use in the method of the invention for monitoring binding reactions. Thus, in its first aspect, the invention provides a method for determining one or more kinetic parameters of binding between a first binding member and a second binding member comprising:
(a) adsorbing the first binding member to a surface at a plurality of microspots; (b) presenting the second binding member to the first binding member at each of the microspots, there being a plurality of combinations of first binding member surface density and second binding member concentration among the plurality of microspots; (c) simultaneously obtaining data indicative of a binding reaction between the first and second binding members at each of the plurality of microspots by a biosensor detection method; and (d) processing the data so as to obtain one or more kinetic parameters of binding between the first and second binding members.
[0024] In its second aspect, the invention provides a method for localizing a molecular species at each of two or more microspots on a surface, comprising, for each of one or more localization regions:
(a) activating the surface in the localization region; (b) for each of one or more microspots in the localization region, adsorbing a molecular species to the microspot; and (c) optionally deactivating the localization region.
[0028] In its third aspect, the invention provides a probe array produced by the method of the invention.
[0029] In its fourth aspect the invention provides a system for simultaneously monitoring a plurality of binding reactions between one or more probe species and one or more target species comprising
(a) A surface; (b) An applicator capable of applying probe species to microspots on the surface so as to allow the probe species to be adsorbed to the microspot, the applicator being further capable of presenting a target to each probe species adsorbed to the surface; (c) A photosurface receiving light reflected from the surface and generating signals indicative of the binding of the targets to the probes; and
[0033] (d) A processor configured to receive the signals generated by the photosurface and to analyze the signals so as to produce a kinetic analysis of the binding.
BRIEF DESCRIPTION OF FIGURES
[0034] In order to understand the invention and to see how it may be carried out in practice, a preferred embodiment will now be described by way of non-limiting example only, with reference to the following accompanying drawings, in which:
[0035] FIG. 1 shows a system for performing multiple binding reactions in accordance with one embodiment of the invention;
[0036] FIG. 2 shows a system for performing multiple binding reactions in accordance with another embodiment of the invention;
[0037] FIG. 3 shows a method for preparing a probe array in accordance with one embodiment of the invention;
[0038] FIG. 4 shows a method for preparing a probe array in accordance with another embodiment of the invention;
[0039] FIG. 5 shows binding curves of IL-4 to anti-IL-4 antibody obtained by the method of the invention; and
[0040] FIG. 6 shows binding curves of five antigen targets to six antibody probes.
[0041] FIG. 7 shows binding curves of various compound targets to six CYP450 enzyme probes.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0042] FIGS. 1 a and 1 b schematically show a system 10 for simultaneously carrying out multiple binding reactions in accordance with one embodiment of this aspect of the invention. The system 10 includes an SPR device 80 comprising an array 24 of light sources 26 and a prism 30 having a sensor surface 32 . The light sources 26 provide light at a wavelength appropriate for SPR applications as is known in the art. The light array 24 is positioned at the focal plane of an optical system schematically represented by a lens 46 having an optical axis 48 . Lens 46 collects and collimates light from each light source 26 into a beam of parallel light rays and directs the collimated light so that it is incident on an “input” prism surface 50 of prism 30 . Light directed by collimator 46 that is incident on input surface 50 enters prism 30 and is incident on sensor surface 32 .
[0043] All light incidents on the sensor surface 32 from a given light source 26 is incident on the sensor surface at substantially a same incident angle and light from different light sources 26 is incident on the sensor surface at different incident angles. The angle at which light from a given light source 26 is incident on sensor 26 on sensor surface 32 is determined by the position of the given light source along the axis of the array 24 , the focal length of the lens 46 and the index of refraction of the material from which prism 30 is formed. The SPR device 80 may include a “displacement plate” (not shown) formed from a transparent material that is positioned between light source array 24 and prism 30 . The angular orientation of displacement plate is set so that the normal to the displacement plate is oriented at a desired angle with respect to the optic axis 48 .
[0044] Light incident on sensor surface 32 that is reflected from the surface exits prism 30 through an output prism surface 52 and is collected and imaged by a camera 55 having a lens 53 and a two dimensional photosurface 54 such as a CCD. A polarizer (not shown) is positioned between the array 24 and the prism 30 or preferably between the prism 30 and the camera 55 . The polarizer linearly polarizes light received by photosurface 54 so that relative to sensor surface 32 it has substantially only a p component of polarization.
[0045] The camera 55 outputs signals 57 that are indicative of images formed on the photosurface 54 . The signals 57 are input to a processor 59 having a memory 63 for storing signals 57 . The processor 59 is configured to analyze the signals as described below. Any of the signals 57 or results of the analysis performed by the processor may be displayed on an associated display screen 65 .
[0046] The system 10 includes a flow cell 34 having m microchannels 36 for flowing liquid across and in contact with the sensor surface 32 . In the device 80 , m=5 microchannels 36 a to 36 e are shown. This is by way of example only, and the method of the invention may be carried out using flow cell having any number m of microchannels. The outer form of flow cell 34 is shown in ghost lines and details of internal features, such as microchannels 36 , of the flow cell are shown in solid lines for clarity of presentation. Each microchannel 36 has at one end an inlet (not visible in the perspectives shown in FIGS. 1 a and 1 b ) and, at its other end, an outlet 61 through which fluid flowing in the microchannel exits the microchannel. Each of the inlets is adapted to be independently connected to a suitable pumping apparatus (not shown) in order to introduce a fluid independently into each of the m microchannels 36 .
[0047] In the system 10 , the flow cell 34 is mountable onto the SPR surface in two orientations. One of the two orientations is shown in FIG. 1 a and is referred to herein as “the probe orientation”. The second orientation, shown in FIG. 1 b is referred to herein as the “target orientation”. In each of the two orientations, the microchannels are perpendicular to the microchannels in the other orientation. Each microchannel 36 is open on a side of the microchannel facing sensor surface 32 so that fluid flowing in the microchannel, in either orientation, contacts the SPR surface in a rectangular region. In the probe orientation shown in FIG. 1 a , fluid flowing in a microchannel contacts the sensor surface at a respective rectangular region 42 referred to herein as the microchannel's “probe region” (see FIG. 1 b ). In the target orientation shown in FIG. 1 b , fluid flowing in a microchannel contacts the sensor surface at a respective rectangular region 43 referred to herein as the microchannel's “target region” (see FIG. 1 a ). The probe regions and the target regions are thus perpendicular to each other. Regions of some microchannels 36 in the system 10 in FIGS. 1 a and 1 b are cut away to show microspots 58 formed at the crossover regions of the probe regions and the target regions.
[0048] FIG. 2 schematically shows a system 11 for simultaneously carrying out multiple binding assays in accordance with another embodiment of this aspect of the invention. The system 11 includes an SPR device 20 having several components in common with the SPR device 80 shown in FIG. 1 , and similar components are indicated with the same reference numeral in both figures. In particular, the SPR device 80 includes an optical system comprising an array 24 of light sources 26 , a prism 30 having a sensor surface 32 , a lens 46 having an optical axis 48 , and a two dimensional photosurface 54 such as a CCD. A suitable SPR conductor (not shown) is formed on the sensor surface.
[0049] The system 11 includes a flow cell 34 having m microchannels 36 for flowing liquid across and in contact with the sensor surface 32 . In the device 80 , m=5 microchannels 36 a to 36 e are shown. This is by way of example only, and the method of the invention may be carried out using a flow cell having any number m of microchannels. The outer form of flow cell 34 is shown in ghost lines and details of internal features, such as microchannels 36 , of the flow cell are shown in solid lines for clarity of presentation. Each microchannel 36 has at one end an inlet (not visible in the perspectives shown in FIGS. 1 a and 1 b ) and, at its other end, an outlet 61 through which fluid flowing in the microchannel exits the microchannel. Each of the inlets is adapted to be independently connected to a suitable pumping apparatus (not shown) in order to introduce a fluid independently into each of the m microchannels 36 .
[0050] The SPR device 20 has n strip electrodes 33 . The n strip electrodes are used to create n independently activatable regions. While n=5 strip electrodes 33 a to 33 b are shown in FIG. 2 , this is by way of example only and the method of the invention may be carried out with an SPR device having any number of strip electrodes.
[0051] In the system 11 , the flow cell 34 is mounted onto prism 30 so that the m microchannels are perpendicular to the n strip-electrodes 33 . Each microchannel 36 is open on a side of the microchannel facing sensor surface 32 so that fluid flowing in the microchannel contacts each strip electrode 33 at a microspot 58 located at the crossover region of the microchannel with the strip electrode. In an SPR device having m microchannels and n strip electrodes, a total of m×n microspots are formed at eh crossover regions of the m microchannels with the n strip electrodes. Regions of some microchannels 36 in SPR device 20 in FIG. 2 are cut away to show microspots 58 .
[0052] Each strip electrode 33 is independently connected to a power supply 60 . Power supply 60 is controllable to independently bring each strip electrode 33 to a voltage relative to a reference electrode 62 connected to the power supply so as to generate an electric field having a component perpendicular to the sensor surface 32 . The electric field passes through the lumen of the microchannels 36 at the crossover region of the microchannels with the strip electrode.
[0053] FIG. 3 schematically shows a method for preparing a probe array on a surface 70 in accordance with one embodiment of the method of the invention. In FIG. 3 a , a first surface region 72 a on the surface 70 is activated. Activation of a surface region allows probe molecules to be adsorbed to the surface region. One or more probe species 71 are then adsorbed to the activated first surface region 72 ( FIG. 3 b ) at distinct microspots in the first surface region 72 . FIG. 3 b schematically shows the application of 6 probe species 71 a to 71 f to the activated first surface region 72 a . This is by way of example only and the method of the invention may be carried out with any number of probe species 71 being adsorbed to the first surface region 72 . This produces the probe array shown in FIG. 3 c , in which each probe species is adsorbed to a different microspot 74 . FIG. 3 c shows 6 microspots 74 a to 74 f . The probe species may all be different or some of the probe species may be the same possibly at different concentrations.
[0054] The first surface region is now deactivated and a second surface region 72 b is activated. One or more probe species are then adsorbed to distinct microspots on the second surface region 72 b , as explained above for the first surface region 72 a . The process is repeated, each time activating a different one of the surface regions 72 until probe species have been adsorbed to microspots on each of the surface regions 72 . This produces the probe array shown in FIG. 3 d in which a plurality of probe species is adsorbed to microspots 75 . In FIG. 3 d, 6 surface regions 72 a to 72 f are shown. This is by way of example only, and the method of the invention may be carried out with any number of surface regions 72 . In the example shown in FIG. 3 d , on each of the 6 surface regions 72 , 6 probe species were adsorbed. This produces the array of 36 microspots shown in FIG. 3 d . The probe species adsorbed on different surface regions may be different, so that up to 36 different probe species may be adsorbed onto the surface 70 .
[0055] After the probe array on the surface 70 has been prepared, for each surface region, a target species may presented to the probe species adsorbed to the microspots.
[0056] The method of preparing a probe array on a surface shown in FIG. 3 will now be demonstrated with reference to the system 10 of FIG. 1 . In this example, m 2 probe species are to be adsorbed to the SPR surface at the m 2 microspots 58 (m 2 =25 in the SPR device 80 of FIG. 1 ) located at the m 2 crossover regions of the m probe regions with the m target regions. To prepare an appropriate microarray of the m 2 probes on the probe regions, the flow cell 34 is first placed in one orientation ( FIG. 1 b ) and buffer or water is first pumped through the first microchannels 36 in order to clean and prepare the first surface region 43 a . Flow of buffer or water through the first microchannel 36 a is then stopped a solution of a chemical surface activator is then made to flow through the first microchannel 36 a in order to activate the first surface region 43 a . The first surface region is now activated.
[0057] The flow cell is now rotated 90° to bring it from the target orientation shown in FIG. 1 b to the probe orientation shown in FIG. 1 a . An appropriate solution comprising a probe species is pumped through each of the m microchannels 36 . The m probe species may all be different, or some may be the same probe species, possibly at different concentrations. As a result of the activation of the first surface region 43 a , each probe species is adsorbed to the first surface region 43 a and is not adsorbed by the other m−1 surface regions 43 b 43 e . Each of the probe species is thereby immobilized at a different one of the m microspots 58 located at the m crossover regions of the m probe regions 42 with the first surface region 54 a . The probes are substantially prevented from immobilizing at the m×(m−1) microspots 58 located at the crossover regions of the m probe regions 42 with the m−1 other surface regions 43 b - 43 e.
[0058] During immobilization of the probes, the process of immobilization and the quantities of probe proteins immobilized at each microspot 58 are monitored by performing an SPR angular scan of the sensor surface 64 , as is known in the art. The signals 57 generated by the CCD 54 responsive to light from each light source 26 reflected at each microspot 58 on the first surface region 43 a during adsorption of the probes are input to the processor 59 . The processor 59 is configured to analyze the signals so as to determine an SPR parameter for the microspot. The SPR parameter may be, for example, the SPR resonance angle, resonance wavelength, or the reflectance and phase changes that characterize a surface Plasmon resonance. The processor is further configured to analyze the SPR parameter so as to monitor accumulation of the probe immobilized at the microspot. Signals 57 from microspots of the other m−1 surface regions and from regions of the probe surface that are not crossover regions are analyzed by the processor to correct and normalize signals from crossover regions of the first surface region.
[0059] After termination of the flow of the probe solutions in the microchannels, the flow cell is rotated 90° back to the target orientation ( FIG. 1 b ) and a solution containing a surface activator blocker is made to flow through the microchannels 36 to prevent further binding to the first surface region.
[0060] The above-described process is repeated for each of the other remaining m−1 surface regions 43 b - 43 a with m probe solutions, until a probe species has been immobilized at each of as many as m 2 different microspots 58 located at the m 2 crossover regions of the m probe regions and the m surface regions. Each surface region 43 may thus be activated individually. As used herein, the term “activatable region” is used to refer to a region that can, when activated, bind one or more probe species. Thus, with the method of the invention, a probe microarray comprising as many as m 2 different probe species may be formed on the SPR surface of the SPR device 80 .
[0061] Following preparation of the probe microarray, a solution containing a target species is made to flow in each of the m microchannels 36 in the flow cell with the flow cell in the target orientation. The m target species may all be different, or some of the target species may be the same, possibly at different concentrations. Thus, for each of the m target solutions, the target is presented to each of the m probe species in the m microspots 58 located at the m crossover regions of the target's target region with the m probe regions. The signals 57 provided by the CCD 54 responsive to light from the light sources reflected from each of the m 2 microspots 58 during flow of the target molecules in the microchannels are input to the processor 59 . The processor 59 is configured to analyze these signals in order to monitor the binding of target to probe at each microspot. A total of as many as m 2 binding reactions can thus be monitored simultaneously involving as many as m 2 different probe species and as many as m different target species. As known in the art, reference surface must be used and be subtracted from any signal obtained from ‘active spot’. In one aspect of this invention, and as a novel outcome of the method, the surface between the spots, termed “inter-spot” is used as a reference surface.
[0062] The method of preparing a probe array on a surface shown in FIG. 3 will now be demonstrated with reference to the system 11 of FIG. 2 . In this example, m×n probe species are to be adsorbed to the SPR surface that at the m×n microspots 58 (m×n=25 in the system 11 of FIG. 2 ) located at the m×n crossover regions of the m microchannels 36 with the n strip electrodes 33 . To prepare an appropriate microarray of the m×n probes on the strip electrodes 33 , buffer or water is first pumped through the microchannels 36 to clean and prepare the strip electrodes for immobilization of the probe molecules at the microspots 58 . Flow of buffer or water through the m microchannels is then stopped and the first strip electrode 33 a is now activated as explained above. The remaining strip electrodes are all brought to a potential with respect to the reference electrode 62 having a polarity opposite to that of the first electrode. An appropriate solution comprising a probe species is pumped through each of the m microchannels 36 . The m probe species may all be different, or some may be the same probe species, possibly at different concentrations. As a result of the activation of the first strip electrode 33 a and the charge on the m probe species in the microchannels, each probe species is adsorbed to the first strip electrode 33 a and is not adsorbed by the other n−1 strip electrodes 33 b - 33 e . Each of the probe species is thereby immobilized at a different one of the m microspots 58 located at the m crossover regions of the m microchannels with the first strip electrode 33 a . The probes are substantially prevented from immobilizing at the m×(n−1) microspots 58 located at the crossover regions of the m microchannels with the n−1 other strip electrodes 33 b - 33 e.
[0063] During immobilization of the probes, the process of immobilization and the quantities of probe proteins immobilized at each microspot 58 are monitored by performing an SPR angular scan of the sensor surface 64 , as is known in the art. The signals 57 generated by the CCD 54 responsive to light from each light source 26 reflected at each microspot 58 on the first strip electrode 33 a during adsorption of the probes are input to the processor 59 . The processor 59 is configured to analyze the signals so as to determine an SPR parameter for the microspot. The processor is further configured to analyze the SPR parameter so as to monitor accumulation of the probe immobilized at the microspot. Signals from microspots of the other n−1 strip electrodes 33 b - 33 e and from regions of the probe surface that are not crossover regions are analyzed by the processor to correct and normalize signals from crossover regions of the first target region.
[0064] After termination of the flow of the probe solutions in the microchannels, buffer or water is again made to flow through the microchannels 36 to eliminate unbound probe proteins.
[0065] The above-described process is repeated for each of the other remaining n−1 strip electrodes 33 b - 33 e with m probe solutions, until a probe species has been immobilized at each of as many as m×n different microspots 58 located at the m×n crossover regions of the m microchannels 36 and the n strip electrodes 33 . Thus, with the method of the invention, a probe microarray comprising as many as m×n different probe species may be formed on the SPR surface of the SPR device 20 .
[0066] Following preparation of the probe microarray, a solution containing a target species is made to flow in each of the m microchannels 36 . The m target species may all be different, or some of the target species may be the same, possibly at different concentrations. Thus, for each of the m target solutions, the target is presented to each of the n probe species in the n microspots 58 located at the n crossover regions of the target's microchannel with the n strip electrodes. The signals 57 provided by the CCD 54 responsive to light from the light sources reflected from each of the m 2 microspots 58 during flow of the target molecules in the microchannels are input to the processor 59 . The processor 59 is configured to analyze these signals in order to monitor the binding of target to probe at each microspot. A total of as many as m×n binding reactions can thus be monitored simultaneously involving as many as m×n different probe species and as many as m different target species. In a preferred embodiment, a region of the surface, referred to as “an interspot” is used as a reference surface to provide a reference signal.
[0067] FIG. 4 shows a method for preparing a probe array on a surface 80 in accordance with another embodiment of the method of the invention (termed “OSK” or “one-shot kinetics”). This embodiment may be used when it is desired to perform a binding assay involving one probe species and one target species at different combinations of probe and target concentrations. In this embodiment, m probe regions 82 are simultaneously activated. 6 probe regions 82 a to 82 f are shown in FIG. 4 a . This is by way of example only, and the method may be carried out with any number of probe regions. The m probe regions 82 are activated and the probe is adsorbed onto the probe regions 82 . A different probe concentration is adsorbed onto each probe region. One of the probe regions 82 f may be used as a reference region upon which no probe is adsorbed.
[0068] As depicted in FIG. 4 b , n concentrations of the target are then presented to the probe array (designated analytes 1 - 6 ). Each concentration is presented to a different microspot on each of the probe regions. The reaction assay thus consists of all of the m×n combinations of the probe and target concentrations.
[0069] The method of performing a binding assay shown in FIG. 4 will now be demonstrated with reference to the system 10 of FIG. 1 . This embodiment is used when it is desired to perform a binding assay involving one probe species and one target species at different combinations of probe and target concentrations. The probe species is applied to each of the m probe regions at a different concentration, and the target is applied to each of the m target regions at a different concentration. To prepare this microarray, the flow cell 34 is first placed in the probe orientation ( FIG. 1 a ) and buffer or water is first pumped through the m microchannels 36 in order to clean and prepare the m probe regions 42 . Flow of buffer or water through the m microchannels 36 is then stopped and any residual buffer or water in the flow system is drained away. A solution of a chemical surface activator is then made to flow through the m microchannels 36 in order to activate the m probe regions 42 . The surface activator may be, for example, EDC/NHS. The m probe regions are now activated.
[0070] An appropriate solution comprising the probe is pumped through each of the m microchannels 36 . In this embodiment, the probe is present in each of the different microchannels at a different concentration. As a result of the activation of the target regions 42 , probe molecules in each microchannel are adsorbed to the n microspots 58 in contact with the microchannel.
[0071] During immobilization of the probes, the process of immobilization and the quantities of probe proteins immobilized at each microspot 58 are monitored by performing an SPR angular scan of the sensor surface 64 , as is known in the art. The signals 57 generated by the CCD 54 responsive to light from each light source 26 reflected at each probe region 42 during adsorption of the probe are input to the processor 59 . The processor 59 is configured to analyze the signals so as to determine an SPR parameter for each probe region 42 . The processor is further configured to analyze the SPR parameter so as to monitor accumulation of the probe immobilized on each probe region 42 . Signals 57 regions of the SPR surface not in a probe region are analyzed by the processor to correct and normalize signals from the probe regions.
[0072] After termination of the flow of the probe solutions in the microchannels, a solution containing a surface activator blocker is made to flow through the microchannels 36 to prevent further binding of molecules to the SPR surface. The surface activator blocker may be, for example, ethanolamine.
[0073] The flow cell is now rotated 90° from the probe orientation to the target orientation ( FIG. 1 b ). A solution containing the target species is made to flow in each of the m microchannels 36 of the flow cell. In this embodiment, the target is present in the different microchannels at a different concentration. Thus, for each of the m target solutions, the target is presented to each of the m probe concentrations species in the m microspots 58 located at the m crossover regions of the target solution with the m probe regions. The signals 57 provided by the CCD 54 responsive to light from the light sources reflected from each of the m 2 microspots 58 during flow of the target molecules in the microchannels are input to the processor 59 . The processor 59 is configured to analyze these signals in order to monitor the binding of target to probe at each microspot. In this embodiment, a total of m 2 binding reactions are thus monitored simultaneously involving as many as m 2 different combinations of probe concentration and target concentration. This allows the collection of kinetic data on the binding of the target to the probe for kinetic analysis in a single binding assay, without the need to regenerate the surface at any time. This is in contrast to prior art methods in which reactions are performed sequentially, each time with a different combination of probe and target concentrations which requires regeneration of the surface between successive binding reactions.
[0074] The method of performing a binding assay shown in FIG. 4 will now be demonstrated with reference to the system 11 of FIG. 2 . The probe species is applied to each of the m probe regions at a different concentration, and the target is applied to each of the m target regions at a different concentration. To prepare this microarray, the flow cell 34 is positioned as shown in FIG. 2 with the m microchannels 36 perpendicular to the n strip electrodes 33 . Buffer or water is first pumped through the microchannels 36 to clean and prepare the SPR surface in contact with the microchannels Flow of buffer or water through the m microchannels is then stopped and the n strip electrodes 33 are now activated as explained above. An appropriate solution comprising the probe is pumped through each of the m microchannels 36 . In this embodiment, the probe is present in each of the different microchannels at a different concentration. As a result of the activation of the strip electrodes 33 and the charge on the probe in the microchannels, probe molecules are adsorbed to the strip electrodes 33 . Probe molecules are thereby immobilized at a different one of the n microspots 58 located at the n crossover regions of the microchannel with the n strip electrodes 33 .
[0075] During immobilization of the probes, the process of immobilization and the quantities of probe proteins immobilized at each microspot 58 are monitored by performing an SPR angular scan of the sensor surface 64 , as is known in the art. The signals 57 generated by the CCD 54 responsive to light from each light source 26 reflected at each microspot 58 on the first strip electrode 33 a during adsorption of the probes are input to the processor 59 . The processor 59 is configured to analyze the signals so as to determine an SPR parameter for the microspot. The processor is further configured to analyze the SPR parameter so as to monitor accumulation of the probe immobilized at each microspot. Signals 57 from regions of the probe surface that are not microspots are analyzed by the processor to correct and normalize signals from of the microspots.
[0076] After termination of the flow of the probe solutions in the microchannels, buffer or water is again made to flow through the microchannels 36 to eliminate unbound probe proteins.
[0077] The flow cell 34 now removed from the SPR surface and a second flow cell (not shown) having n microchannels is positioned on the SPR surface with a microchannel overlying each of the n strip electrodes 33 . In the case that m=n, the flow cell 34 may also be used as the second flow cells by rotting it 90° from the orientation shown in FIG. 2 to an orientation (not shown) in which the microchannels 36 overlay the strip electrodes 33 . A solution containing the target is made to flow in each of the n microchannels. In this embodiment, the target is present in the different microchannels at a different concentration. Thus, for each of the n target solutions, the target is presented to each of the m probe concentrations in the m microspots 58 located at the m crossover regions of the targets microchannel with the m probe regions. The signals 57 provided by the CCD 54 responsive to light from the light sources reflected from each of the n×m microspots 58 during flow of the target molecules in the microchannels are input to the processor 59 . The processor 59 is configured to analyze these signals in order to monitor the binding of target to probe at each microspot. This allows collection of kinetic data on the binding of the target to the probe for kinetic analysis in a single binding assay, without the need to regenerate the surface at any time. This is in contrast to prior art methods in which reactions are performed sequentially, each time with a different combination of probe and target concentrations which requires regeneration of the surface between successive binding reactions.
EXAMPLES
Example 1
[0078] A binding assay was carried out using the system 10 shown in FIG. 1 . Anti-IL-4 antibody (αIL-4) was used as a probe in this experiment and was localized on the SPR surface in each of six rectangular probe regions 42 (see FIG. 1 ), as explained above in the description of the system 10 . The probe regions were labeled (a) to (f). The density of the antibody, in “response units” (RU), in each of the 6 probe regions is given in Table 1.
TABLE 1 Probe Target (αI1-4) concentration region (pg/mm 2 ) (RU) (a) 530 (b) 315 (c) 346 (d) 360 (e) 334 (f) 355
[0079] IL-4 was used as the target in this experiment was presented to the αIL-4 in each of five target regions 43 (see FIG. 1 ), as explained above. The target regions were numbered 1 to 5. The concentration of IL-4 in each target region is given in Table 2.
TABLE 2 Probe Target (IL-4) Localization concentration Site (nM) (1) 26.7 (2) 8.89 (3) 2.96 (4) 0.98 (5) 0.33
[0080] The binding assay thus involved 30 binding reactions that were performed simultaneously. Binding of IL-4 to αIL-4 in the 30 microspots was monitored simultaneously as described above. The results of the binding are shown in FIG. 5 . Each graph in FIG. 5 shows binding of IL-4 to αIL-4 in the probe region indicated in the graph. Each of the 5 curves in the graph shows the results of the binding of IL-4 to αIL-4 in the microspot located at the intersection of the probe region of the graph and the target region specified for each curve. At the times indicated by the arrow in each graph, unbound IL-4 was rinsed away, and the dissociation of bound IL-4 from αIL-4 in the 30 microspots was monitored simultaneously by the method of the invention. The processor 63 was configured to analyze the curves in each graph to obtain the association constant (Ka) and the dissociation constant (Kd) of the binding of Il-4 to αIL-4 at the antibody concentration of the graph. The Ka and Kd of each graph are shown in each of the graphs in FIG. 5 . From these, the affinity constant (KD) can be derived, as is known in the art.
Example 2
[0081] Binding between 6 antibody probes (αIgG1, αIgG2b, αIgA, αIgG2a and αIgG3) to 5 antigen targets (IgG1, IgG1, IgG2a, IgG2b and IgG3) was studied using the system 10 of FIG. 1 . The concentrations used of the probes and targets are given in Tables 3 and 4, respectively. The binding curves obtained are shown in FIG. 6 and the binding response of each of the 30 binding reactions is shown in Table 5.
TABLE 3 Probe Probe concentrations Probe region (pg/mm 2 ) (RU) Anti mouse IgG2a a 3410 Anti mouse IgG2b b 4170 Anti mouse IgG1 c 3970 Anti mouse IgG3 d 3500 Anti mouse IgA e 3770 Reference surface f —
[0082]
TABLE 4
Target
Target
concentrations(μg/ml)
IgG1 (anti IL-2)
2.5
IgG1 (anti IL-4)
2.5
IgG2a
5
IgG2b
5
IgG3
5
Mouse IgG
5
The Binding Responses to Different Antibody Subclasses (in Response Units)
[0083]
TABLE 5
Anti
Anti
Anti
Anti
Anti
Ligand
mouse
mouse
mouse
mouse
mouse
Analyte
IgG2a
IgG2b
IgG1
IgG3
IgA
IgG1
21
42
44
—
—
(anti IL-2)
IgG1
23
—
45
—
—
(anti IL-4)
IgG2a
90
—
—
—
—
IgG2b
—
241
—
—
—
IgG3
—
—
—
97
—
IgG polyclonal
122
67
44
30
—
Example 3
[0084] The binding of five Cytochrome-P450 (CYP) enzyme probes (3A4, 2C19, 1A2, 2C9 and 2D6) with 6 different targets (Ketoconazole, Nifedipine, Dextromethorphan, Diclofenac, Dulfaphenazole and Propranolol) was carried out using the system 10 of FIG. 1 . The targets were presented at concentrations of 1,000, 500, 250, 125, 62.5, 31.25, 15.5, and 7.8 μM. The affinity constant, KD was determined for each reaction. The results are shown in FIG. 7 and Table 6.
TABLE 6 Affinity constants (KD in [M]) determined for binding of various compounds to five CYP enzymes. CYP-P450 3A4 2C19 1A2 2C9 2D6 Ketoconazole 2.59E−05 5.21E−05 1.33E−03 7.65E−05 2.10E−04 Nifedipine 1.84E−03 2.24E−03 5.81E−02 1.42E−03 4.37E−03 Dexomethorphan 1.26E−02 7.90E−03 — 2.83E−02 6.04E−02 Diclofenac 4.47E−04 7.17E−04 1.42E−02 1.66E−04 6.81E−04 Sulfaphenazole 1.65E−01 1.14E−02 1.15E−03 2.06E−03 7.11E−02 Propranolol 7.53E−02 6.59E−03 8.73E−04 5.13E−03 5.22E−03
Example 4
[0085] Table 7 shows immobilization of Rabbit IgG and Goat IgG probes on 36 independent microspots prepared by the method shown in FIG. 3 , using the system 10 of FIG. 1 . Each probe region was sequentially activated and six alternate probes of Rabbit IgG and Goat IgG were adsorbed onto the activated probe region. This resulted in the immobilization of 36 alternate probes in the 36 microspots (6 in each surface region), as shown in Table 7.
TABLE 7 1 2 3 4 5 6 1 Goat IgG Rabbit IgG Goat IgG Rabbit IgG Goat IgG Rabbit IgG 543 RU 1640 RU 963 RU 1950 RU 1050 RU 1420 RU 2 Rabbit IgG Goat IgG Rabbit IgG Goat IgG Rabbit IgG Goat IgG 1620 RU 1060 RU 1800 RU 1020 RU 1320 RU 1060 RU 3 Goat IgG Rabbit IgG Goat IgG Rabbit IgG Goat IgG Rabbit IgG 525 RU 1870 RU 1200 RU 1960 RU 1300 RU 1430 RU 4 Rabbit IgG Goat IgG Rabbit IgG Goat IgG Rabbit IgG Goat IgG 1730 RU 1300 RU 2070 RU 1240 RU 1540 RU 1360 RU 5 Goat IgG Rabbit IgG Goat IgG Rabbit IgG Goat IgG Rabbit IgG 608 RU 1660 RU 1200 RU 2160 RU 1340 RU 1730 RU 6 Rabbit IgG Goat IgG Rabbit IgG Goat IgG Rabbit IgG Goat IgG 1680 RU 1080 RU 1910 RU 1120 RU 1530 RU 1110 RU
[0086] Mouse anti-rabbit and mouse anti-goat antibody targets were then presented to the probe array. Table 8 shows the target binding responses. Each of the 36 independently selected probes in the probe array reacts with its corresponding target allowing 36 different and independent interactions to be performed and monitored simultaneously (in a “checker board” pattern).
TABLE 8 1 2 3 4 5 6 Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit (0 RU) (348 RU) (2 RU) (431 RU) (1 RU) (291 RU) Anti Goat Anti Goat Anti Goat Anti Goat (Anti Goat Anti Goat (308 RU) (5 RU) (553 RU) (0 RU) (584 RU) (0 RU) Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit (354 RU) (0 RU) (415 RU) (0 RU) (262 RU) (0 RU) Anti Goat Anti Goat Anti Goat Anti Goat (Anti Goat Anti Goat (0 RU) (573 RU) (0 RU) (571 RU) (1 RU) (579 RU) Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit (4 RU) (402 RU) (1 RU) (435 RU) (0 RU) (291 RU) Anti Goat Anti Goat Anti Goat Anti Goat (Anti Goat Anti Goat (299 RU) (4 RU) (650 RU) (1 RU) (687 RU) (1 RU) Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit (362 RU) (0 RU) (480 RU) (0 RU) (309 RU) (0 RU) Anti Goat Anti Goat Anti Goat Anti Goat (Anti Goat Anti Goat (1 RU) (674 RU) (0 RU) (660 RU) (1 RU) (704 RU) Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit (0 RU) (355 RU) (3 RU) (475 RU) (1 RU) (360 RU) Anti Goat Anti Goat Anti Goat Anti Goat (Anti Goat Anti Goat (353 RU) (0 RU) (642 RU) (0 RU) (708 RU) (0 RU) Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit Anti Rabbit (358 RU) (0 RU) (435 RU) (1 RU) (300 RU) (0 RU) Anti Goat Anti Goat Anti Goat Anti Goat Anti Goat Anti Goat (4 RU) (580 RU) (2 RU) (602 RU) (2 RU) (595 RU)
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A method for determining one or more kinetic parameters of binding between a first binding member and a second binding member. The method comprises adsorbing the first binding member to a surface at a plurality of microspots. The second binding member is then presented to the first binding member at each of the microspots, there being a plurality of combinations of first binding member surface density and second binding member concentration among the plurality of microspots. Data indicative of a binding reaction between the first of microspots are then obtained and analyzed so as to obtain one or more kinetic parameters of the binding between the first and second binding members. The invention also provides a system for carrying out the method. A method for localizing a molecular species at microspots on a surface, and a probe array produced by the method are also provided.
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This application claims the benefit of U.S. Provisional Application No. 60/056,308, filed Sep. 3, 1997.
FIELD OF THE INVENTION
This invention is directed to anti-atherosclerotic agents and more specifically to compounds, compositions and methods for treating atherosclerotic conditions such as dyslipoproteinimias and coronary heart disease. This invention specifically relates to substituted tetrahydro-pyrimidine-2(1H)-thione derivatives that elevate HDL cholesterol (HDL-C) concentration and which may be useful for the treatment of atherosclerotic conditions and coronary heart disease.
BACKGROUND OF THE INVENTION
Numerous studies have demonstrated that both the risk of coronary heart disease (CHD) in humans and the severity of experimental atherosclerosis in animals are inversely correlated with serum HDL cholesterol (HDL-C) concentrations (Russ et al., Am. J. Med., 11, 480-483 (1951); Gofman et al., Circulation, 34, 679-697 (1966); Miller and Miller, Lancet, 1, 16-19 (1975); Gordon et al., Circulation, 79, 8-15 (1989); Stampfer et al., N. Engl. J. Med. 325, 373-381 (1991); Badimon et al., Lab. Invest., 60, 455-461 (1989)). Atherosclerosis is the process of the accumulation of cholesterol within the arterial wall which results in the occlusion, or stenosis, of coronary and cerebral arterial vessels and subsequent myocardial infarction and stroke. Angiographic studies have shown that elevated levels of some HDL particles in humans appear to be correlated to a decreased number of sites of stenosis in the coronary arteries of humans (Miller et al., Br. Med. J., 282, 1741-1744 (1981)).
There are several mechanisms by which HDL may protect against the progression of atherosclerosis. Studies in vitro have shown that HDL is capable of removing cholesterol from cells (Picardo et al., Arteriosclerosis, 6, 434-441 (1986)). Data of this nature suggest that one antiatherogenic property of HDL may lie in its ability to deplete tissue of excess free cholesterol and eventually lead to the delivery of this cholesterol to the liver (Glomset, J. Lipid Res., 9, 155-167 (1968)). This has been supported by experiments showing efficient transfer of cholesterol from HDL to the liver (Glass et al., J. Biol. Chem., 258 7161-7167 (1983); McKinnon et al., J. Biol. Chem., 26, 2548-2552 (1986)). In addition, HDL may serve as a reservoir in the circulation for apoproteins necessary for the rapid metabolism of triglyceride-rich lipoproteins (Grow and Fried, J. Biol. Chem., 253, 1834-1841 (1978); Lagocki and Scanu, J. Biol. Chem., 255, 3701-3706 (1980); Schaefer et al., J. Lipid Res., 23, 1259-1273 (1982)). Accordingly, agents which increase HDL cholesterol concentrations would be of utility as antiatherosclerotic agents, useful particularly in the treatment of dyslipoproteinimias and coronary heart disease.
Cyclic ureas and thioureas have heretofore been used for various purposes, all of which are unrelated to their antiatherosclerotic effects.
For example, JP 3-176475 discloses the preparation of cyclic ureas and thioureas such as 1,3-disubstituted tetrahydro-pyrimidine-2-thiones and their use as herbicidal agents. European Patent Application Publication Nos. 0612741 and 0503548 disclose cyclic urea (thiourea) derivatives useful as aggregation inhibitors and inhibitors of cell-cell and cell-matrix interactions, respectively.
The J. Chem. Soc. Perkin I, 6, 1622-1625 (1981) describes the regioselective preparation of 3,4-dihydro and 3,4,5,6-tetrahydro-pyrimidine-2(1H)-ones and the corresponding thiones useful as intermediates in the synthesis of diamines, thiazines and pyrimidine-2(1H)-ones. Synthesis, 1175-1180 (1994) describes the synthesis of antiinflammatory pyrimidobenzimidazoles from 1-aryl-6-hydroxy-tetrahydro-pyrimidine-2-(1H)-thiones.
The use of 6-hydroxy-tetrahydro-pyrimidine-2(1H)-thiones as antiamoebic and antihelmintic agents is disclosed in Indian Drugs, 31, 317-320 (1994). Other uses of similar compounds are disclosed in, e.g., Arzneim. - Forsch., 40, 55-57 (1990) (1-phenyl-tetrahydro-pyrimidine-2(1H)-thione as immunomodulator agents); and Farmakol. Toksikol. (Moscow), 41, 494-497 (1978) (1-substituted 4-hydroxy-hexahydro-pyrimidine-2-thione derivatives as radioprotectors). The production of similar thione derivatives, without reference to a specific utility has been disclosed in Dokl. Bolg. Akad. Nauk., 35, 49-51 (1982) (the mass spectra of 1-substituted 2-oxo (or 2-thio)hexahydropyrimidines); Khim. Gerotsikl. Soedin., 1273-1278 (1983) (the mass spectra of 1-substituted 4-hydroxy-hexahydro-pyrimidine-2-thiones; and Khim. Gerotsikl. Soedin., 889-895 (1989) (the synthesis of 4-hydroxy-hexahydro-pyrimidine-2-thiones). None of these references disclose the use of cyclic ureas and thioureas to raise the HDL cholesterol concentrations in mammals.
SUMMARY OF THE INVENTION
In accordance with this invention, there are provided 1-(aryl-substituted)-3-substituted tetrahydro-pyrimidine-2(1H)-thiones which are useful as antiatherosclerotic agents.
More particularly, this invention provides antiatherosclerotic agents of Formula 1 having the following structure:
wherein
R 1 is hydrogen, alkyl of 1-6 carbon atoms, cycloalkyl of 3-8 carbon atoms, alkenyl of 2-7 carbon atoms, alkynyl of 2-7 carbon atoms, or phenylalkyl of 7-10 carbon atoms; and
R 2 , R 3 , R 4 , R 5 , and R 6 are each, independently, hydrogen, halogen, alkyl of 1-6 carbon atoms, cycloalkyl of 3-8 carbon atoms, alkenyl of 2-7 carbon atoms, alkynyl of 2-7 carbon atoms, aralkyl of 7-10 carbon atoms, alkoxy of 1-6 carbon atoms, aryloxy of 6-12 carbon atoms, aralkyloxy of 7-12 carbon atoms, fluoroalkoxy of 1-6 carbon atoms, trifluoromethyl, alkylthio of 1-3 carbon atoms, alkylsulfonyl of 1-3 carbon atoms, —SCF 3 , nitro, alkylamino in which the alkylamino moiety has 1-6 carbon atoms, or dialkylamino in which each alkyl group has 1-6 carbon atoms;
or a pharmaceutically acceptable salt thereof.
This invention also provides methods of elevating the HDL concentration and treating or inhibiting atherosclerosis and related coronary heart disease, or dyslipoproteinemias, and improving the HDL/LDL cholesterol ratio in a mammal in need thereof which comprises administering to the mammal a compound of Formula 1 having the structure:
wherein
R 1 is hydrogen, alky of 1-6 carbon atoms, cycloalkyl of 3-8 carbon atoms, alkenyl of 2-7 carbon atoms, alkynyl of 2-7 carbon atoms, or phenylalkyl of 7-10 carbon atoms; and
R 2 , R 3 , R 4 , R 5 , and R 6 are each, independently, hydrogen, halogen, alkyl of 1-6 carbon atoms, cycloalkyl of 3-8 carbon atoms, alkenyl of 2-7 carbon atoms, alkynyl of 2-7 carbon atoms, aralkyl of 7-10 carbon atoms, alkoxy of 1-6 carbon atoms, aryloxy of 6-12 carbon atoms, aralkyloxy of 7-12 carbon atoms, fluoroalkoxy of 1-6 carbon atoms, trifluoromethyl, alkylthio of 1-3 carbon atoms, alkylsulfonyl of 1-3 carbon atoms, —SCF 3 , nitro, alkylamino in which the alkylamino moiety has 1-6 carbon atoms, or dialkylamino in which each alkyl group has 1-6 carbon atoms;
or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
It is preferred that the compounds of the present invention are represented by the compounds of Formula 1 where R 1 is alkyl of 1-6 carbon atoms, alkenyl of 2-7 carbon atoms or cycloalkyl of 3-8 carbon atoms; and R 2 , R 3 , R 4 , R 5 , and R 6 are each, independently, hydrogen, halogen or alkyl of 1-6 carbon atoms.
More preferably, the compounds of the present invention are represented by the compounds of Formula 1 where R 1 is methyl, ethyl, isopropyl or cyclobutyl; and R 2 , R 3 , R 4 , R 5 , and R 6 are each, independently, chlorine or methyl.
As used in describing this invention, the terms “alkyl”, “alkenyl”, and “alkynyl” include both straight chain as well as branched moieties. This includes the alkyl portions of substituents such as alkoxy, thioalkyl, alkylsulfinyl, alkylsulfonyl, fluoroalkoxy, and the like. The terms “halo” and “halogen” include fluorine, chlorine, bromine, and iodine. Fluoroalkoxy includes mono-, di-, tri-, and polyfluorinated alkoxy moieties, such as —OCF 3 , —OCH 2 F, —OCHF 2 , —OCH 2 CF 3 , and the like. The term “aryl” includes radicals such as benzyl, phenyl or naphthyl.
As used in describing this invention, the term “compounds of this invention” includes the broader description encompassing the formula used in accordance with the above methods, as well as the narrower description encompassing the formula used in accordance with the above novel compounds.
The pharmaceutically acceptable salts of the compounds of this invention are those derived from organic and inorganic acids such as, but not limited to: acetic, lactic, citric, tartaric, succinic, fumaric, maleic, malonic, mandelic, malic, hydrochloric, hydrobromic, phosphoric, nitric, sulfuric, methane sulfonic, toluene sulfonic and similarly known acceptable acids.
The most preferred compounds of the present invention are:
1-(4-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-phenyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(4-chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(2,6-dimethyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(5-chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(5-chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(4-chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
3-allyl-1-(5-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(5-chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
3-allyl-1-(4-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(4-chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
3-allyl-1-(6-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(6-chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(5-chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1 H)-thione;
1-(6-chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(6-chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(4-chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydro-pyriniidine-2(1H)-thione;
1-(6-chloro-2-methyl-phenyl)-3-cyclobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione;
1-(5-chloro-2-methyl-phenyl)-3-cyclobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione; and
1-(6-chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione.
The 1-(aryl-substituted)-3-substituted-tetrahydro-pyrimidine-2(1H)-thiones of this invention may be prepared by cyclocondensation of an appropriately substituted diamine of formula (2) with a thiocarbonylating agent as shown in Scheme 1.
wherein R 1 , R 2 , R 3 , R 4 , R 5 , and R 6 are as described above for Formula 1.
The thiocarbonylation agent (3) of Scheme 1 may be thiophosgene in an organic aprotic solvent, such as dichloromethane or chloroform, in the presence of an organic base such as triethylamine, at temperatures ranging from 0° C. to ambient essentially according to the method of Sharma et al., J. Med. Chem., 18, 913 (1975) (for a review of thiophosgene in organic syntheses see Sharma, Synthesis, 803 (1978)).
Alternatively, the cyclocondensation can be carried out with a heterocyclic thiocarbonyl transfer reagent (3) such as 1,1′-thiocarbonyldiimidazole (as disclosed in Staab et al., Angew. Chemie, 73, 148 (1961); Staab et al., Justus Liebigs Ann. Chem., 657, 98 (1962); and Larsen et al., J. Org. Chem., 43, 337 (1978)), or 1,1′-thiocarbonyl-di-1,2,4-triazole (as disclosed in Larsen et al., J. Org. Chem., 43, 337 (1978)) in an organic aprotic solvent such as dichloromethane or dioxane at temperatures ranging from ambient to the reflux temperature of the solvent.
It is generally accepted that the cyclocondensation proceeds through the intermediacy of an heterocyclic N-thiocarboxamide such as imidazole- or 1,2,4-triazole-N-thiocarboxamide of general formula (4) as shown in Scheme 2 (Staab, Angew. Chemie Int. Ed., 1, 351 (1962)). It has been found that cyclocondensation of the intermediate (4) to the desired tetrahydro-pyrimidine-2(1H)-thiones of formula (1) can be accelerated by the addition of an organic acid (5) such as para-toluene sulfonic acid monohydrate to the reaction mixture containing the intermediate N-thiocarboxamide of formula (3).
wherein R 1 , R 2 , R 3 , R 4 , R 5 , and R 6 are as described above for Formula 1.
The intermediate substituted diamines of general formula (2) of Schemes 1 and 2 can be prepared by either one of the two routes shown in Scheme 3.
Thus, an appropriately substituted aniline of general formula (6) can be alkylated with a haloalkylamine, preferably a bromo(chloro)alkylamine of formula (7, W=Br, Cl), in the absence of a solvent and at temperatures ranging from ambient to the reflux temperature of the aniline employed, to provide the desired diamines of Formula (2) of Schemes 1 and 2.
Alternatively, the aniline of formula (6) is first allylated with a haloalkanol, preferably a bromo(chloro)alkanol of general formula (8, W=Br, Cl), to provide the intermediate aminoalkanol of formula (9) which is in turn converted to the haloalkylamine intermediate of formula (10, W=Br, Cl). Reaction of (10) with an amine of formula (11) yields the desired diamines of formula (2) of Schemes 1 and 2, wherein R 1 , R 2 , R 3 , R 4 , R 5 , and R 6 are as described above for formula 1.
The appropriately substituted aniline starting materials (6) of Scheme 3 are either available commercially or can be prepared by procedures analogous to those in the literature for known compounds (see, e.g., J. March, Advanced Organic Chemistry, 3rd Ed., Wiley-Interscience, NY, page 1153).
The preferred bromo(chloro)alkylamines of formula (7) of Scheme 3 can be obtained by halogenation of the corresponding aminoalkanols of formula (12) as shown in Scheme 4 (see, Angiolini et al., Gazz. Chim. Ital., 106, 111 (1976); Crabb et al., Tetrahedron, 26, 3941 (1970); Deady et al., J. Chem. Soc. Perkin I, 782 (1973); Deady et al., J. Org. Chem., 28, 511 (1963); Sammes et al., J. Chem. Soc. Perkin I, 2415 (1984)).
The preferred aminoalkanols of formula (12) of Scheme 4 are either available commercially or can be prepared by procedures analogous to those in the literature for known compounds (see, e.g., Will et al., Annalen, 568, 34 (1950); Elderfield et al., J. Am. Chem. Soc., 68, 1579 (1946); Angiolini et al., Gazz. Chim. Ital., 106, 111 (1976); Jones et al., J. Chem. Soc. ( B ), 1300 (1971)).
The preferred bromo(chloro)alkanols of formula (8) of Scheme 3 are either available commercially or are known in the art.
Representative compounds of this invention were evaluated in an in vivo standard pharmacological test procedure which measured the ability of the compounds of this invention to elevate HDL cholesterol levels. The following briefly describes the procedure used and results obtained. Male Sprague-Dawley rats weighing 200-225 g were housed two per cage and fed Purina Rodent Chow Special Mix 5001-S supplemented with 0.25% cholic acid and 1.0% cholesterol and water ad libitum for 8 days. Each test substance was administered to a group of six rats fed the same diet with the test diet mixed in as 0.005-0.1% of the total diet. Body weight and food consumption were recorded prior to diet administration and at termination. Typical doses of the test substances were 5-100 mg/kg/day.
At termination, blood was collected from anesthetized rats and the serum was separated by centrifugation. Total serum cholesterol was assayed using the Sigma Diagnostics enzymatic kit for the determination of cholesterol, Procedure No. 352, modified for use with ninety-six well microtiter plates. After reconstitutiton with water the reagent contains 300 U/l cholesterol oxidase, 100 U/l cholesterol esterase, 1000 U/l horse radish peroxidase, 0.3 mmol/l 4-aminoantipyrine and 30.0 mmol/l p-hydroxybenzene sulfonate in a pH 6.5 buffer. In the reaction cholesterol was oxidized to produce hydrogen peroxide which was used to form a quinoneimine dye. The concentration of dye formed was measured spectrophotometrically by absorbance at 490 nm after incubation at 25° C. for 30 minutes. The concentration of cholesterol was determined for each serum sample relative to a commercial standard from Sigma.
HDL cholesterol concentrations in serum were determined by separation of lipoprotein classes by fast protein liquid chromatography (FPLC) by a modification of the method of Kieft et al., ( J. Lipid Res., 32, 859-866 (1991). Using this methodology, 25 mL of serum was injected onto Superose 12 and Superose 6 (Pharmacia), in series, with a column buffer of 0.05 M Tris (2-amino-2-hydroxymethyl-1,3-propanediol) and 0.15 M sodium chloride at a flow rate of 0.5 mL/min. The eluted sample was mixed on line with Boehringer-Mannheim cholesterol reagent pumped at 0.2 mL/min. The combined eluents were mixed and incubated on line through a knitted coil (Applied Biosciences) maintained at a temperature of 45° C. The eluent was monitored by measuring absorbance at 490 nm and gives a continuous absorbance signal proportional to the cholesterol concentration. The relative concentration for each lipoprotein class was calculated as the percent of total absorbance. HDL cholesterol concentration in serum was calculated as the percent of total cholesterol as determined by FPLC multiplied by the total serum cholesterol concentration.
The results obtained in this standard pharmaceutical test procedure are shown below in Table 1. In Examples 5-7, 9, 10 and 12-20 the test compounds were administered at a dose of 100 mg/kg. In Examples 1, 2, 3 and 11, the test compounds were administered at a dose of 50 mg/kg. In Example 4, the test compound was administered at a dose of 46 mg/kg and in Example 8 at a dose of 90 mg/kg. The duration of treatment for all examples was eight days.
Table I
TABLE I
HDL Cholesterol
Compound of Example
Level Increase (%)
Example 1
86
Example 2
20
Example 3
151.5
Example 4
34
Example 5
183
Example 6
137
Example 7
92
Example 8
21
Example 9
143
Example 10
57
Example 11
86
Example 12
19
Example 13
81
Example 14
66
Example 15
86
Example 16
85
Example 17
12
Example 18
42
Example 19
37
Example 20
24
The results set forth in Table I demonstrate that the compounds of this invention are useful in raising the concentration of HDL cholesterol. Therefore, the compounds of this invention are useful for treating or inhibiting atherosclerosis, related cardiovascular disease, or dyslipoproteinemias, and for improving the HDL/LDL cholesterol ratio, and several metabolic conditions associated with low concentrations of HDL such as low HDL-cholesterol levels in the absence of dyslipidemia, metabolic syndrome, non-insulin dependent diabetes mellitus (NIDDM), familial combined hyperlipidemia, familial hypertriglyceridemia, and dyslipidemia in peripheral vascular disease (PVD).
The compounds of this invention may be administered orally or parenterally, neat or in combination with conventional pharmaceutical carriers. Applicable solid carriers can include one or more substances which may also act as flavoring agents, lubricants, solubilizers, suspending agents, fillers, glidants, compression aids, binders or tablet-disintegrating agents or an encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active ingredient. In tablets, the active ingredient is mixed with a carrier having the necessary compression properties in suitable proportions and compacted in the shape and size desired. The powders and tablets preferably contain up to 99% of the active ingredient. Any of the solid carriers known to those skilled in the art may be used with the compounds of this invention. Particularly suitable solid carriers include, for example, calcium phosphate, magnesium stearate, talc, sugars, lactose, dextrin, starch, gelatin, cellulose, methyl cellulose, sodium carboxymethyl cellulose, polyvinylpyrrolidone, low melting waxes and ion exchange resins.
Liquid carriers may be used in preparing solutions, suspensions, emulsions, syrups and elixirs of the compounds of this invention. The compounds of this invention can be dissolved or suspended in a pharmaceutically acceptable liquid carrier such as water, an organic solvent, a mixture of both or pharmaceutically acceptable oils or fat. The liquid carrier can contain other suitable pharmaceutical additives such as solubilizers, emulsifiers, buffers, preservatives, sweeteners, flavoring agents, suspending agents, thickening agents, colors, viscosity regulators, stabilizers or osmo-regulators. Suitable examples of liquid carriers for oral and parenteral administration include water (particularly containing additives as above e.g. cellulose derivatives, preferably sodium carboxymethyl cellulose solution), alcohols (including monohydric alcohols and polyhydric alcohols e.g. glycols) and their derivatives and oils (e.g. fractionated coconut oil and arachis oil). For parenteral administration, the carrier can also be an oily ester such as ethyl oleate and isopropyl myristate. Sterile liquid carriers are used in sterile liquid form compositions for parenteral administration.
Liquid pharmaceutical compositions which are sterile solutions or suspensions can be utilized by, for example, intramuscular, intraperitoneal or subcutaneous injection. Sterile solutions can also be administered intravenously. Compositions for oral administration may be either liquid or solid composition form.
Preferably, the pharmaceutical compositions containing the compounds of this invention are in unit dosage form, e.g. as tablets or capsules. In such form, the compositions may be sub-divided in unit doses containing appropriate quantities of the present compounds. The unit dosage forms can be packaged compositions, for example packeted powders, vials, ampoules, prefilled syringes or sachets containing liquids. Alternatively, the unit dosage form can be, for example, a capsule or tablet itself, or it can be the appropriate number of any such compositions in package form.
The therapeutically effective amount of the compounds of this invention that is administered and the dosage regimen depends on a variety of factors, including the weight, age, sex, and medical condition of the subject, the severity of the disease, the route and frequency of administration, and the specific compound employed, and thus may vary widely. However, it is believed that the pharmaceutical compositions may contain the compounds of this invention in the range of about 0.1 to about 2000 mg, preferably in the range of about 0.5 to about 500 mg and more preferably between about 1 and about 100 mg. Projected daily dosages of active compound are about 0.01 to about 100 mg/kg body weight. The daily dose can be conveniently administered two to four times per day.
The following non-limiting examples illustrate the preparation of representative compounds of this invention.
EXAMPLE 1
1-(4-Chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N-(4-Chloro-2-methyl-phenyl)-propane-1,3-diamine
A mixture of 4-chloro-2-methylaniline (8 g) and 3-bromopropylamine hydrobromide (5 g) was heated at 100° C. for fifteen minutes. After cooling to room temperature, the resulting crystalline solid was dissolved in water (50 mL) and one equivalent of sodium hydroxide was added. This solution was then washed with ethyl ether and basified with excess sodium hydroxide. It was then extracted with dichloromethane, the combined extracts were dried over anhydrous potassium carbonate and evaporated to dryness.
The resulting diamine was obtained as an amber oil (4.2 g, 93%) which was used as such in the next step.
1 H NMR (300 MHz, CDCl 3 ) δ7.1 (m, 2H), 6.5 (d, 1H), 3.2 (t, 2H), 2.9 (t, 2H), 2.1 (s, 3H), 1.8 (quiny, 2H).
Step B. 1-(4-Chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H )-thione
The diamine of Step A and one equivalent of 1,1′-thiocarbonyldiimidazole were dissolved in dioxane (20 mL) and refluxed under nitrogen for one hour. The solvent was then removed and the residue triturated with ethyl ether/ethyl acetate. The solid was filtered and washed with ethyl ether to provide the title compound (4.2 g, 83%) as an off-white solid, m.p. 266-268° C.
Anal. Calcd. for C 11 H 13 ClN 2 S: C, 54.88; H, 5.44, N, 11.69. Found: C, 54.45; H, 5.28; N, 11.46.
EXAMPLE 2
1-Phenyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N-Phenyl-propane-1,3-diamine
Prepared in the manner of Example 1, Step A from aniline and 3-bromopropylamine hydrobromide salt.
Step B. 1-Phenyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Prepared in the manner of Example 1, Step B from N-phenyl-propane-1,3-diamine of Step A and 1,1′-thiocarbonyldiimidazole, except that the cyclization was effected in dichloromethane. Workup consisted of washing with water, drying over magnesium sulfate, filtration and removal of solvent in vacuo. Purfication by flash chromatography on silica gel Merck-60 eluting with 1% methanol in dichloromethane followed by trituration with ethyl ether to provide the title compound as a white solid (2.74 g, 78%), m.p: 211-212° C., identical to the material described by Kashima et al., J. Chem. Soc. Perkin I, 1622 (1981).
Anal. Calc. for C 10 H 12 N 2 S: C, 62.46; H, 6.29; N, 14.57. Found C, 61.88; H, 6.19; N, 14.44.
EXAMPLE 3
1-(4-Chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N-Acetyl-1-amino-3-hydroxy-propane
1-Amino-3-hydroxy-propane (25 g) dissolved in methyl acetate (200 mL) was refluxed under nitrogen for three days. The methyl acetate was removed in vacuo, the residue was redissolved in toluene (100 mL) and refluxed for two days. The bottom layer containing the product was separated and the residual toluene removed in vacuo to provide the intermediate N-acetyl-1-amino-3-hydroxy-propane as a yellow liquid (36.3 g, 93%) which was used as such in the next step.
Step B. N-Ethyl-1-amino-3-hydroxy-propane
To a stirred suspension of lithium aluminum hydride (16.3 g) in dry tetrahydrofuran (300 mL) was added dropwise a solution of N-acetyl-1-amino-3-hydroxy-propane (25.2 g) of Step A in tetrahydrofuran (100 mL) over 30 minutes. The reaction mixture was then refluxed under nitrogen for 48 hours, cooled to room temperature, diluted with dichloromethane (400 mL) and quenched by the careful addition of water (31 mL) followed by 2.5 N sodium hydroxide (58 mL). The mixture was filtered through Celite and the solvent removed in vacuo to provide the intermediate N-ethyl-1-amino-3-hydroxy-propane as an orange liquid (19.5 g, 88%) which was used as such in the next step.
Step C. N-ethyl-1-amino-3-bromopropane 1:1 salt with hydrobromic acid
The N-ethyl-1-amino-3-hydroxy-propane (19.5 g) of Step B was dissolved in 48% hydrobromic acid (200 mL) and the solution was refluxed under nitrogen for 2 hours. The reaction mixture was then cooled and the hydrobromic acid was removed in vacuo. The dark residue was dissolved in dichloromethane and filtered through magnesium sulfate. The solvent was then removed and the residue was crystallized from 10% acetonitrile in ethyl acetate to provide the title hydrobromide salt as an off-white crystalline solid (22.97 g, 49%), m.p. 141-143° C.
Anal. Calcd. for C 5 H 12 BrN: C, 24.32; H, 5.31; N, 5.67. Found: C, 24.40; H, 5.42; N, 5.74.
Step D. N′-(4-Chloro-2-methyl-phenyl)-N-ethyl-propane-1,3-diamine
Prepared in the manner of Example 1, Step A using 2-methyl-4-chloroaniline and the N-ethyl-1-amino-3-bromopropane hydrobromide salt of Step C (12.7 g).
Step E. 1-(4-Chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-primidine-2(1H)-thione
The cyclization of the crude diamine of Step D was carried out with one equivalent of 1,1′-thiocarbonyldiimidazole in refluxing dioxane under nitrogen for one hour. Subsequently, two equivalents of para-toluenesulfonic acid hydrate were added and the mixture was refluxed for 48 hours. The solvent was removed in vacuo and the residue was dissolved in dichloromethane (100 mL). The solution was washed with water, dried over magnesium sulfate, filtered and evaporated. The crude product was purified by flash chromatography (on Merck-60 silica gel) eluting with 10-25% petroleum ether/ethyl acetate. The title compound was obtained as a white solid (4.4 g, 52%), m.p. 116-118° C.
Anal. Calcd. for C 13 H 17 ClN 2 S: C, 58.09; H, 6.37; N, 10.42. Found: C, 58.24; H, 6.39; N, 10.32.
EXAMPLE 4
1-(2,6-Dimethyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N-(2,6-Dimethyl-phenyl)-propane-1,3-diamine
Prepared in the manner of Example 1, Step A except that 2,6-dimethylaniline was used as the amine.
Step B. 1-(2,6-Dimethyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Prepared in 22% yield in the manner of Example 1, Step B from the diamine of Step A above except that dichloromethane was used as the solvent for the cyclization. The reaction mixture was cooled, washed with water, dried over magnesium sulfate, filtered and the solvent removed in vacuo to yield the title compound as a white solid, m.p. 249-251° C.
Calcd. for C 12 H 16 N 2 S: C, 65.41; H, 7.32; N, 12.71 Found: C, 64.55; H, 7.36; N, 12.58.
EXAMPLE 5
1-(5-Chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(5-Chloro-2-methyl-phenyl)-N-ethyl-propane-1,3-diamine
A mixture of 5-chloro-2-methylaniline (12.3 g) and the N-ethyl-1-amino-3-bromopropane hydrobromide salt of Example 3, Step C (8.6 g) was heated at 100° C. under nitrogen for 20 minutes. After cooling, a solid mass formed which was partitioned between dichloromethane and 1 N sodium hydroxide. The organic phase was washed with brine, dried over anhydrous potassium carbonate, filtered and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 100% dichloromethane to 9:1 dichloromethane-methanol containing 0.2% ammonium hydroxide) provided the title compound (7.3 g, 92.8%) as a brown oil, which was used as such in the next step.
1 H NMR (DMSO-d 6 , 400 MHz): δ1.01 (t, 3H), 1.66-1.73 (m, 2H), 2.02 (s, 3H), 2.51 (q, 2H), 2.60 (t, 2H), 3.07-3.12 (m, 2H), 5.62-5.65 (m, 1H), 6.45-6.47 (m, 2H), 6.90-6.92 (m, 1H)
MS [EI, m/z]: 226 [M] + .
Step B. 1-(5-Chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
A solution of the diamine of Step A (7.1 g) in dioxane (250 mL) and 1,1′-thiocarbonyldiimidazole (5.6 g) was refluxed under nitrogen for 2.5 hrs. Following the addition of para-toluenesulfonic acid monohydrate (11.9 g), the reaction mixture was heated at reflux for 48 hrs. The reaction was cooled and filtered and the filtrate was concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 20% ethyl acetate in hexane provided a brown solid which was triturated with diethyl ether to give the title product (2.1 g, 25.0%) as a white solid, m.p. 111-112° C.
1 H NMR (DMSO-d 6 , 400 MHz): δ1.13 (t, 3H), 1.97-2.10 (m, 2H), 2.12 (s, 3H), 3.33-3.58 (m, 4H), 3.86 (q, 2H), 7.19-7.25 (m, 3H)
MS [EI, m/z]: 268 [M] +
Anal. Calcd. for C 13 H 17 ClN 2 S: C, 58.09; H, 6.38; N, 10.42. Found: C, 57.86; H, 6.29; N, 10.31.
EXAMPLE 6
1-(5-Chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N-isopropyl-1-amino-3-hydroxy-propane
1-Bromopropanol (20.85 g) was added dropwise to isopropylamine (35.4 g, 51 mL) over 30 minutes. The mixture was kept in an oil bath at 40-45° C. for 8 hours during which time a precipitate formed. After standing overnight at ambient temperature, the solid mass was treated with an ice cold aqueous sodium hydroxide solution (9 g in 21 mL of water) and then extracted with dichloromethane. The extracts were washed with brine, filtered and dried over anhydrous potassium carbonate. Removal of the solvent provided a volatile yellow oil (15.53 g, 88.5%) which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ0.89 (d, 6H), 1.49 (m, 2H), 2.52 (m, 2H), 2.63 (m, 1H), 3.4 (m, 2H).
Step B. 3-Bromo-N-isopropyl-1-amino-propane 1:1 salt with hydrobromic acid
An ice-cold solution of the amino alcohol of Step A (15.53 g) in carbon tetrachloride (150 mL) was saturated with HBr gas over ca. 30 minutes. The solvent was evaporated to yield an off-white spongy solid. Under ice cooling 48% HBr (150 mL) was added under nitrogen and the mixture was heated to reflux for 2.5 hours. The clear brown solution was evaporated in vacuo. The brown solid residue was twice azeotroped with water and toluene and the residue redissolved in ethanol. The solvent was evaporated and the residue was triturated with anhydrous ethyl ether-hexane to provide a solid which was collected, washed with hexane and dried. Trituration with anhydrous ether-hexane provided a grey solid (25.46 g, 73.5%), m.p. 175-176° C. (dec).
NMR (DMSO-d 6 , 400 MHz): δ1.22 (d, 6H), 2.15 (m, 2H), 2.99 (m, 2H), 3.3 (m, 1H), 3.60 (m, 2H), 8.46 (broad, 2H).
Step C. N′-(5-Chloro-2-methyl-phenyl)-N-isopropyl-propane-1,3-diamine
A mixture of 4-chloro-2-methylaniline (16.12 g) and the hydrobromide salt of Step B (9.9 g) was heated at 70° C. until homogeneous and then at 100° C. for 30 minutes. The mixture was then cooled and partitioned between dichloromethane and 1N sodium hydroxide. The organic layer was washed with brine, dried over anhydrous potassium carbonate and evaporated to dryness. The residue was dissolved in dichloromethane and absorbed on a flash column of Merck-60 flash silica gel. Elution with a dichloromethane-methanol gradient (9:1 to 1:1) containing 0.2% ammonium hydroxide, provided the title compound (8.23 g, 90.4%) which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ0.97 (d, 6H), 1.69 (m, 2H), 2.02 (s, 3H), 2.60 (m, 2H), 2.66 (m, 1H), 3.09 (m, 2H), 5.61 (m, 1H), 6.45 (m, 2H), 6.91 (m, 1H).
Step D. 1-(5-Chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To a suspension of the diamine of Step C (6.47 g) in dioxane (100 mL) was added N,N′-thiocarbonyl-di-1,2,4-triazole (4.85 g) and the mixture was stirred at room temperature for 2 hours. Para-toluenesulfonic acid monohydrate (7.07 g) was added and the reaction mixture was heated at reflux under nitrogen until the reaction was complete by TLC (31 hours). Upon cooling the mixture was evaporated to dryness. The solid residue was redissolved in ethyl acetate, the solution was washed with water and brine, dried over magnesium sulfate and evaporated to dryness. The residue was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel packed in hexane. Elution with a gradient of 20-25% ethyl acetate in hexane provided the title compound (5.81 g, 76.4%) as a white solid which was further triturated in hexane, m.p. 176-178° C.
NMR (DMSO-d 6 , 400 MHz): δ1.10 (m, 6H), 2.01 (m, 2H), 2.10 (s, 3H), 3.3 and 3.52 (m, 4H), 5.62 (m, 1H), 7.20 (m, 3H).
MS (EI, m/z): 282/284 [M] +
Anal. Calcd. for C 14 H 19 ClN 2 S: C, 59.45; H, 6.77; N, 9.90. Found C, 59.43; H, 6.83; N, 9.87.
EXAMPLE 7
1-(4-Chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(4-Chloro-2-methyl-phenyl)-N-isopropyl-propane-1,3-diamine
A mixture of the hydrobromide salt of Example 6, Step B (9.9 g) and 4-chloro-2-methyl aniline (16.12 g) was heated at 70° C. under nitrogen until homogeneous and then at 100° C. for 20 minutes. After cooling, the brown solution was partitioned between ice-cold 1N sodium hydroxide and dichloromethane. The extracts were washed with brine, dried over anhydrous potassium carbonate and evaporated to dryness. The residue was dissolved in dichloromethane and absorbed on a column of Merck-60 flash silica gel. Elution with a dichloromethane-methanol gradient (from 9:1 to 1:1) containing 0.2% ammonium hydroxide, provided the title compound (8.2 g, 90.3%), as a brown solid, which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ0.96 (d, 6H), 1.68 (m, 2H), 2.04 (s, 3H), 2.59 (m, 2H), 2.66 (m, 1H), 3.08 (m, 2H), 5.42 (m, 1H), 6.45 (m, 1H), 6.99 (m, 2H)
MS (+FAB, m/z): 241/243 [M+H] + .
Step B. 1-(4-Chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To a solution of the diamine of Step A (6 g) in dioxane (100 mL) under nitrogen was added N,N′-thiocarbonyl-di-1,2,4-triazole (4.5 g). After stirring at room temperature for 3 hours, para-toluene sulfonic acid monohydrate was added in one portion (9.5 g) and the mixture was heated at reflux for 8 hours. Additional para-toluene sulfonic acid monohydrate was added (1 g) and reflux was resumed for another 2 hours. The mixture was cooled and diluted with ethyl acetate. The precipitate was collected and washed with ethyl acetate. The combined filtrates were washed with brine, dried over magnesium sulfate, and evaporated to dryness. The residue was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 20% ethyl acetate in hexane provided the title compound as a white crystalline solid (5.26 g, 74.6%). The material was slurried in hexane-ether, sonicated and collected to provide 4.91 g of pure product, m.p. 147-149° C.
NMR (DMSO-d 6 , 400 MHz): δ1.10 (m, 6H), 2.01 (m, 2H), 2.12 (s, 3H), 3.31 and 3.48 (m, 4H), 5.62 (m, 1H), 7.10 (m, 1H), 7.20 (m, 1H), 7.29 (m, 1H)
MS (+FAB, m/z): 283/285 [M+H] +
Anal. Calcd.for C 14 H 19 ClN 2 S: C, 59.45; H, 6.77; N, 9.90. Found: C, 59.76; H, 6.87; N, 9.90.
EXAMPLE 8
3-Allyl-1-(5-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. 1-(5-Chloro-2-methyl-phenyl)amino-3-hydroxy-propane
A mixture of 5-chloro-2-methylaniline (10.1 g) and 3-bromo-1-propanol (2.5 mL) were heated at 100° C. under nitrogen for 45 minutes. After cooling, a solid mass formed which was partitioned between dichloromethane and 1N sodium hydroxide. The organic phase was washed with brine, dried over anhydrous potassium carbonate, and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 20% ethyl acetate in hexane gave the title compound (5.6 g, 98.1%) as a brown oil, which was used as such in the next step.
1 H NMR (DMSO-d 6 , 400 MHz): δ1.68-1.75 (m, 2H), 2.01 (s, 3H), 3.08-3.13 (m, 2H), 3.48-3.53 (m, 2H), 4.56 (t, 1H), 5.13 (t, 1H), 6.45-6.48 (m, 2H), 6.91-6.93 (m, 1H)
MS [EI, m/z]: 199 [M] + .
Step B. 3-Bromo-1-(5-chloro-2-methyl-phenyl)amino-propane 1:1 salt with hydrobromic acid
A mixture of the amino alcohol of Step A (5.6 g) and 48% aqueous hydrobromic acid (56 mL) was heated at reflux under nitrogen for 1 hour. The hydrobromic acid was removed in vacuo and the solid residue azeotroped repeatedly with water and ethanol to provide the title compound (7.5 g, 77.7%) as a pale-orange solid, m.p. 154-156° C.
1 H NMR (DMSO-d 6 , 400 MHz): δ2.06 (s, 3H), 2.08-2.13 (m, 2H), 3.20 (t, 2H), 3.61 (t, 2H), 6.10-6.40 (m, 2H), 6.56-6.59 (m, 2H), 6.96-6.98 (m, 1H)
MS [EI, m/z]: 261 [M] +
Anal. Calcd. for C 10 H 13 BrClN.HBr: C, 34.97; H, 4.11; N, 4.08. Found: C, 35.20; H, 4.05; N, 4.07.
Step C. N-Allyl-N′-(5-chloro-2-methyl-phenyl)-propane-1,3-diamine
A mixture of allylamine (1.0 mL) and the hydrobromide salt of Step B (1.0 g) was heated at 100° C. under nitrogen for 45 minutes. The reaction was cooled and partitioned between dichloromethane and 1 N sodium hydroxide. The aqueous layer was extracted with dichloromethane, the extracts were dried over sodium sulfate and concentrated in vacuo to give a yellow oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 98:2 dichloromethane-methanol to 90:10 dichloromethane-methanol containing 0.2% ammonium hydroxide) provided the title compound (0.35 g, 50.5%) as a yellow oil which was used as such in the next step.
1 H NMR (DMSO-d 6 , 400 MHz): δ1.68-1.74 (m, 2H), 2.01 (s, 3H), 2.61 (t, 2H), 3.06-3.25 (m, 5H), 5.03-5.06 (m, 1H), 5.13-5.19 (m, 1H), 5.47-5.50 (m, 1H, NH), 5.79-5.87 (m, 1H), 6.45-6.47 (m, 2H), 6.91-6.93 (m, 1H)
MS [+FAB, m/z]: 239 [M+H] + .
Step D. 3-Allyl-1-(5-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To an ice-cold solution of the diamine of Step C (3.4 g) and triethylamine (4.0 mL) in dry chloroform (50 mL) was added dropwise under nitrogen thiophosgene (1.1 mL). After 30 minutes at ambient temperature, additional triethylamine (1.0 mL) and thiophosgene (0.28 mL) were added. After 15 minutes, no starting material remained. The reaction was quenched with water, the pH adjusted to 8 with triethylamine, and extracted with dichloromethane. The extracts were combined, dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 10% ethyl acetate in hexane provided a yellow solid which was triturated with diethyl ether to give the title compound (1.69 g, 42.4%) as a white solid, m.p. 71-72° C.
1 H NMR (DMSO-d 6 , 400 MHz): δ2.02-2.12 (m, 2H), 2.13 (s, 3H), 3.36-3.61 (m, 4H), 4.45-4.62 (m, 2H ), 5.16-5.20 (m, 2H), 5.78-5.87 (m, 1H), 7.20-7.26 (m, 3H)
MS [EI, m/z]: 280 [M] +
Anal. Calcd. for C 14 H 17 ClN 2 S: C, 59.88; H, 6.10; N, 9.98. Found: C, 59.91; H, 6.14; N, 9.83.
EXAMPLE 9
1-(5-Chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(5-Chloro-2-methyl-phenyl)-N-methyl-propane-1,3-diamine
To an 8.03 M solution of methylamine in ethanol (27 mL) was added the hydrobromide salt of Example 8, Step B (7.5 g). The reaction was stirred at ambient temperature for 18 hours. The solvent was removed in vacuo and the residue partitioned between dichloromethane and 1N sodium hydroxide. The organic phase was washed with brine, dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 98:2 to 90:10 dichloromethane-methanol containing 0.2% ammonium hydroxide) gave the title compound (3.9 g, 84.1%) as a pale orange oil, which was used as such in the next step.
1 H NMR (DMSO-d 6 , 400 MHz): δ1.67-1.71 (m, 2H), 2.01 (s, 3H), 2.28 (s, 3H), 2.56 (t, 2H), 2.96-3.04 (m, 1H), 3.05-3.09 (m, 2H), 5.48-5.56 (m, 1H), 6.44-6.47 (m, 2H), 6.90-6.92 (m, 1H)
MS [EI, ml/z]: 212 [M] + .
Step B. 1-(5-Chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidine-2-(1H)-thione
To a solution of the diamine of Step A (3.8 g) in dioxane (100 mL) under nitrogen was added 1,1′-thiocarbonyl-di-1,2,4-triazole (3.38 g). After 45 minutes additional thiocarbonyl reagent (0.5 g) was added, followed after 30 minutes by para-toluenesulfonic acid monohydrate (6.88 g). The reaction mixture was heated at reflux for 4 hours at which point additional para-toluenesulfonic acid monohydrate (2.0 g) was added. After refluxing for 18 hours, another portion of para-toluenesulfonic acid monohydrate (1.5 g) was added. The reaction mixture was refluxed for an additional 24 hours, cooled and concentrated in vacuo to give a brown oil which crystallized on standing. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 20% ethyl acetate in hexane provided a light pink solid which was triturated with diethyl ether to give the title compound (2.9 g, 63.9%) as a white solid, m.p. 143-145° C.
1 H NMR (DMSO-d 6 , 400 MHz): δ2.04-2.12 (m, 2H), 2.13 (s, 3H), 3.31 (s, 3H), 3.34-3.60 (m, 4H), 7.19-7.25 (m, 3H)
MS [EI, m/z]: 254 [M] +
Anal. Calcd. for C 12 H 15 ClN 2 S: C, 56.57; H, 5.93; N, 11.00. Found: C, 56.23; H, 5.75; N, 10.86.
EXAMPLE 10
3-Allyl-1-(4-chloro-2-methyl-phenly)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. 1-(4-Chloro-2-methyl-phenyl)amino-3-hydroxy-propane
A mixture of 4-chloro-2-methylaniline (35.7 g) and 3-bromo-1-propanol (8.75 g) was heated at 100° C. under nitrogen for 1 hour. After cooling, a solid mass formed which was partitioned between dichloromethane and 1N sodium hydroxide. The organic layer was washed with brine, dried over anhydrous potassium carbonate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 100% dichloromethane to 95:5 dichloromethane-methanol) provided the title product (18.0 g, 90%) as a brown oil, which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ1.68-1.74 (m, 2H), 2.04 (s, 3H), 3.08-3.13 (m, 2H), 3.48-3.53 (m, 2H), 4.55 (t, 1H), 4.96 (t, 1H), 6.46-6.49 (m, 1H), 6.97-7.01 (m, 2H)
MS [EI, m/z]: 199 [M] + .
Step B. 1-(4-Chloro-2-methyl-phenyl)amino-3-bromo-propane 1:1 salt with hydrobromic acid
A mixture of the amino alcohol of Step A (7.0 g) and 48% aqueous hydrobromic acid (70 mL) was heated at reflux under nitrogen for 2 hours. After cooling, the hydrobromic acid was removed in high vacuo. The solid residue was then washed with water and ethanol and dried in high vacuo to give the title compound (10.7 g, 89.0%) as a pale-orange solid, m.p. 145-148° C.
NMR (DMSO-d 6 , 400 MHz): δ2.09-2.14 (m, 2H), 2.18 (s, 3H), 3.23 (t, 2H), 3.61 (t, 2H), 5.50-6.30 (m, 2H), 6.81-6.83 (m, 1H), 7.13-7.16 (m, 2H)
MS [EI, m/z]: 261 [M] +
Anal. Calcd. for C 10 H 13 BrClN.HBr: C, 34.97; H, 4.11; N, 4.08. Found: C, 35.12; H, 4.02; N, 4.07.
Step C. N-Allyl-N′-(4-chloro-2-methyl-phenyl)-propane-1,3-diamine
A mixture of allylamine (18 mL) and the hydrobromide salt of Step B (8.2 g) was heated at 100° C. under nitrogen for 30 minutes. The reaction mixture was cooled and partitioned between dichloromethane and 1N sodium hydroxide. The aqueous layer was extracted with dichloromethane and the combined organic layers were dried over sodium sulfate and concentrated in vacuo to give a yellow oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 98:2 dichloromethane-methanol to 95:5 dichloromethane-methanol containing 0.2% ammonium hydroxide) gave the title compound (5.3 g, 92.9%) as a light brown oil which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ1.67-1.73 (m, 2H), 2.04 (s, 3H), 2.59 (t, 2H), 3.05-3.16 (m, 5H), 5.01-5.04 (m, 1H), 5.11-5.16 (m, 1H), 5.26-5.36 (m, 1H), 5.78-5.87 (m, 1H), 6.45-6.47 (m, 1H), 6.98-7.00 (m, 2H)
MS [+FAB, m/z]: 239 [M+H] + .
Step D. 3-Allyl-1-(4-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To a solution of the diamine of Step C (5.6 g) and triethylamine (6.6 mL) in dry chloroform (70 mL) under nitrogen was added thiophosgene (1.79 mL). After 30 minutes at ambient temperature, additional thiophosgene (0.6 mL) was added. After 15 minutes, the reaction was quenched with water and extracted with dichloromethane. The organic layers were combined, dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 11% ethyl acetate in hexane provided a yellow solid which was triturated with diethyl ether to give the title compound (3.1 g, 47.0%) as a white solid, m.p. 101-103° C.
NMR (DMSO-d 6 , 400 MHz): δ2.02-2.12 (m, 2H), 2.15 (s, 3H), 3.36-3.58 (m, 4H), 4.44-4.63 (m, 2H), 5.16-5.23 (m, 2H), 5.78-5.87 (m, 1H), 7.12-7.31 (m, 3H)
MS [+FAB, m/z]: 281 [M+H] +
Anal. Calcd. for C 14 H 17 ClN 2 S: C, 59.88; H, 6.10; N, 9.98. Found: C, 59.68; H, 6.26; N, 9.94.
EXAMPLE 11
1-(4-Chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)thione
Step A. N′-(4-Chloro-2-methyl)phenyl)-N-methyl-propane-1,3-diamine
To an 8.03 M solution of methylamine in ethanol (38 mL) was added the 1-(4-chloro-2-methyl-phenyl)amino-3-bromo-propane hydrobromide salt of Example 10, Step B (10.6 g). The reaction mixture was stirred at ambient temperature for 30 minutes. The ethanol was removed in vacuo and the residue was partitioned between dichloromethane and 1N sodium hydroxide. The organic phase was washed with brine, dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 100% dichloromethane to 98:2 dichloromethane-methanol containing 0.2% ammonium hydroxide) gave the title compound (4.1 g, 62.6%) as a pale orange oil, which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ1.66-1.72 (m, 2H), 2.04 (s, 3H), 2.28 (s, 3H), 2.56 (t, 2H), 3.04-3.30 (m, 3H), 5.28-5.38 (m, 1H), 6.45-6.47 (m, 1H), 6.97-7.01 (m, 2H)
MS [+FAB, m/z]: 213 [M+H] + .
Step B. 1-(4-Chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidin-2(1H)-thione
To a solution of the diamine of Step A (4.0 g) in dioxane (100 mL) under nitrogen was added 1,1′-thiocarbonyl-di-1,2,4-triazole (3.5 g). After 30 minutes additional thiocarbonyl reagent (1.0 g) was added. After 30 minutes para-toluenesulfonic acid monohydrate (10.2 g) was added in one portion and the reaction mixture was heated at reflux for 24 hours. Additional para-toluenesulfonic acid monohydrate (2.5 g) was added at this point and after another 24 hours at reflux, the reaction was cooled and filtered. The filtrate was concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 20% ethyl acetate in hexane gave the title product (2.7 g, 56.4%) as a white solid, m.p. 143-145° C.
NMR (DMSO-d 6 , 400 MHz): δ2.04-2.11 (m, 2H), 2.14 (s, 3H), 3.31 (s, 3H), 3.34-3.57 (m, 4H), 7.10-7.30 (m, 3H)
MS [EI, m/z]: 254 [M] +
Anal. Calcd. for C 12 H 15 ClN 2 S: C, 56.57; H, 5.93; N, 11.00. Found: C, 56.37; H, 5.97; N, 11.01.
EXAMPLE 12
3-Allyl-1-(6-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. 1-(6-Chloro-2-methyl-phenyl)amino-3-hydroxy-propane
A mixture of the 6-chloro-2-methyl aniline (70.8 g) and 3-bromo-1-propanol (27.8 g) was heated under nitrogen to 100° C. for 2 hours. The mixture was cooled and partitioned between dichloromethane and 1N sodium hydroxide. The organic layer was washed with 20% aqueous sodium chloride, dried over anhydrous potassium carbonate and evaporated to dryness. The residue was flash chromatographed on Merck-60 flash silica gel. Elution with a hexane-ethyl acetate gradient (from 8:1 to 3:1) provided the title compound (30.86 g, 77.5%) as a pale yellow oil, which was used as such in the next step.
Step B. 1-(6-Chloro-2-methyl-phenyl)amino-3-bromo-propane 1:1 salt with hydrobromic acid
A mixture of the amino alcohol of Step A (13.0 g) and 48% aqueous HBr (130 mL) were heated at reflux under nitrogen for 2.5 hours. After cooling, the hydrobromic acid was removed in vacuo. The solid residue was then washed with water and ethanol and dried in vacuo to give the title compound (21.1 g, 94.5%) as an orange to brown solid, m.p. 161-163° C.
NMR (DMSO-d 6 , 400 MHz): δ2.10 (m, 2H), 2.35 (s, 3H), 3.26 (m, 2H), 3.61 (m, 2H), 7.03 (m, 1H), 7.18 (m, 1H), 7.30 (m, 1H)
MS [EI, m/z]: 261 [M] +
Anal. Calcd. for C 10 H 13 BrClN.HBr: C, 34.97; H, 4.11; N, 4.08. Found: C, 35.27; H, 4.00; N, 4.12.
Step C. N-Allyl-N′-(6-chloro-2-methyl-phenyl)-propane-1,3-diamine
A mixture of allylamine (20 mL) and the hydrobromide salt of Step B (8.6 g) was heated at 100° C. under nitrogen for 30 minutes. The reaction mixture was cooled and partitioned between dichoromethane and 1N sodium hydroxide. The aqueous layer was extracted with dichloromethane, and the combined organic layers were dried over sodium sulfate and concentrated in vacuo to give a yellow oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 1:1 ethyl acetate-hexane followed by 80:20 dichloromethane-methanol containing 0.2% ammonium hydroxide gave the title compound (5.0 g, 83.8%) as a yellow oil which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ1.56-1.63 (m, 2H), 2.24 (s, 3H), 2.54 (t, 2H), 3.05-3.20 (m, 5H), 4.25-4.45 (m, 1H), 4.99-5.15 (m, 2H), 5.76-5.86 (m, 1H), 6.73-6.77 (m, 1H), 7.01-7.04 (m, 1H), 7.13-7.16 (m, 1H)
MS [EI, m/z]: 238 [M] + .
Step D. 3-Allyl-1-(6-chloro-2-methyl-phenyl)-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To an ice-cold solution of the diamine of Step C (4.9 g) and triethylamine (5.8 mL) in chloroform (70 mL) under nitrogen was added thiophosgene (1.6 mL). After 20 minutes at ambient temperature, additional thiophosgene (0.5 mL) was added. After 15 minutes, the reaction was quenched with water and extracted with dichloromethane. The extracts were dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 11% ethyl acetate in hexane provided a yellow solid which was triturated with diethyl ether to give the title product (3.2 g, 55.6%) as a white solid, m.p. 82-84° C.
NMR (DMSO-d 6 , 400 MHz): δ2.09-2.12 (m, 2H), 2.21 (s, 3H), 3.42-3.46 (m, 4H), 4.52-4.57 (m, 2H), 5.17-5.23 (m, 2H), 5.79-5.86 (m, 1H), 7.15-7.21 (m, 2H), 7.30-7.32 (m, 1H)
MS [EI, m/z]: 280 [M] +
Anal. Calcd. for C 14 H 17 ClN 2 S: C, 59.88; H, 6.10; N, 9.97. Found: C, 59.75; H, 5.99; N, 9.80.
EXAMPLE 13
1-(6-Chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(6-Chloro-2-methyl-phenyl)-N-methyl-propane-1,3-diamine
To an 8.03 M solution of methylamine in ethanol (31 mL) was added the hydrobromide salt of Example 12, Step B (8.6 g) and the mixture was stirred at ambient temperature for 17 hours. The ethanol was removed in vacuo and the residue was partitioned between dichloromethane and 1N sodium hydroxide. The organic phase was washed with brine, dried over sodium sulfate, and concentrated in vacuo to give a yellow oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 98:2 to 80:20 dichloromethane-methanol containing 0.2% ammonium hydroxide) gave the title compound (3.9 g, 84.1%) as a pale yellow oil, which was used as such in the next step.
NMR (DMSO-d 6 , 400MHz): δ1.55-1.62 (m, 2H), 2.23 (s, 3H), 2.24 (s, 3H), 2.51 (t, 2H), 2.95-3.12 (m, 3H, NH), 4.25-4.50 (m, 1H), 6.72-6.76 (m, 1H), 7.01-7.03 (m, 1H), 7.13-7.15 (m, 1H)
MS [+FAB, m/z]: 213 [M+H] + .
Step B. 1-(6-Chloro-2-methyl-phenyl)-3-methyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To a solution of the diamine of Step A (4.16 g) in dioxane (110 mL) was added under nitrogen 1,1′-thiocarbonyl-di-1,2,4-triazole (7.12 g). After 30 minutes, para-toluenesulfonic acid monohydrate (15.1 g) was added and the reaction mixture was heated at reflux for 20 hours. More para-toluenesulfonic acid monohydrate (4.0 g) was added at this point, and after an additional 2.5 hours at reflux, the reaction was cooled and filtered. The filtrate was concentrated in vacuo to give an orange oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 20% ethyl acetate in hexane provided a white solid which was triturated with diethyl ether to give the title product (2.0 g, 40.3%) as a white solid, m.p. 164-165° C.
NMR (DMSO-d 6 , 400 MHz): δ2.09-2.13 (m, 2H), 2.20 (s, 3H), 3.32 (s, 3H), 3.41 (t, 2H), 3.52 (t, 2H), 7.14-7.21 (m, 2H), 7.29-7.31 (m, 1H)
MS [EI, m/z]: 254 [M] +
Anal. Calcd. for C 12 H 15 ClN 2 S: C, 56.57; H, 5.93; N, 10.99. Found: C, 56.19; H, 5.71; N, 10.67.
EXAMPLE 14
1-(5-Chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydro-pyrimidine-2-(1H)-thione
Step A. N′-(5-Chloro-2-methyl-phenyl)-N-isobutyl-propane-1,3-diamine
A mixture of isobutylamine (27.2 mL) and the hydrobromide salt of Example 8, Step B (9.4 g) was heated at 90° C. under nitrogen for 1 hour. The reaction was cooled and partitioned between dichloromethane and 1N sodium hydroxide. The aqueous layer was extracted with dichloromethane, and the combined extracts were dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 25% ethyl acetate in hexane followed by 80:20 dichloromethane-methanol containing 0.2% ammonium hydroxide gave the title compound (6.0 g, 85.9%) as a brown oil, which was used as such in the next step.
NMR(DMSO-d 6 , 400MHz): δ0.86 (d, 6H), 1.63-1.74 (m, 3H), 2.02 (s, 3H), 2.31 (d, 2H), 2.59 (t, 2H), 3.08-3.12 (m, 2H), 5.43-5.46 (m, 1H), 6.45-6.47 (m, 2H), 6.90-6.93 (m, 1H)
MS [EI, m/z]: 254 [M] + .
Step B. 1-(5-Chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydro-pyrimidine-2-(1H)-thione
To an ice-cold solution of the diamine of Step A (5.0 g) and triethylamine (5.2 mL) in dry chloroform (50 mL) under nitrogen was added thiophosgene (1.5 mL). After 5 minutes at ambient temperature, additional thiophosgene (1.0 mL) was added. After 10 minutes the reaction was quenched with water and extracted with dichloromethane. The combined extracts were dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 11% ethyl acetate in hexane provided a pale brown solid which was triturated with diethyl ether to give the title product (2.8 g, 48.1%) as a white solid, m.p. 96-98° C.
NMR (DMSO-d 6 , 400 MHz): δ0.89 (d, 6H), 2.04-2.11 (m, 2H), 2.12 (s, 3H), 2.14-2.20 (m, 1H), 3.35-3.92 (m, 6H), 7.19-7.25 (m, 3H)
MS [EI, m/z]: 296 [M] +
Anal. Calcd. for C 15 H 21 ClN 2 S: C, 60.69; H, 7.13; N, 9.44. Found: C, 60.97; H, 7.34; N, 9.49.
EXAMPLE 15
1-(6-Chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(6-Chloro-2-methyl-phenyl)-N-isopropyl-propane-1,3-diamine
A mixture of isopropylamine (18.3 mL) and the hydrobromide salt of Example 7, Step B (15 g) was heated at 100° C. under nitrogen for 45 minutes. The reaction was cooled and partitioned between water and ethyl acetate. The aqueous layer was extracted with ethyl acetate, and the combined extracts were dried over sodium sulfate and concentrated in vacuo. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 95:5 to 80:20 dichloromethane-methanol containing 0.2% ammonium hydroxide) gave the title compound (48.25 g, 78.4%) as a yellow oil which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ0.94 (d, 6H), 1.55-1.62 (m, 2H), 2.24 (s, 3H), 2.55 (t, 2H), 2.63-2.69 (m, 1H), 3.08-3.14 (m, 2H), 4.35-4.52 (m, 1H), 6.73-6.77 (m, 1H), 7.01-7.03 (m,1H), 7.13-7.15 (m, 1H)
MS [EI, m/z]: 240 [M] + .
Step B. 1-(6-Chloro-2-methyl-phenyl)-3-isopropyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To an ice-cold solution of the diamine of Step A (8.2 g) and triethylamine (9.09 mL) in dry chloroform (180 mL) under nitrogen was added thiophosgene (3.92 mL). After 10 minutes in the cold and 30 minutes at ambient temperature, the pH was adjusted to 8 with triethylamine and the reaction was quenched with water and extracted with dichloromethane. The combined extracts were dried over sodium sulfate, and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 11% ethyl acetate in hexane provided a white crystalline solid which was triturated with diethyl ether to give the title product (4.5 g, 46%), m.p. 135-136° C.
NMR (DMSO-d 6 , 400MHz): δ1.11 (d, 6H), 2.03-2.06 (m, 2H), 2.18 (s, 3H), 3.34-3.38 (m, 4H), 5.60-5.63 (m, 1H), 7.15-7.18 (m, 2H), 7.29-7.31 (m, 1H)
MS [+FAB, m/z]: 283 [M+H] + .
Anal. Calcd. for C 14 H 19 ClN 2 S: C, 59.45; H, 6.77; N, 9.91. Found: C, 59.65; H, 6.82; N, 9.89.
EXAMPLE 16
1-(6-Chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(6-Chloro-2-methyl-phenyl)-N-ethyl-propane-1,3-diamine
A mixture of a 2.0 M solution of ethylamine in tetrahydrofuran (139.5 mL) and the hydrobromide salt of Example 12, Step A (9.5 g) was stirred at ambient temperature under nitrogen for 48 hours. The tetrahydrofuran was removed in vacuo and the residue was partitioned between dichloromethane and 1N sodium hydroxide. The extracts were washed with brine, dried over sodium sulfate, and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 95:5 to 80:20 dichloromethane-methanol containing 0.2% ammonium hydroxide) gave the title compound (3.4 g, 54.3%) as a yellow oil, which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ0.98 (t, 3H), 1.56-1.62 (m, 2H), 2.24 (s, 3H), 2.49 (q, 2H), 2.56 (t, 2H), 2.80-3.05 (m, 1H), 3.13 (t, 2H), 4.35-4.50 (m, 1H), 6.73-6.77 (m, 1H), 7.01-7.04 (m, 1H), 7.13-7.15 (m, 1H)
MS [EI, m/z]: 226 [M] + .
Step B. 1-(6-Chloro-2-methyl-phenyl)-3-ethyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To an ice-cold solution of the diamine of Step A (3.4 g) and triethylamine (4.0 mL) in dry chloroform (50 mL) was added thiophosgene (1.7 mL). After 20 minutes at ambient temperature, the reaction was quenched with water and extracted with dichloromethane. The extracts were combined, dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 11% ethyl acetate in hexane provided an orange solid which was triturated with diethyl ether to give the title product (2.4 g, 59.5%) as a white solid, m.p. 88-90° C.
NMR (DMSO-d 6 , 400 MHz): δ1.13 (t, 3H), 2.07-2.11 (m, 2H), 2.19 (s, 3H), 3.37-3.41 (m, 2H), 3.48-3.50 (m, 2H), 3.81-3.94 (m, 2H), 7.14-7.20 (m, 2H), 7.29-7.31 (m, 1H).
MS [+FAB, m/z]: 269 [M+H] +
Anal. Calcd. for C 13 H 17 ClN 2 S: C, 58.09; H, 6.37; N, 10.42. Found: C, 57.94; H, 6.43; N, 10.27.
EXAMPLE 17
1-(4-Chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(4-Chloro-2-methyl-phenyl)-N-isobutyl-propane-1,3-diamine
A mixture of isobutylamine (27 mL) and the hydrobromide salt of Example 10, Step B (9.3 g) was heated under nitrogen at 90° C. for 2 hours. The reaction was cooled and partitioned between dichloromethane and 1N sodium hydroxide. The aqueous layer was extracted with dichloromethane and the combined extracts were dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 33% ethyl acetate in hexane followed by 80:20 dichloromethane-methanol containing 0.2% ammonium hydroxide gave the title compound (4.9 g, 71.0%) as a brown oil, which was used a such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ0.85 (d, 6H), 1.62-1.73 (m, 3H), 2.04 (s, 3H), 2.31 (d, 2H), 2.59 (t, 2H), 3.06-3.11 (m, 2H), 5.20-5.30 (m, 1H), 6.46-6.48 (m, 1H), 6.98-7.00 (m, 2H)
MS [EI, m/z]: 254 [M] + .
Step B. 1-(4-Chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To an ice-cold solution of the diamine of Step A (4.8 g) and triethylamine (5.0 mL) in dry chloroform (75 mL) was added thiophosgene (2.2 mL). After 10 minutes at ambient temperature, the reaction was quenched with water and extracted with dichloromethane. The extracts were combined, dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with 11% ethyl acetate in hexane provided a yellow solid which was triturated with diethyl ether to give the title product (2.4 g, 43.0%) as a white solid, m.p. 88-90° C.
NMR (DMSO-d 6 , 400 MHz): δ0.88 (d, 6H), 2.04-2.10 (m, 2H), 2.14 (s, 3H), 2.16-2.21 (m, 1H), 3.35-3.91 (m, 6H), 7.09-7.29 (m, 3H).
MS [EI, m/z]: 296 [M] +
Anal. Calcd. for C 15 H 21 ClN 2 S: C, 60.69; H, 7.13; N, 9.44. Found: C, 60.48; H, 6.95; N, 9.33.
EXAMPLE 18
1-(6-Chloro-2-methyl-phenyl)-3-cyclobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(6-Chloro-2-methyl-phenyl)-N-cyclobutyl-propane-1,3-diamine
A mixture of the hydrobromide salt of Example 12, Step B (6.64 g) and cyclobutylamine (4.15 g) was heated at 90° C. for 1.5 hours. The cooled mixture was diluted with water and extracted with dichloromethane. The extracts were washed with 20% aqueous sodium chloride, dried over anhydrous potassium carbonate and evaporated to a brown oil, which was flash chromatographed on Merck-60 flash silica gel (eluant: hexane-EtOAc 1:1 to remove less polar impurities, followed by dichloromethane-methanol-ammonium hydroxide 95:5:0.1) to provide the title compound (3.08 g, 63.5%), which was used as such in the next step.
Step B. 1-(6-Chloro-2-methyl-phenyl)-3-cyclobutyl-3,4,5,6-tetrahydropyrimidine-2(1H)-thione
To a solution of the diamine of Step A (3.28 g) in dry chloroform (48 mL) was added dropwise under nitrogen at 0° C. triethylamine (3.62 mL). Thiophosgene (1.49 mL) was then added dropwise via syringe and the mixture was stirred in the cold for another 15 minutes. Stirring was continued at room temperature for 1.5 hours, water was added and the the pH was adjusted to 8 with triethylamine. The aqueous layer was further extracted with dichloromethane and the combined extracts were washed with 20% aqueous sodium chloride, dried over anhydrous potasium carbonate and evaporated to dryness. The residue was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with hexane-ethyl acetate 9:1 provided the title compound (3.1 g, 81%) which was further triturated and sonicated with hexane and hexane-ether. The off-white solid was collected, washed with hexane and dried (2.69 g, 75.3%), m.p. 89-91° C.
NMR (DMSO-d 6 , 400 MHz): δ1.60 (m, 2H), 2.08 (m, 6H), 2.16 (s, 3H), 3.36 (t, 2H), 3.51 (t, 2H), 5.74 (m, 1H), 7.16 (m, 2H), 7.30 (m, 1H)
MS (EI, m/z): 294/296 [M] + .
Anal. Calcd. for C 15 H 19 ClN 2 S: C, 61.10; H, 6.50; N, 9.50. Found: C, 61.39; H, 6.51; N, 9.49.
EXAMPLE 19
1-(5-Chloro-2-methyl-phenyl)-3-cyclobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(5-Chloro-2-methyl-phenyl)-N-cyclobutyl-propane-1,3-diamine
To neat cyclobutylamine (10.0 mL) was added the hydrobromide salt of Example 8, Step B in two equal portions (2×4.3 g) 15 minutes apart at ambient temperature. The mixture was heated at reflux under nitrogen for 30 minutes, then cooled and partitioned between dichloromethane and 1N sodium hydroxide The aqueous layer was extracted with dichloromethane, the combined extracts were dried over sodium sulfate and concentrated in vacuo to give a brown oil. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 98:2 dichloromethane-methanol to 80:20 dichloromethane-methanol containing 0.2% ammonium hydroxide) gave the title compound (3.7 g, 58.5%) as a brown solid, which was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ1.51-1.69 (m, 6H), 2.01 (s, 3H), 2.05-2.11 (m, 2H), 2.52 (t, 2H), 3.06-3.30 (m, 4H), 5.58-5.61 (m, 1H), 6.44-6.47 (m, 2H), 6.90-6.92 (m, 1H)
MS [EI, m/z]: 252 [M] + .
Step B. 1-(5-Chloro-2-methyl-phenyl)-3-cyclobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
To an ice-cold solution of the diamine of Step A (3.6 g) and triethylamine (3.8 mL) in dry chloroform (40 mL) under nitrogen was added thiophosgene (1.7 mL). After 10 minutes at ambient temperature, the reaction was quenched with water and extracted with dichloromethane. The extracts were combined and dried over sodium sulfate and concentrated in vacuo to give a brown solid. The crude material was dissolved in dichloromethane and absorbed onto a column of Merck-60 flash silica gel. Elution with a solvent gradient (from 11% ethyl acetate in hexane to 8:1:1 hexane-ethyl acetate-dichloromethane) provided pure material which was triturated with diethyl ether to give the title product (2.3 g, 54.9%) as a white solid, m.p. 152-154° C.
NMR (DMSO-d 6 , 400 MHz): δ1.54-1.65 (m, 2H), 2.00-2.21 (m, 9H), 3.28-3.55 (m, 4H), 5.75-5.80 (m, 1H), 7.19-7.25 (m, 3H)
MS [EI, m/z]: 294 [M] +
Anal. Calcd. for C 15 H 19 ClN 2 S: C, 61.10; H, 6.50; N, 9.50. Found: C, 60.77; H, 6.52; N, 9.43.
EXAMPLE 20
1-(6-Chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydro-pyrimidine-2(1H)-thione
Step A. N′-(6-Chloro-2-methyl-phenyl)-N-isobutyl-propane-1,3-diamine
Under cooling the hydrobromide salt of Example 12, Step B (6.82 g) was mixed with isobutylamine (5.85 g). The mixture was warmed to 85° C. under nitrogen until homogeneous and then refluxed for 2.5 hours. After cooling, it was diluted with water and the basic solution extracted with dichloromethane. The extracts were washed with 20% aqueous sodium chloride, dried over anhydrous potassium carbonate and evaporated to a brown oil which was flash chromatographed (on Merck-60 flash silica gel). The less polar impurities were eluted with 1:1 hexane- EtOAc and the desired material with 95:5:0.1 dichloromethane-methanol-ammonium hydroxide. The low melting material (3.82 g, 75%) was used as such in the next step.
NMR (DMSO-d 6 , 400 MHz): δ0.83 (d, 6H), 1.60 (m, 3H), 2.24 (s, 3H), 2.27 (m, 2H), 2.54 (m, 2H), 3.11 (m, 2H), 6.74 (m, 1H), 7.02 (m, 1H), 7.14 (m, 1H)
MS (EI, m/z): 254/256 [M] + .
Step B. 1-(6-Chloro-2-methyl-phenyl)-3-isobutyl-3,4,5,6-tetrahydropyrimidine-2(1H)-thione
To a solution of the diamine of Step A (3.82 g) in dry chloroform (55 mL) was added dropwise at 0° C. under nitrogen triethylamine (4.18 mL) followed by thiophosgene (2.6 g). The mixture was stirred in the cold for 15 minutes and then at room temperature for 60 minutes. It was then diluted with water and after adjusting the pH to 8 with triethylamine, was extracted with dichloromethane. The combined extracts were washed with 20% aqueous sodium chloride, dried over anhydrous potassium carbonate and evaporated to dryness. The residue was flash chromatographed (on Merck-60 flash silica gel, 85:15 hexane-EtOAc) to provide 3.37 g of the title compound. Trituration and sonication with hexane and hexane-ether yielded an off-white solid (2.26 g, 51.1%), m.p. 119-121° C.
NMR (DMSO-d 6 , 400 MHz): δ0.89 (d, 6H), 2.07-2.17 (m, 3H), 2.19 (s, 3H), 3.39 (t, 2H), 3.49 (t, 2H), 3.66-3.84 (m, 2H), 7.17 (m, 2H), 7.30 (m, 1H)
MS (+FAB, m/z): 2971299 [M+H] +
Anal. Calcd for C 15 H 21 ClN 2 S: C, 60.69; H, 7.13; N, 9.44. Found: C, 60.80; H, 6.94; N, 9.42.
The present invention may be embodied in other specific forms without departing from the spirit and essential attributes thereof and accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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Antiatherosclerotic agents are provided having the following structure:
wherein:
R 1 is hydrogen, alkyl of 1-6 carbon atoms, cycloalkyl of 3-8 carbon atoms, alkenyl of 2-7 carbon atoms, alkynyl of 2-7 carbon atoms, or phenylalkyl of 7-10 carbon atoms; and
R 2 , R 3 , R 4 , R 5 , and R 6 are each, independently, hydrogen, halogen, alkyl of 1-6 carbon atoms, cycloalkyl of 3-8 carbon atoms, alkenyl of 2-7 carbon atoms, alkynyl of 2-7 carbon atoms, aralkyl of 7-10 carbon atoms, alkoxy of 1-6 carbon atoms, aryloxy of 6-12 carbon atoms, aralkyloxy of 7-12 carbon atoms, fluoroalkoxy of 1-6 carbon atoms, trifluoromethyl, alkylthio of 1-3 carbon atoms, alkylsulfonyl of 1-3 carbon atoms, —SCF 3 , nitro, alkylamino in which the alkylamino moiety has 1-6 carbon atoms, or dialkylamino in which each alkyl group has 1-6 carbon atoms; or a pharmaceutically acceptable salt thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a divisional application of U.S. Ser. No. 09/884,286, filed on Jun. 19, 2001 now U.S. Pat. No. 6,649,933, which claims priority to Taiwanese Application No. 89112829, filed on Jun. 29, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a thin film transistor and the manufacturing method thereof, and more particularly to a thin film transistor used in a thin film transistor liquid crystal display.
2. Description of the Related Art
In an active matrix liquid crystal displays, a thin film transistor (TFT) is commonly adopted for good driving and switching capabilities. FIG. 1 shows the essential components of a TFT used in a thin film transistor liquid crystal display (TFT-LCD). The substrate 1 is made from glass or quartz. A metal layer 2 a is used as the gate electrode of the TFT. The electrode 2 b is an electrode of a storage capacitor. A insulating layer 3 is formed on the substrate 1 . A semiconductor layer 4 is further formed above the insulating layer 3 and usually made from amorphous silicon. An n type doped polysilicon layer 5 and a metal electrode 6 are used to form source/drain electrodes of the TFT. A passivation layer 7 is formed above the substrate 1 . A transparent conductive layer 8 , such as an ITO layer, is used to form the pixel electrode. Between the source electrode and the drain electrode, a channel 9 is defined.
According to the TFT shown in FIG. 1 , the amorphous silicon layer 4 is formed on the insulating layer 3 , and the channel 9 is defined by etching the amorphous silicon layer 4 . During the above etching process, if any amorphous silicon is left above the insulating layer 3 at the position outside the TFT, it will harm the properties of the TFT and reduce the quality of the TFT-LCD. Additionally, two dielectric layers, including the insulating layer 3 and the passivaton layer 7 , are formed on the substrate 1 and will reduce the transmittance of the substrate 1 .
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method for forming a thin film transistor liquid crystal display (TFT-LCD) using metallic electrodes as a mask to remove the unwanted amorphous silicon layer when forming the source/drain electrodes. This method avoids the problems resulting from unwanted amorphous silicon layer, and enhances the TFT quality.
Another object of the present invention is to provide a manufacturing method for forming a thin film transistor liquid crystal display (TFT-LCD) to efficiently reduce the thickness of the insulating layer by controlling the etching condition for forming the drain/source electrodes without affecting the quality of the TFT. It also increases the capacitance Cs of the storage capacitor by reducing the thickness of the insulating layer.
Yet another object of the present invention is to provide a method for forming a thin film transistor liquid crystal display (TFT-LCD) to define a shielding metal layer above a lower electrode of a storage capacitor. After the drain/source electrodes are patterned, a number of layers are formed between the lower electrode and the shielding metal layer for increasing the storage capacitor.
To achieve the objects described, the present invention provides a first method for forming a thin film transistor liquid crystal display (TFT-LCD) . The TFT-LCD has at least one thin film transistor (TFT) and one storage capacitor. The manufacturing process is described below. First, a substrate is provided, a first and a second conductive layer are then deposited on the substrate to respectively form a gate electrode of the TFT and a bottom electrode of the storage capacitor. Then, forming an insulating layer above these conductive layers and the substrate. Further, sequentially forming a semiconductor layer and a doped silicon layer on the insulating layer, then depositing a sacrifice layer with an island shape on the doped silicon layer, especially directly above the first conductive layer. A metal layer is formed covering the island-shaped sacrifice layer and the doped silicon layer, the metal layer is then patterned to form source and drain electrodes above the first conductive layer. A channel is defined between the source electrode and the drain electrode, and the sacrifice layer is exposed in the channel. A portion of the substrate not covered by the source electrode, the drain electrode, and the channel is defined as a non-TFT region so as to expose the doped silicon in the non-TFT region. By using the source and the drain electrodes as a mask, several etching processes are performed at the same time during: (a) the island-shaped sacrifice layer and the doped silicon layer in the channel are removed so that the semiconductor layer is exposed in the channel; and (b) the doped silicon layer and the semiconductor layer on the non-TFT region are removed so that the insulating layer is exposed in the non-TFT region. Finally, a passivation layer is formed to cover the source electrode, the drain electrode, the channel, and the substrate.
To achieve the objects described, the present invention provides a second method for forming a thin film transistor liquid crystal display (TFT-LCD) . The TFT-LCD has at least one thin film transistor (TFT) and one storage capacitor. The manufacturing process is described below. First, a substrate is provided, a first and a second conductive layer are then deposited on the substrate to form a gate electrode of the TFT and a bottom electrode of the storage capacitor. Then, forming an insulating layer above these conductive layers and the substrate. Further, sequentially forming a semiconductor layer and a doped silicon layer on the insulating layer, then depositing a sacrifice layer with an island shape on the doped silicon layer, especially directly above the first conductive layer. A metal layer is formed covering the island-shaped sacrifice layer and the doped silicon layer, the metal layer is then patterned to form a source electrode and a drain electrode above the first conductive layer, and form a shielding metal layer above the second conductive layer. A channel is defined between the source electrode and the drain electrode, and the sacrifice layer is exposed in the channel. A capacitor region is defined as a portion of the substrate covered by the shielding metal layer. A portion of the substrate not covered by the source electrode, the drain electrode, the capacitor, and the channel is defined as a non-TFT region so as to expose the doped silicon in the non-TFT region. By using the source electrode, the drain electrode, and the shielding metal layer as a mask, several etching processes are performed at the same time during: (a) the island-shaped sacrifice layer and the doped silicon layer in the channel are removed so that the semiconductor layer is exposed in the channel; and (b) the doped silicon layer and the semiconductor layer on the non-TFT region are removed so that the insulating layer is exposed. Finally, a passivation layer is formed to cover the source electrode, the drain electrode, the channel, and the capacitor region.
To achieve the objects described, the present invention provides a third method for forming a thin film transistor liquid crystal display (TFT-LCD). The third manufacturing method is similar to the first manufacturing method. The major difference between the third method and the first method is the position of the sacrifice layer. In the third method, the island-shaped sacrifice layer is formed on the semiconductor layer, and the doped silicon layer is formed above the sacrifice layer in the channel.
To achieve the objects described, the present invention provides a fourth method for forming a thin film transistor liquid crystal display (TFT-LCD). The fourth manufacturing method is similar to the second manufacturing method. The major difference between the fourth method and the second method is the position of the sacrifice layer. In the fourth method, the island-shaped sacrifice layer is formed on the semiconductor layer, and the doped silicon layer is formed above the sacrifice layer in the channel.
In these methods mentioned above, the etching rates of the island-shaped sacrifice layer, the doped silicon layer, and the semiconductor layer are R IS , R n , and R a respectively. The thickness of the island-shaped sacrifice layer, the doped silicon layer, and the semiconductor layer are T IS , T n , and T a respectively. The time for removing the island-shaped sacrifice layer in the channel and the doped silicon layer (T IS /R IS +T n /R n ) is not less than the time for removing the doped silicon layer and the semiconductor layer on the non-TFT region (T n /R n +T a /R a ).
By controlling the thickness of the sacrifice layer, the thickness of the insulating layer on the non-TFT region is reduced at the same time during the etching processes for etching the doped silicon layer and the sacrifice layer in the channel as well as etching away the doped silicon layer, the semiconductor layer, and a portion of the insulating layer in the non-TFT region.
The portion of the removed insulating layer has an etching rate R INS and a thickness T INS , and the time for removing the sacrifice layer and the doped silicon layer in the channel (T IS /R IS +T n /R n ) is equal to the time for removing the doped silicon layer, the semiconductor layer and the removed insulating layer in the non-TFT region (T n /R n +T a /R a +T INS /R INS ).
One type of thin film transistor (TFT) is produced in the present invention. The TFT includes a gate electrode with an island shape formed on a substrate, an insulating layer covering the island-shaped gate electrode, an semiconductor layer with an island shape formed on the insulating layer, and a source doped silicon layer and a drain doped silicon layer formed on the semiconductor layer. The island-shaped semiconductor layer is positioned above the island-shaped gate electrode. A channel is defined between the source doped silicon layer and the drain doped silicon layer, and the island-shaped semiconductor layer is exposed in the channel. The TFT further includes first and second sacrifice layers having island shapes and respectively formed on the source doped silicon layer and drain doped silicon layer. The first and the second island-shaped sacrifice layers are separated by the channel. The TFT further includes a source electrode formed on the first sacrifice layer and the source dope silicon layer, and a drain electrode formed on the second sacrifice layer and the drain doped silicon layer. The thickness of the first and second sacrifice layers are varied according to the thickness of the island-shaped semiconductor layer because the time for etching the first and second sacrifice layers is substantially equal to the time for etching the semiconductor layer in the subsequent process.
A second type of thin film transistor is produced in the present invention. The TFT includes a gate electrode with an island shape formed on a substrate, an insulating layer covering the island-shaped gate electrode, and semiconductor layer with an island shape formed on the insulating layer, and first and second sacrifice layers with island shapes formed on the semiconductor layer. The first and second island-shaped sacrifice layers are positioned above the gate electrode. A channel is defined between the first and the second sacrifice layers, and the semiconductor layer is exposed in the channel. The TFT further includes a source doped silicon layer and a drain doped silicon layer formed above the first sacrifice layer, the second sacrifice layer, and the semiconductor layer. The source and drain doped silicon layers are spaced apart by the channel. The TFT further includes a source electrode and a drain electrode respectively formed on the source doped silicon layer and the drain doped silicon layer. The thickness of the first and second island-shaped sacrifice layers are varied according to the thickness of the island-shaped semiconductor layer because the time for etching the first and second island-shaped sacrifice layers is substantially equal to the time for etching the semiconductor layer in the subsequent process.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more fully understood by reading the subsequent detailed description in conjunction with the examples and references made to the accompanying drawings, wherein:
FIG. 1 is a perspective diagram of the essential component of a TFT-LCD in the prior art;
FIG. 2A to FIG. 2F are the sectional diagrams of the manufacturing process described in the first embodiment of the present invention;
FIG. 3A to FIG. 3F are the sectional diagrams of the manufacturing process described in the second embodiment of the present invention;
FIG. 4A to FIG. 4F are the sectional diagrams of the manufacturing process described in the third embodiment of the present invention;
FIG. 5A to FIG. 5F are the sectional diagrams of the manufacturing process described in the forth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The First Embodiment
FIG. 2A to FIG. 2F are the sectional diagrams of the manufacturing process described in the first embodiment of the present invention.
First of all, a first conductive layer 22 a and a second conductive layer 22 b are deposited on a substrate 21 to form a gate electrode 22 a of a thin film transistor (TFT) and a bottom electrode 22 b of a storage capacitor. Usually, the first and the second conductive layers 22 a and 22 b are metal layers, and the substrate 21 is made of glass or quartz.
Next, forming an insulating layer 23 above the first and the second conductive layers 22 a, 22 b and the substrate 21 , as shown in FIG. 2A . Then, a semiconductor layer 24 and a doped silicon layer 25 are formed on the insulating layer 23 . In the present embodiment, the semiconductor layer 24 is an amorphous silicon layer, and the doped silicon layer 25 is an n type doped poly-silicon layer.
A sacrifice layer 29 with an island shape is formed on the doped silicon layer 25 , and especially above the first conductive layer 22 a as shown in FIG. 2B . A metal layer 26 is formed to cover the island-shaped sacrifice layer 29 and the doped silicon layer 25 . As shown in FIG. 2 c, the metal layer 26 is patterned to form a source electrode 26 a and a drain electrode 26 b above the gate electrode 22 a. A channel 30 is defined between the source electrode 26 a and the drain electrode 26 b so as to expose the sacrifice layer 29 in the channel 30 . A portion of the substrate 21 which is not covered by the source electrode 26 a, the drain electrode 26 b, and the channel 30 is defined as a non-TFT region, and the doped silicon layer is exposed in the non-TFT region as shown in FIG. 2C .
By using the source and the drain electrodes 26 a and 26 b as a mask to perform the following etching processes at the same time: (1) removing the island-shaped sacrifice layer 29 and the doped silicon layer 25 in the channel, and (2) removing the doped silicon layer 25 and the semiconductor layer 24 in the non-TFT region, so that the semiconductor layer 24 is exposed in the channel 30 and the insulating layer 23 is exposed in the non-TFT region as shown in FIG. 2D .
In the etching process, etching rates of the island-shaped sacrifice layer 29 , the doped silicon layer 25 , and the semiconductor layer 24 are respectively R IS , R n , and R a . The thickness of the island-shaped sacrifice layer 29 , the doped silicon layer 25 , and the semiconductor layer 24 are T IS , T n , and T a , respectively. The amount of T IS , T n , and T a can be adjusted in advance to cooperate with a suitable etching process so that the time T 1 for removing the sacrifice layer 29 and the doped silicon layer 25 in the channel is equal to the time T 2 for removing the doped silicon layer 25 and the semiconductor layer 24 in the non-TFT region. T 1 equals to T IS /R IS +T n /R n , and T 2 equals to T n /R n +T a /R a , that is (T IS /R IS +T n /R n )≧(T n /R n +T a /R a ). After the etch process, the semiconductor layer 24 is exposed in the channel 30 , and the insulating layer 23 is exposed in the non-TFT region.
The thickness of the island-shaped sacrifice layer 29 can be adjusted so that a portion of the insulating layer 23 can be removed after etching away the doped silicon layer 25 and the semiconductor layer 24 in the non-TFT region during the etching process for removing the island-shaped sacrifice layer 29 and the doped silicon layer 25 in the channel, as shown in FIG. 2D . In other words, when the etching rate and the thickness of the removed portion of the insulating layer 23 are respectively R INS and T INS , the time T 1 for removing the sacrifice layer 29 and the doped silicon layer 25 in the channel (T 1 =T IS /R IS +T n /R n ) is equal to the time T 3 for removing the doped silicon layer 25 , the semiconductor layer 24 , and the removed insulating layer 23 in the non-TFT region (T 3 =T n /R n +T a /R a +T INS /R INS ).
Further, a passivation layer 27 is formed to cover the source electrode 26 a, the drain electrode 26 b, and the channel 30 . Therefore, this kind of TFT can be suitable for applying in an in-plane-switch (IPS) type TFT-LCD.
In the non-IPS type TFT-LCD, the passivation layer 27 is patterned to expose the drain electrode 26 b as shown in FIG. 2E . Finally, a transparent conductive layer 28 is formed on the passivation layer 27 to electrically connect to the drain electrode 26 b as shown in FIG. 2F . The transparent conductive layer can be an indium tin oxide (ITO) layer.
The Second Embodiment
FIG. 3A to FIG. 3F are the sectional diagrams of the manufacturing process described in the second embodiment of the present invention. The same structures are label by the same symbolic numberings as FIG. 2A to FIG. 2F .
The process of the second embodiment is similar to that of the first embodiment. The major difference is that a shielding metal layer 31 is formed directly above the lower electrode 22 b of the storage capacitor during the process for defining the source and drain electrodes 26 a and 26 b, as shown in FIG. 3C . Thereby, the shielding metal layer 31 , the doped silicon layer 25 , and the semiconductor layer 24 form a stack layer SL above the insulating layer 23 and the lower electrode 22 b , as shown in FIG. 3D .
A channel 32 is defined between the source and the drain electrodes 26 a and 26 b. A portion of the substrate uncovered by the source electrode 26 a, the drain electrode 26 b, the channel 32 , and the storage capacitor is defined as a non-TFT region. Meanwhile, the time T 1 for removing the sacrifice layer 29 and the doped silicon layer 25 in the channel (T 1 =T IS /R IS +T n /R n ) is not less than the time T 2 for removing the doped silicon layer 25 and the semiconductor layer 24 (T 2 =T n /R n +T a /R a ). When the etching process is terminated, the semiconductor layer 24 is exposed in the channel 32 , and the insulating layer 23 is exposed on the non-TFT region as shown in FIG. 3D .
According to FIG. 3E , a passivation layer 27 is formed to cover the TFT, and the passivation layer 27 is then patterned to expose the drain electrode 26 b and the stack layer SL. Finally, defining a transparent conductive layer 28 on the passivation layer 27 . The transparent conductive layer 28 is made of ITO, and electrically connected to the drain electrode 26 b. The transparent conductive layer 28 also connects to the shielding metal layer 31 to form an upper electrode of the storage capacitor.
The Third Embodiment
FIG. 4A to FIG. 4F are the sectional diagrams of the manufacturing process in the third embodiment of the present invention.
First of all, a first conductive layer 42 a and a second conductive layer 42 b are deposited on a substrate 41 to form a gate electrode 42 a of a thin film transistor (TFT) and a bottom electrode 42 b of a storage capacitor.
Next, forming an insulating layer 43 above the first and the second conductive layers 42 a, 42 b and the substrate 41 , as shown in FIG. 4A . Then, a semiconductor layer 44 is formed on the insulating layer 43 . In the present embodiment, the semiconductor layer 44 is an amorphous silicon layer.
A sacrifice layer 49 with an island shape is then formed on the semiconductor layer 44 , and directly above the first conductive layer 42 a . Next, a doped silicon layer 45 is formed on the island-shaped sacrifice layer 49 and the semiconductor layer 44 . The doped silicon layer 45 can be an n type doped poly-silicon layer.
A metal layer 46 is formed to cover the doped silicon layer 45 . As shown in FIG. 4 c , the metal layer 46 is patterned to form a source electrode 46 a and a drain electrode 46 b above the gate electrode 42 a . A channel 52 is defined between the source electrode 46 a and the drain electrode 46 b so as to expose the doped silicon layer 45 in the channel 52 . A portion of the substrate 41 which is not covered by the source electrode 46 a , the drain electrode 46 b , and the channel 52 is defined as a non-TFT region, and the doped silicon layer 45 is also exposed in the non-TFT region as shown in FIG. 4C .
By using the source and the drain electrodes 46 a and 46 b as a mask to perform the following etching processes at the same time: (1) removing the doped silicon layer 45 and the island-shaped sacrifice layer 49 in the channel 52 , and (2) removing the doped silicon layer 45 and the semiconductor layer 44 in the non-TFT region, so that the semiconductor layer 44 is exposed in the channel 52 and the insulating layer 43 is exposed in the non-TFT region as shown in FIG. 4D .
In the etching process, etching rates of the island-shaped sacrifice layer 49 , the doped silicon layer 45 , and the semiconductor layer 44 are respectively R IS , R n , and R a . The thickness of the island-shaped sacrifice layer 49 , the doped silicon layer 45 , and the semiconductor layer 44 are T IS , T n , and T a respectively. The amount of T IS , T n , and T a can be adjusted in advance to cooperate with a suitable etching process so that the time T 1 for removing the sacrifice layer 49 and the doped silicon layer 45 in the channel is not less than the time T 2 for removing the doped silicon layer 45 and the semiconductor layer 44 in the non-TFT region. T 1 equals to T IS /R IS +T n /R n and T 2 equals to T n /R n +T a /R a , that is (T IS /R IS +T n /R n )≧(T n /R n +T a /R a ). After the etching process, the semiconductor layer 44 is exposed in the channel 52 , and the insulating layer 43 is exposed in the non-TFT region.
Further, the thickness of the island-shaped sacrifice layer 49 is controlled so that a portion of the insulating layer 43 can be removed when etching the sacrifice layer 49 and the doped silicon layer 45 in the channel 52 . Therefore, the thickness of the insulating layer 43 can be reduced.
More clearly, the etching rate and the thickness of the removed portion of the insulating layer 43 are R INS and T INS . The time T 1 for removing the island-shaped sacrifice layer 49 and the doped silicon layer 45 in the channel 52 (T 1 =T IS /R IS +T n /R n ) will be equal to the time T 3 for removing the doped silicon layer 45 , the semiconductor layer 44 , and the removed part of the insulating layer 43 on the non-TFT region (T 3 =T n /R n +T a /R a +T INS /R INS ). The thickness of the insulating layer 43 is reduced so that the transmittance of the substrate 41 can be increased, and the capacitance of the storage capacitor can also be increased.
Then, a passivation layer 47 is formed and patterned to expose the drain electrode 46 b ,as shown in FIG. 4E . Finally, a transparent conductive layer 48 , such as an ITO layer, is formed on the passivation layer 47 , and electrical connected to the drain electrode 46 b , as shown in FIG. 4F .
The Fourth Embodiment
FIG. 5A to FIG. 5F are the sectional diagrams of the manufacturing process described in the fourth embodiment of the present invention. The same structures are labeled by the same symbolic numberings as FIG. 4A to FIG. 4F .
The process of the fourth embodiment is similar to that of the third embodiment. The major difference is that a shielding metal layer 51 is formed directly above the lower electrode 42 b of the storage capacitor during the process for defining the source and drain electrodes 46 a and 46 b , as shown in FIG. 5C . Therefore, the metal shielding layer 51 , the doped silicon layer 45 , and the semiconductor layer 44 form a stack layer SL above the insulating layer 43 and the lower electrode 42 b , as shown in FIG. 5D .
A channel 53 is defined between the source and the drain electrodes 46 a and 46 b . A portion of the substrate uncovered by the source electrode 46 a , the drain electrode 46 b , the channel 53 , and the storage capacitor is defined as a non-TFT region. Meanwhile, the time for removing the sacrifice layer 49 and the doped silicon layer 45 in the channel T 1 (=T IS /R IS +T n /R n ) is not less than the time spent for removing the doped silicon layer 45 and the semiconductor layer 44 T 2 (=T n /R n +T a /R a ). When the etching process is terminated, the semiconductor layer 44 is exposed in the channel 53 , and the insulating layer 43 is exposed on the non-TFT region as shown in FIG. 5D .
Finally, defining a transparent conductive layer 48 on the passivation layer 27 . The transparent conductive layer 48 is made of ITO, and electrically connected to the drain electrode 46 b . The transparent conductive layer 48 also connects to the shielding metal layer 51 to form an upper electrode of the storage capacitor.
Besides, when forming the channel 53 , a portion of the insulating layer 43 can be removed. The etching rate and the thickness of the removed portion of the insulating layer 43 are R INS and T INS . The time T 1 for removing the island-shaped sacrifice layer 49 and the doped silicon layer 45 in the channel 53 (T 1 =T IS /R IS +T n /R n ) will be equal to the time T 3 for removing the doped silicon layer 45 , the semiconductor layer 44 , and the removed part of the insulating layer 43 on the non-TFT region (T 3 =T n /R n +T a /R a +T INS /R INS ). The thickness of the insulating layer 43 is reduced so that the transmittance of the substrate 41 can be increased.
Although a part of the insulating layer is removed, there is still a stack layer SL formed between the lower electrode 42 b and the upper electrode of the storage capacitance. The stack layer SL can increase the capacitance when the insulating layer 43 is thinner.
From the embodiments described, the present invention uses metal electrodes as a mask to thoroughly remove the semiconductor layer outside the thin film transistor on the substrate. This reduces the product defects caused by the residual semiconductor layer, thus enhancing the product quality. Moreover, forming stacked layers between the lower and upper electrodes of the capacitor can increase the capacitance of the capacitor. The thickness of the insulating layer can be reduced for increasing the light transmittance of the TFT-LCD. Referring to the FIG. 2F and 3F , One kind of thin film transistor (TFT) is described as follows. The thin film transistor (TFT) includes a gate electrode 22 a with an island shape formed on a substrate 21 , an insulating layer 23 covering the gate electrode 22 a , and a semiconductor layer 24 with an island shape formed on the insulating layer 23 , and positioned directly above the gate electrode 22 a . The TFT further includes source and drain doped silicon layers 25 formed on the semiconductor layer 24 . A channel 30 or 32 is defined between the source doped silicon layer and the drain doped silicon layer 25 to expose the semiconductor layer 24 in the channel. The TFT further includes the first and second sacrifice layers 29 , a source electrode 26 a , and a drain electrode 26 b . The first and second sacrifice layers 29 have island shapes and are respectively formed on the source and drain doped silicon layers 25 . The first and second sacrifice layers 29 are spaced apart by the channel 30 , 32 . The source electrode 26 a is formed above the first sacrifice layer 29 and the source dope silicon layer 25 . The drain electrode 26 b is formed above the second sacrifice layer 29 and the drain doped silicon layer 25 . The thickness of the first and second sacrifice layers 29 varies according to the thickness of the semiconductor layer 24 because the time for etching the first and second sacrifice layers 29 is substantially equal to the time for etching the semiconductor layer 24 in the subsequent process.
Referring to the FIGS. 4F and 5F , a second kind of thin film transistor (TFT) is described as follows. The thin film transistor (TFT) includes a gate electrode 42 a with an island shape formed on a substrate 41 , an insulating layer 43 covering the gate electrode 42 a , a semiconductor layer 44 with an island shape formed on the insulating layer 43 and positioned above the gate electrode 42 a , and first and second sacrifice layers 49 with island shapes formed on the semiconductor layer. A channel 52 , 53 is defined between the first and second sacrifice layers 49 so as to expose the semiconductor layer 44 in the channel 52 , 53 . The TFT further includes source and drain doped silicon layers 45 formed above the first sacrifice layer 49 , second sacrifice layer 49 , and the semiconductor layer 44 . The source and the drain doped silicon layers 45 are spaced apart by the channel 52 , 53 . The TFT further includes a source electrode 46 a and a drain electrode 46 b respectively formed on the source and drain doped silicon layers 45 . The thickness of the first and second sacrifice layers 49 varies with the thickness of the semiconductor layer 44 because the time for etching the first and second sacrifice layers 49 is substantially equal to the time for etching the semiconductor layer 44 in the subsequent process.
Finally, while the invention has been described by way of example and in terms of the preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A manufacturing method and the structure of a thin film transistor liquid crystal display (TFT-LCD) are disclosed. The TFT-LCD uses metal electrodes as a mask to thoroughly remove the unwanted semiconductor layer during the etching process for forming the source and drain electrodes. This manufacturing method can reduce the problems caused by the unwanted semiconductor layer, hence improving the quality of the TFT.
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This is a file wrapper continuation of application Ser. No. 08/283,358, filed Aug. 1, 1994, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the production of elemental material from the halides thereof and has particular applicability to those metals and non-metals for which the reduction of the halide to the element is exothermic. Particular interest exists for titanium and the present invention will be described with particular reference to titanium but is applicable to other metals and non-metals such as Al, As, Sb, Be, B, Ta, Ge, V, Nb, Mo, Ga, Ir, Os, U and Re, all of which produce significant heat upon reduction from the halide to the metal. For the purposes of this application, elemental materials include those metals and non-metals listed above or in Table 1.
At present titanium production is by reduction of titanium tetrachloride, which is made by chlorinating relatively high-grade titanium dioxide ore. Ores containing rutile can be physically concentrated to produce a satisfactory chlorination feed material; other sources of titanium dioxide, such as ilmenite, titaniferous iron ores and most other titanium source materials, require chemical beneficiation.
The reduction of titanium tetrachloride to metal has been attempted using a number of reducing agents including hydrogen, carbon, sodium, calcium, aluminum and magnesium. The magnesium reduction of titanium tetrachloride has proved to be a commercial method for producing titanium metal. However, the resultant batch process requires significant material handling with resulting opportunities for contamination and also in quality variation from batch to batch. The greatest potential for decreasing production cost is the development of a continuous reduction process with attendant reduction in material handling.
There is a strong demand for the development of a process that enables continuous economical production of titanium powder suitable for use without additional processing for application to powder metallurgy or vacuum-arc melting to ingot form. The Kroll process and the Hunter process are the two present day methods of producing titanium commercially.
In the Kroll process, titanium tetrachloride is chemically reduced by magnesium at about 1000° C. The process is conducted in a batch fashion in a metal retort with an inert atmosphere, either helium or argon. Magnesium is charged into the vessel and heated to prepare a molten magnesium bath. Liquid titanium tetrachloride at room temperature is dispersed dropwise above the molten magnesium bath. The liquid titanium tetrachloride vaporizes in the gaseous zone above the molten magnesium bath. A surface reaction occurs to form titanium and magnesium chloride. The Hunter process is similar to the Kroll process, but uses sodium instead of magnesium to reduce the titanium tetrachloride to titanium metal and produce sodium chloride.
For both processes, the reaction is uncontrolled and sporadic and promotes the growth of dendritic titanium metal. The titanium fuses into a mass that encapsulates some of the molten magnesium (or sodium) chloride. This fused mass is called titanium sponge. After cooling of the metal retort, the solidified titanium sponge metal is broken up, crushed, purified and then dried in a stream of hot nitrogen. Powder titanium is usually produced through grinding, shot casting or centrifugal processes. A common technique is to first cause the titanium to absorb hydrogen to make the sponge brittle to facilitate the grinding process. After formation of the powder titanium hydride, the particles are dehydrogentated to produce a usable product. The processing of the titanium sponge into a usable form is difficult, labor intensive, and increases the product cost by a factor of two to three.
During these processing steps, some sponge particles as large as several centimeters in size may be ignited in air and are thereby converted to titanium oxynitride, which is usually not destroyed during the melting operation. The resulting inclusions of hard material within the titanium metal parts have been identified as causing disastrous failures of jet engine parts, leading to crashes of aircraft.
The processes discussed above have several intrinsic problems that contribute heavily to the high cost of titanium production. Batch process production is inherently capital and labor intensive. Titanium sponge requires substantial additional processing to produce titanium in a usable form, increasing cost, increasing hazard to workers and exacerbating batch quality control difficulties. Neither process utilizes the large exothermic energy reaction, requiring substantial energy input for titanium production (approximately 6 kw-hr/kg product metal). In addition, the processes generate significant production wastes that are of environmental concern.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a method and system for producing non-metals or metals or alloys thereof which is continuous having significant capital and operating costs advantages over existing batch technologies.
Another object of the present invention is to provide a method and system for producing metals and non-metals from the exothermic reduction of the halide while preventing the metal or non-metal from sintering onto the apparatus used to produce same.
Still another object of the invention is to provide a method and system for producing non-metal or metal from the halides thereof wherein the process and system recycles the reducing agent, thereby substantially reducing the environmental impact of the process.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.
FIG. 1 is a process flow diagram showing the continuous process for producing as an example titanium metal from titanium tetrachloride;
FIG. 2 is a heat balance flow sheet for a process wherein the reactants exiting the burner are about 300° C.;
FIG. 3 is an energy balance for a process in which the reactants exits the burner at about 850° C.; and
FIG. 4 is a schematic representation of a batch process.
DETAILED DESCRIPTION OF THE INVENTION
The process of the invention may be practiced with the use of any alkaline or alkaline earth metal depending upon the transition metal to be reduced. In some cases, combinations of an alkali or alkaline earth metals may be used. Moreover, any halide or combinations of halides may used with the present invention although in most circumstances chlorine, being the cheapest and most readily available, is preferred of the alkali or alkaline earth metals, by way of example, sodium will be chosen not for purposes of limitation but merely purposes of illustration, because it is cheapest and preferred, as has chlorine been chosen for the same purpose.
Regarding the non-metals or metals to be reduced, it is possible to reduce a single metal such as titanium or tantalum or zirconium, selected from the list set forth hereafter. It is also possible to make alloys of a predetermined composition by providing mixed metal halides at the beginning of the process in the required molecular ratio. By way of example, Table 1 sets forth heats of reaction per gram of sodium for the reduction of non-metal or metal halides applicable to the inventive process.
TABLE 1______________________________________FEEDSTOCK HEAT kJ/g______________________________________TiCl.sub.4 10AlCL.sub.3 9SbCl.sub.3 14BeCl.sub.2 10BCl.sub.3 12TaCl.sub.5 11VCl.sub.4 12NbCl.sub.5 12MoCl.sub.4 14GaCl.sub.3 11UF.sub.6 10ReF.sub.6 17______________________________________
The process will be illustrated, again for purposes of illustration and not for limitation, with a single metal titanium being produced from the tetrachloride.
A summary process flowsheet is shown in FIG. 1. Sodium and titanium tetrachloride are combined in a burner reaction chamber 10 where titanium tetrachloride vapor from a source thereof in the form of a distillation column 11 is injected into a flowing sodium stream from a source (not shown) thereof. Make up sodium is produced in an electrolytic cell 12. The reduction reaction is highly exothermic, forming molten reaction products of titanium and sodium chloride. The molten reaction products are quenched in the bulk sodium stream. Particle sizes and reaction rates are controlled by metering of the titanium tetrachloride vapor flowrate, dilution of the titanium tetrachloride vapor with an inert gas, such as He or Ar, and the sodium flow characteristics and mixing parameters where the burner includes concentric nozzles having an inner nozzle for the TiCl 4 and the outer nozzle for the liquid sodium, the gas is intimately mixed with the liquid and the resultant temperature, significantly affected by the heat of reaction, can be controlled by the quantity of sodium and maintained below the sintering temperature of the produced metal, such as titanium or about 1000° C.
The bulk sodium stream then contains the titanium and sodium chloride reaction products. These reaction products are removed from the bulk sodium stream by conventional separators 13 and 14 such as cyclones or particulate filters. Two separate options for separation of the titanium and the sodium chloride exist.
The first option removes the titanium and sodium chloride products in separate steps. This is accomplished by maintaining the bulk stream temperature such that the titanium is solid but the sodium chloride is molten through control of the ratio of titanium tetrachloride and sodium flowrates to the burner 10. For this option, the titanium is removed first, the bulk stream cooled to solidify the sodium chloride, then the sodium chloride is removed from separator 14. In this option, the process heat for titanium tetrachloride distillation would be removed from the bulk stream immediately after the titanium separator 13.
In the second option for reaction product removal, a lower ratio of titanium tetrachloride to sodium flowrate would be maintained in the burner 10 so that the bulk sodium temperature would remain below the sodium chloride solidification temperature. For this option, titanium and sodium chloride would be removed simultaneously. The sodium chloride and any residual sodium present on the particles would then be removed in a water-alcohol wash.
Following separation, the sodium chloride is then recycled to the electrolytic cell 12 to be regenerated. The sodium is returned to the bulk process stream for introduction to burner 10 and the chlorine is used in the ore chlorinator 15. It is important to note that while both electrolysis of sodium chloride and subsequent ore chlorination will be performed using technology well known in the art such integration and recycle of the reaction byproduct is not possible with the Kroll or Hunter process because of the batch nature of those processes and the production of titanium sponge as an intermediate product. Operators of the Kroll and Hunter processes purchase titanium tetrachloride for use in the manufacture of titanium. The integration of these separate processes enabled by the inventive chemical manufacturing process has significant benefits with respect to both improved economy of operation and substantially reduced environmental impact achieved by recycle of waste streams.
Chlorine from the electrolytic cell 12 is used to chlorinate titanium ore (rutile, anatase or ilmenite) in the chlorinator 15. In the chlorination stage, the titanium ore is blended with coke and chemically converted in the presence of chlorine in a fluidized-bed or other suitable kiln chlorinator 15. The titanium dioxide contained in the raw material reacts to form titanium tetrachloride, while the oxygen forms carbon dioxide with the coke. Iron and other impurity metals present in the ore are also converted during chlorination to their corresponding chlorides. The titanium chloride is then condensed and purified by means of distillation in column 11. With current practice, the purified titanium chloride vapor would be condensed again and sold to titanium manufacturers; however, in this integrated process, the titanium tetrachloride vapor stream is used directly in the manufacturing process.
After providing process heat for the distillation step in heat exchanger 16, the temperature of the bulk process stream is adjusted to the desired temperature for the burner 10 at heat exchanger 17, and then combined with the regenerated sodium recycle stream, and injected into the burner. It should be understood that various pumps, filters, traps, monitors and the like will be added as needed by those skilled in the art.
Referring now to FIGS. 2 and 3, there is disclosed flow diagrams, respectively, for a low temperature process in FIG. 2 and a high temperature process in FIG. 3. The principal differences are the temperatures at which the sodium enters and leaves the burner 10. Like numbers have been applied for like equipment, the purpose of which was explained in FIG. 1. For instance in FIG. 2 for the low temperature process, the sodium entering the burner 10 is at 200° C. having a flow rate of 38.4 kilograms per minute. The titanium tetrachloride from the boiler 11 is at 2 atmospheres and at a temperature of 164° C., the flow rate through line 15a being 1.1 kg/min. Pressures up to 12 atmospheres may be used, but it is important that back flow be prevented, so an elevated at pressure of at least 2 atmospheres is preferred to ensure that flow through the burner nozzle is critical or choked. Another way of expressing the pressure required to prevent back flow is that the halide vapor flow must be at sonic velocity. In all aspects, for the process of FIGS. 1 as well as the processes of FIGS. 2 and 3, it is important that the titanium that is removed from the separator 13 be at or below and preferably just below the sintering temperature of titanium in order to preclude and prevent the solidification of the titanium on the surfaces of the equipment, which is one of the fundamental difficulties with the processes commercially used presently. By maintaining the temperature of the titanium metal below the sintering temperature of titanium metal, the titanium will not attach to the walls of the equipment as it presently does and, therefore, the physical removal of same will be obviated. This is an important aspect of this invention and is obtained by the use of sufficient Na metal or diluent gas or both to control the temperature of the elemental (or alloy) product.
By way of interest, batch processes now in use, shown in FIG. 4, require that the titanium sponge be jackhammered from the collection vessel and considering the hardness of the sponge, is no mean task.
The high-temperature process illustrated in FIG. 3 shows that the temperature at which the sodium enters the boiler is at 750°, having a flow rate of about 33.4 kg.
The temperature of product from the burner in the low temperature process of FIG. 2 is about 300° C. whereas the high temperature process is at about 850° C. It is clear that even at the high temperature process, the titanium is well below the sintering temperature which is approximately 1000° C., thereby ensuring that the shortcomings of the present day process are avoided. The heat exchangers in both FIGS. 2 and 3 are identified by the numeral 20 although the values of the power removed is different for the processes of FIG. 2 (low temperature) and FIG. 3 (high temperature), due in part because of the placement of the heat exchanger 20 in the high temperature process prior to the separation of sodium chloride while in the low temperature process, the heat exchanger 20 is subsequent to the separation of sodium chloride resulting in different power outputs as indicated. In both flow diagrams of FIGS. 2 and 3, sodium make-up is indicated by the line 12A and this may come from an electrolytic cell 12 or some other source of sodium entirely different. In other aspects, both FIGS. 2 and 3 are illustrative of the types of design parameters which may be used to produce titanium metal in a continuous process which avoids the problems inherent in the batch process presently in use commercially.
The invention has been illustrated by reference to titanium alone and titanium tetrachloride as a feedstock, in combination with sodium as the reducing metal. However, it should be understood that the foregoing was for illustrative purposes only and the invention clearly pertains to those metals and non-metals in Table 1, which of course include the fluorides of uranium and rhenium and well as other halides such as bromides. Moreover, sodium while being the preferred reducing metal because of cost and availability, is clearly not the only available reductant. Lithium, potassium as well as calcium and other alkaline earth metals are available and thermodynamically feasible. It is well within the skill of the art to determine from the thermodynamic Tables which metals are capable of acting as a reducing agent in the foregoing reactions, the principal applications of the process being to those reactions which are highly exothermic as illustrated in Table 1 when the chloride or halide is reduced to the metal. Moreover, it is well within the skill of the art and it is contemplated in this invention that alloys can be made by the process of the subject invention by providing a suitable halide feed in the molecular ratio of the desired alloy.
While there has been disclosed what is considered to be the preferred embodiment of the present invention, it is understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
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A method of producing a non-metal element or a metal or an alloy thereof from a halide or mixtures thereof. The halide or mixtures thereof are contacted with a stream of liquid alkali metal or alkaline earth metal or mixtures thereof in sufficient quantity to convert the halide to the non-metal or the metal or alloy and to maintain the temperature of the reactants at a temperature lower than the lesser of the boiling point of the alkali or alkaline earth metal at atmospheric pressure or the sintering temperature of the produced non-metal or metal or alloy. A continuous method is disclosed, particularly applicable to titanium.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119 of German Patent Application No. 10 2010 052 713.0, filed on Nov. 26, 2010, the disclosure of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a drivable device for compacting a soil layer structure, having at least one vibration means or device, such as a vibration roller or a vibration plate, via which load pulses which compact the soil layer structure can be introduced into at least one load introduction area.
[0003] In addition, the present invention relates to a method for ascertaining a layer modulus of elasticity of an uppermost layer of a soil layer structure, in particular a roadway asphalt layer, during a compaction procedure.
BACKGROUND OF THE INVENTION
[0004] Such drivable devices for compacting a soil layer structure are known from the prior art. For example, there are machine driven rollers, and in particular road rollers, by which a soil layer structure, and in particular an asphalt road including its substrate, can be compacted. For this purpose, the drivable devices and also the above-mentioned road roller have a vibration means or device, via which load pulses which compact the soil layer structure can be introduced into the surface of the soil layer structure.
[0005] The drivable device moves in multiple work steps over the soil layer structure to be compacted, a further compaction up to a maximum compaction being achieved upon each passage. After achieving the maximum compaction, further compaction of the soil layer structure is no longer necessary or is even counterproductive, because it results in renewed loosening of the compacted soil layer structure and excess strain of the compaction device. For this reason, it is important to detect the degree of compaction of the soil layer structure continuously or at specific intervals.
[0006] However, it is problematic in this case that because of the structure of the soil composed of different layers, precise detection of the moduli of elasticity of the respective layers, i.e., the layer moduli of elasticity, is only imprecisely possible, since the moduli of elasticity of the individual layers, in particular unbound layers, mutually influence one another.
[0007] A method using the so-called “falling weight deflectometer” (FWD) is known from the prior art, in which a relatively precise detection of a layer modulus of elasticity is possible by ascertaining a depression trough caused by a load pulse via an established number of detection devices. In particular, in the case of the evaluation of the carrying capacity of existing asphalt roads, the carrying capacity studies using the FWD are increasingly gaining significance. Using the FWD, a load pulse is applied to the road surface using a falling mass, which serves to simulate a wheel rollover. The briefly occurring vertical deformation of the surface of the soil layer structure is recorded in the load center and remotely at eight predefined distances from the load center.
[0008] The stiffness of the entire road structure is ascertained via the measured depressions of the depression trough. The influence of the deeper layers on the measured depressions increases with increasing distance from the load introduction point. This means that the depression at the load introduction point is a function of the carrying capacity of the entire layer structure, while the depression at the most remote pickup is essentially determined by the carrying capacity of the substrate or deeper layers. The calculation of the stiffnesses or the layer moduli of elasticity is then performed based on the theory of the elastic half-space and a multilayer model (e.g., a 2-layer or 3-layer model) according to Boussinesq/Odemark.
[0009] The modulus of stiffness at the load introduction point results in the so-called equivalent modulus, i.e., the modulus of elasticity of the entire soil layer structure under the influence of all layers. At the far remote measuring point, the so-called bedding modulus, the modulus of elasticity of the substrate, is ascertained. The moduli of elasticity of the individual layers are then ascertained by means of back calculation from the measured depression troughs or moduli of elasticity of the roadway. The layer thicknesses of the bound and unbound carrier layers are incorporated in the calculation.
[0010] However, this method has the disadvantage that the ascertainment of the layer moduli of elasticity using the FWD is very time-consuming and no further work can be performed on the soil layer structures during the measurement. The values obtained by the FWD are also only available to a soil compaction device, and in particular a road roller, after a time delay, so that a compaction-controlled method or the compaction-controlled soil compaction is only possible with difficulty.
SUMMARY OF THE INVENTION
[0011] The object of the present invention is therefore to specify a device for compacting a soil layer structure of the above-mentioned type, which allows the rapid and cost-effective detection or monitoring of a layer modulus of elasticity of the soil layer structure and in particular an uppermost layer.
[0012] This object is achieved according to one embodiment of the present invention by a drivable device for compacting a soil layer structure having at least one vibration means or device, such as a vibration roller or a vibration plate, via which load pulses, which compact the soil layer structure, can be introduced into at least one load introduction area, at least one first and one second detection means or devices being provided for detecting the modulus of elasticity of the soil layer structure, which are situated on the drivable device spaced apart from one another such that the first detection device allows a detection in the load introduction area and at least the second detection device allows a detection outside the load introduction area.
[0013] This object is achieved with respect to the method by a method for ascertaining a layer modulus of elasticity of a layer of a soil layer structure, in particular a roadway asphalt layer, having the following steps: introducing at least one load pulse into a load introduction area via a surface of the uppermost area of the soil layer structure; detecting a first value of a depression trough of the soil layer structure in the load introduction area by a first detection device, ascertaining the equivalent modulus of the soil layer structure from the detected first value of the depression trough; detecting at least one second value of the depression trough outside the load introduction area by at least one second detection device; ascertaining the bedding modulus and the layer modulus of elasticity of the uppermost layer of the soil layer structure from the detected values of the depression trough, the load pulses being introduced into the soil layer structure via a vibration means or device, such as a vibration roller or vibration plate, of a soil compaction machine.
[0014] An essential point is thus that, corresponding to the above-described FWD method, in the method according to the present invention or the drivable device according to the present invention, the vibration device provided for compacting soil layer structure, i.e., a vibration roller, a vibration plate, a vibration stamper, etc., is used as the load introduction means for initiating a defined load pulse.
[0015] In the scope of the present invention, a drivable device can be understood as any device which has operating means for soil compaction functioning as a vibration means or device and, in particular, which serves for mechanized planar soil compaction, in particular in construction operation. It is relevant that the drivable device is implemented so that the two detection means or devices for detecting the modulus of elasticity or for detecting a depression trough are situated spaced apart from one another so that the first detection device detects in the load introduction area while at least the second detection device detects outside this load introduction area. “Outside this load introduction area” is understood as any position in which the effect of the load pulse is detectable at a distance to a load introduction area.
[0016] As already described above, a deformation trough or a depression trough results through the load pulses introduced by the vibration means or device and, in particular, by a vibration roller in one embodiment.
[0017] Through the arrangement according to the present invention of the first and at least one second detection means, a conclusion about the individual layer moduli of elasticity and in particular a conclusion about the uppermost layer of the soil layer structure can be made via a targeted determination of the values of this depression trough.
[0018] The first detection device is preferably implemented in such a way that it allows a detection of a first value of a depression trough of the soil layer structure in the load introduction area, the second detection device preferably also being implemented in such a way that it allows a detection of at least one second value of the depression trough outside the load introduction area. A targeted determination of the respective layer modulus can then be performed via the values thus detected, as already described above.
[0019] The first detection means or device is preferably implemented and situated so that it allows a detection of a first value of the depression trough in the load introduction area. This first value allows the calculation of the equivalent modulus of the soil layer structure, i.e., the modulus of elasticity of the entire soil layer structure, since all deformations of the soil layer structure, from the uppermost layer to layers lying very far below it, influence it. In particular, it is possible to perform this detection during the soil compaction operation.
[0020] A further modulus of elasticity, namely the bedding modulus, can then be determined via at least the second detection means or device, which is situated outside the load introduction area or outside each load introduction area, so that it only detects effects of the load pulse of the compaction means. This ascertainment is also again performed via the detection of at least one value of the depression trough, namely at least the second value in the area of the second detection device. The bedding modulus can then be determined from at least this second value of the depression trough. The detection is also possible here during the soil compaction operation.
[0021] This bedding modulus is nearly independent of the substrate, since the deformation at this point is essentially only determined by the substrate and not by the uppermost layer, as already described. According to the theory of the multilayer model, the layer modulus of the uppermost layer and in particular the layer modulus of the asphalt layer is ascertained with the layer thicknesses of the individual layers of the soil layer structure. As an asphalt modulus which is corrected for the substrate influence, it represents the stiffness of the asphalt layer substantially more precisely than the equivalent modulus ascertained in the load introduction area.
[0022] By equipping a device for soil compaction with the detection means or device according to the present invention, monitoring of the compaction status, in particular a carrying capacity study of an asphalt road, can therefore also be performed during the compaction operation and in particular during the operation of a road roller or a comparable compaction means or device. The values thus ascertained can then directly influence the regulation procedures of the road construction machine, in order to achieve particularly effective control of the machine in accordance with demands.
[0023] The first and at least the second detection means or devices preferably have at least one geophone or similar deformation meter, via which reflected waves because of the introduced load pulses are detectable in particular in the soil layer structure. In this way, very precise detection of the respective values of the depression trough is possible.
[0024] The first and/or the second detection means or device preferably have a force sensor or a similar load cell, via which the introduced force pulses can be detected and/or relayed to a corresponding processing unit.
[0025] The detected force pulses are preferably stored in this processing unit. This is similarly true for the first and at least second values detected by the detection means, which are also preferably recorded, processed, and stored in a corresponding processing unit. The analysis of the detected values and the ascertainment of the respective moduli of elasticity are preferably possible in this analysis unit. It preferably also assumes the comparison of the ascertained equivalent and bedding moduli and the determination of the respective resulting layer modulus. Corresponding control and regulation programs as well as processing programs are preferably contained or storable for this purpose in the processing unit. The resulting results can then be displayed in a display unit and/or supplied to further program routines, such as the result-oriented regulation of the vibration means.
[0026] The first and at least second detection means or devices are preferably implemented so that they allow a precise detection of the deformations caused by the load introduction pulses in the respective areas. A detection can be performed using all methods and devices known from the prior art. It is thus also possible to perform a detection via the vibration means itself and by its settling movements during the vibration procedure. A very simple detection of the first and at least second values is possible, for example, by means of an electromechanical transducer implemented as a geophone, which converts the soil vibrations into analog voltage signals.
[0027] The detection means or devices are preferably situated so that a static coupling exists between the uppermost layer of the soil layer structure and the detection means.
[0028] In a particular embodiment, the first detection means or device is situated on the device in such a way that it allows a detection in the load center of the load introduction area. A maximum value can be ascertained as the first value of the depression trough in this way. The first detection device is preferably additionally situated coaxially to the load introduction axis of the vibration roller.
[0029] It is possible to situate the first detection means or device on the vibration roller or its bearing unit, in particular on a vibrating drum of the vibration roller. A precise detection of the first value in the load introduction area and in particular the load center of the load introduction area can be performed very simply in this way.
[0030] At least the second detection means or device is preferably situated on a static roller, in particular on the static drum thereof. A static roller is understood in the scope of the present invention as such a roller which does not have independent vibration means. Such a static roller can thus result in compaction of the soil solely because of its weight, for example, it can also only be used as the driving means for the drivable device according to the present invention. The term static roller thus also comprises rubber wheels or similar driving means in the scope of the present invention. The arrangement of the second detection means or device on a further non-vibrating, i.e., static suspension and in particular a static roller also allows the cost-effective and very precise detection of a second value of the depression trough. All methods for detecting the value in the depression trough known from the prior art can also be used here.
[0031] In an advantageous refinement, at least the second detection means or device is situated so it is displaceable, in particular via a support frame, in its position relative to the load introduction area of the vibration device. In this way, direct influence can be taken on the detection location of the second value of the depression trough. In addition, further detection means or devices for detecting further values of the depression trough outside the load introduction area can be situated on such a support frame. Moreover, of course, such further detection means or devices can also be situated on other components of the device, as long as they are spaced apart from the load introduction area.
[0032] The drivable device is preferably implemented as a compactor having a vibration roller and at least one static roller. A soil compaction with simultaneous carrying capacity study and in particular the detection of the carrying capacity status of the uppermost layer of the soil layer structure can then be performed very simply via a compactor equipped according to the present invention.
[0033] It is thus fundamentally possible by means of the drivable device according to the present invention and the method according to the present invention to perform a carrying capacity study, in particular of an uppermost layer of a soil layer structure, during a compaction process of a soil layer structure. A soil compaction machine, as is known from the prior art, is thus preferably equipped with the detection devices according to the present invention and further conversion and regulating units required for this purpose in order to perform a method similar to the method of the carrying capacity study using the “falling weight deflectometer”. It is also possible in this context to offer a drivable device which allows a soil compaction machine to be equipped later with the above detection means or means for detecting a layer modulus of elasticity of an uppermost layer of a layer structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The present invention is described hereafter on the basis of an exemplary embodiment, which is explained in greater detail through the appended drawings. In the schematic figures:
[0035] FIG. 1 shows an illustration of a first embodiment of the drivable device for compacting a soil layer structure; and
[0036] FIG. 2 shows an illustration of the detection means or device arrangement of the embodiment from FIG. 1 .
[0037] The same reference numerals are used hereafter for comparable and identically acting components, apostrophes sometimes also being used for differentiation.
DETAILED DESCRIPTION
[0038] FIG. 1 shows an illustration of an embodiment of a drivable device 1 according to the present invention for compacting a soil layer structure. The device 1 is implemented here as a self-propelled road roller and in particular as a compactor 30 . It comprises a vibration means or device implemented as a vibration roller 6 , which is connected via a bearing unit 16 to a main body 34 of the compactor 30 . A static roller 24 is associated via a further bearing unit 26 , so that the compactor 30 is drivable via the two rollers 6 , 24 .
[0039] In contrast to the static roller 24 , in the case of which compaction of a soil structure 2 occurs exclusively because of its static weight, in the case of the vibration roller 6 , the soil layer structure 2 can be actively compacted via driven vibrating masses.
[0040] The vibration roller 6 relays load pulses P via a load introduction area 8 , which essentially corresponds to the contact area between the vibrating drum 18 of the vibration roller 6 and the surface 33 of the uppermost layer 32 of the soil layer structure 2 , into the substrate. These vibrations, which are caused by the load pulses P and induce settling, are shown by the concentric circles 15 in FIG. 1 .
[0041] Starting from a load center Z, settling in the soil layer structure 2 , which is schematically shown here by the depression trough 14 , occurs because of the introduced load pulses P and the resulting vibrations 15 . It is clear in this case that the settling or compaction caused by the load pulses P decreases with increasing distance A from the load center Z or a load introduction axis A P running vertically to the surface 33 .
[0042] A modulus of stiffness can be ascertained, as is known from the prior art, via the load pulses P introduced at the vibrating drum 18 or vibration roller 6 , which act as compaction or deformation force in the soil layer structure 2 . This modulus of stiffness corresponds to the equivalent modulus, i.e., a mean stiffness value over the entire measurement depth of the soil layer structure 2 . Both the layer modulus of elasticity of the uppermost layer 32 and also of the bedding layers 42 lying underneath thus have influence on this equivalent modulus.
[0043] The detection of the first value “w 1 ” of the depression trough 14 , required for ascertaining the equivalent modulus, is performed via a first detection means or device 10 , which is situated and statically coupled in this embodiment on the vibration roller 6 or its bearing unit 16 .
[0044] A second detection means or device 12 , via which a second detection value “w 2 ” of the depression trough 14 can be ascertained outside the load introduction area 8 , is situated on the static roller 24 or on its static drum 28 or its bearing unit 26 . As is shown in FIG. 1 , the second detection means 12 is spaced apart from the first detection means 10 and the load introduction area 8 in such a way that a detection of a modulus of elasticity of the layers situated below the uppermost layer 32 and in particular the bedding layer 42 is possible. Because of the distance A D between the first detection means or device 10 or the load introduction area 8 and the second detection means or device 12 , the deformations at the detection point of the second value “w 2 ” are essentially determined by the substrate and not by the asphalt layer itself. A value of 1 m to 2.6 m, in particular 1.8 m, has proven to be an advantageous distance value A D here.
[0045] According to the theory of the multilayer model known from the prior art, the layer modulus of elasticity of the asphalt layer 32 to be measured can then be ascertained using the layer thicknesses of the individual soil layers via the two ascertained first and second values “w 1 ” and “w 2 ” and the equivalent or bedding moduli obtained therefrom, the result being an asphalt modulus which is essentially corrected for the substrate influence, and which represents the stiffness of the asphalt layer 32 significantly more precisely than the equivalent modulus, which considers the entire soil structure 2 .
[0046] As a function of the components and detection means used, according to the present invention, a load introduction P can be performed at a frequency of 30 to 50 load introductions per second. A corresponding influence can be taken on the vibration means 4 or the vibration roller 6 here via corresponding control means. It is also possible to regulate the absolute value of the introduced load pulses via a corresponding regulation means in such a way that it corresponds to the required measuring conditions. For example, the load pulse P can be regulated to a value of 50 kN via the regulation means, which essentially corresponds to the wheel load of a truck and therefore allows an informative analysis of the carrying capacity of the soil layer structure 2 and in particular the upper layer 32 . It is thus possible in this regard to activate the device 1 according to the present invention or the compactor 30 in such a way that it allows a reliable and reproducible study of the soil layer structure 2 and in particular the uppermost soil layer 32 .
[0047] FIG. 2 shows a schematic illustration of the drivable device 1 according to FIG. 1 , showing the first and second detection devices 10 and 12 .
[0048] It is shown that a geophone 11 of the first detection means or device 10 is situated on the vibration roller 6 of the drivable device 1 so that it allows detection of the reflected waves which are caused by the load pulses P. Via the geophone 11 or the first detection means or device 10 , as is known from the prior art, the dynamic soil stiffness of the soil layer structure 2 located in the load introduction area 8 is thus detectable. Conclusions about the degree of compaction of the soil layer structure 2 may then be made in a known way via this dynamic soil stiffness.
[0049] A geophone 13 of the second detection means or device 12 , is also situated on the static roller 24 of the drivable device 1 . Since the static roller 24 does not introduce separate load pulses into the soil layer structure 2 , this geophone allows a detection of a stiffness value as a function of the load introduction in the load introduction area 8 , which, because of the distance A D between the two detection means or devices 10 and 12 or geophones 11 and 13 , is essentially only a function of the bedding layer 42 and not the upper layer 32 . Via the value “w 2 ” of the depression curve 14 detected by the geophone 13 or the second detection means or device 12 , the soil stiffness and in particular a bedding modulus may therefore be determined without influence of the upper layer 32 .
[0050] The first and second values “w 1 ”, “w 2 ” ascertained by the two geophones 11 , 13 are transmitted as measurement results to an analysis unit 36 , which compares the two detected first and second values “w 1 ” and “w 2 ” or ascertains equivalent and bedding moduli of a layer modulus of elasticity of the uppermost layer 32 which can be ascertained therefrom. The values thus obtained can then either be output to the operating personnel via a display unit 38 or can directly influence the machine controller of the drivable device 1 .
[0051] In addition, a calibration element 40 is shown in FIG. 2 , via which, for example, the load pulses P introduced into the soil layer structure are fixable at a fixed value and in particular, for example, at a value of 50 kN. The vibration speed and therefore the number of load pulses per second is also preferably settable to a value between 20 and 50 times per second via such a calibration element 40 .
[0052] A support frame 27 is also shown in FIG. 2 , via which the second detection means or device 12 is situated so it is displaceable in its position relative to the load introduction area 8 of the vibration means or device 4 or the vibration roller 6 (preferably essentially parallel to the soil surface 32 ). As a result, the distance A D between the two measuring points of the values “w 1 ” and “w 2 ” is therefore variable via the support frame 27 .
[0053] While the present invention has been illustrated by description of various embodiments and while those embodiments have been described in considerable detail, it is not the intention of Applicants to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. The present invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' invention.
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The present invention relates to a drivable device for compacting a soil layer structure, having at least one vibration means or device, such as a vibration roller or a vibration plate, via which load pulses (P), which compact the soil layer structure, can be introduced into at least one load introduction area. At least one first and one second detection means or devices for detecting the modulus of elasticity of the soil layer structure are provided, which are situated spaced apart from one another on the drivable device in such a way that the first detection means or device allows a detection in the load introduction area and at least the second detection means or devices allows a detection outside the load introduction area. The present invention also relates to a method for ascertaining a layer modulus of elasticity.
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CROSS REFERENCE TO RELATED APPLICATION
The present application relates to copending application Ser. No. 249,596 filed on Sept. 26, 1988 and entitled SEGMENTED RAIL ASSEMBLY FOR CLOSED WORKPIECE CONVEYOR SYSTEM which application is commonly assigned with the present application.
BACKGROUND OF THE INVENTION
The present invention relates to a device for engaging a movable object at one position and advancing it to another position and more particularly relates to a transfer slide assembly employed in a rail conveyor system for transferring a trolley from a rail in a subsidiary system onto an elevator for movement upwardly to a main rail system.
U.S. Pat. No. 4,615,273 discloses a conveyorized transport system of the type embodying the transfer slide assembly of the present invention having a main rail upon which trolleys ride, subsidiary loops located along the main rail leading to and from a work station, and switching means for transferring a trolley between the main rail and each subsidiary loop. It is known to utilize an elevator having a slotted track section which receives a trolley crown portion to lift the trolley from a position adjacent the lower free end of an inclined subsidiary loop rail upwardly toward the switching means for transfer onto the main rail of the conveyor. While the elevator car is sized and shaped to receive the crown portion of the troley, the trolley must be actively and positively pushed or pulled into the elevator car because a trolley travelling down the inclined subsidiary loop rail towards the elevator usually cannot consistently travel from the rail into and through the narrow confines of the elevator car slotted track under the force of its own momentum. In addition, the forward movement of a trolley rolling down off of the inclined subsidiary loop rail end may often be arrested or be significantly reduced by the trolley crown portion entering into the elevator slotted track. Moreover, trolley side sway occurring as the trolley rolls down the rail may further prohibit the crown portion of the trolley from aligning with the elevator car slotted track and thus hinder the trolley from the entering the elevator car.
One type of device previously used to advance a trolley with positive force employs a piston and cylinder assembly such as the one suggested in U.S. Pat. No. 4,615,273 utilizing a hinged claw fixed to a piston rod for gripping a single trolley and pulling it into the slotted track of the elevator. One problem experienced in these previously known advancing mechanisms is the relatively complex mechanical structure of the hinged claw. Since the claw must operate to consistently engage and move successive numbers of trolleys into the slotted track of the elevator, the hinge and the other cooperating mechanical components may become worn and eventually breakdown. In addition, such hinged claw devices tend not to be self-contained compact mechanisms but instead usually involve awkwardly oriented grasping means such as the hinged claw depending from the laterally extending piston rod.
As previously mentioned, a trolley may tend to swing laterally relative to the longitudinal extent of the rail as it approaches the elevator car. This lateral swinging movement may at times prevent an advancing assembly such as the hinged claw from contacting and gripping th trolley crown portion and moving it into the elevator. Moreover, a trolley advancing device such as suggested in U.S. Pat. No. 4,615,273 engages the trolley crown which is positioned on the top portion of a trolley and thereby advances the trolley into the elevator by pulling the trolley from the top. As a result, a yet further problem of tilting about the trolley roller axes occurs when the trolley carries a substantially heavy garment piece and is pulled from its top crown portion by an advancing device. Tilting motion of this type may cause the crown portion of the trolley to become dislodged from the advancing device and in turn may subsequently cause the trolley not to be advanced into the slotted track of the elevator car.
Accordingly, it is the object of the present invention to provide a transfer slide assembly supported at the end of the subsidiary loop rail and positioned adjacent an elevator in a conveyorized transport system having means for positively engaging with a trolley and moving successive ones of such trolleys consistently into the elevator for movement upwardly to a main conveyor rail system.
It is yet another object of the present invention to provide a compact and mechanically simplified transfer slide assembly usable in a conveyorized transport system having generally a two-piece construction such that one piece is fixed to the rail while second piece slides relative to the first to positively push the trolley onto an elevator.
A further object of the present invention is to provide a transfer slide assembly having a dual action stroke capable of advancing a trolley into registry within a slotted track serving as an elevator car.
SUMMARY OF THE INVENTION
A transfer slide assembly is used to advance a trolley from one position to another position and includes an elongate body having a longitudinal axis extending along the longitudinal extent of the body and has a cavity formed throughout the length of the body along the longitudinal axis and the body has at least two surfaces extending parallel with the body longitudinal axis and has an opening extending substantially with said cavity and communicating between the surfaces and the cavity, which surfaces being positioned along either side of the opening for providing a rolling surface upon which the trolley may move along the body. A slide is received within the cavity and is movable relative to the body along the longitudinal axis and has pusher means extending from the slide and is engagable with a trolley to push it from the one position to another position using actuator means for moving the slide relative to said body.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a conveyorized transport system employing the transfer slide assembly of the present invention.
FIG. 2 is a perspective view of a section of the conveyorized transport system of FIG. 1 and includes a stretch of the main rail and propulsion track plus two oppositely disposed subsidiary loops each employing the transfer slide assembly of the present invention.
FIG. 3 is a side view of the transfer slide assembly as it is employed with the elevator assembly in the conveyorized transport system of FIG. 1 and 2 and shows the slide in its extended position.
FIG. 4 is a sectional view of the transfer slide assembly embodying the present invention shown separately from the elevator and shows the slide in its retracted position.
FIG. 5 is an enlarged view taken along line 5--5 in FIG. 4 showing a transverse cross section, the transfer slide body as it is fixed to the rail absent the slide normally received within the slide body.
FIG. 6 shows in side elevation view one embodiment of the slide used in the present invention.
FIG. 6a is an end view taken of the slide shown in FIG. 6 looking to the right.
FIG. 7a is a view taken in transverse section along line 7--7 of FIG. 3 and shows a trolley riding downwardly along a subsidiary loop rail prior to engaging the body of the transfer slide assembly.
FIG. 7b is a view taken in transverse section along line 7--7 of FIG. 3 and shows a trolley engaging the body of the transfer slide assembly after having rolled off the subsidiary loop rail.
FIG. 7c is an end view taken along line 7c--7c of FIG. 3 and shows a trolley positioned on the body of the transfer slide assembly and in line with the elevator car prior to being advanced into it by the slide.
FIG. 8 is a side elevation view of an alternative embodiment of a slide used in the present invention.
FIG. 8a is an end elevation view taken of the slide shown in FIG. 8 looking to the left.
FIG. 9 is a view taken in transverse cross section through a transfer slide assembly employing the slide shown in FIG. 8 and shows a trolley travelling down along the subsidiary loop rail prior to passing over the spring pusher.
FIG. 9a is a view taken in transverse cross section through a transfer slide assembly employing the slide shown in FIG. 8 and shows a trolley resting on the body of the transfer slide assembly after having travelled over the spring pusher.
FIG. 10 is a sectional view of another embodiment of the transfer slide assembly embodying the present invention shown separately from the elevator and shows the modified slide in its retracted position.
FIG. 11 is an enlarged view taken along line 11--11 in FIG. 10 showing in transverse cross section, the slide as it is received within the body of the transfer slide assembly.
FIG. 12 is an elevation view of the modified slide shown in FIG. 10 looking to the left on FIG. 11.
FIG. 13 is a top fragmented view of the slide shown in FIG. 12 showing in detail the pusher structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, a conveyorized transport system embodying the present invention includes a master computer 8, a propulsion track 10 having pushers 15 extending from it, a drive unit 3 for the propulsion track 10, a main rail 12 situated beneath the propulsion track 10, trolleys 14 riding on the rail 12 held by the pushers 15 and subsidiary loops 16 and 32 located along the main rail. Each subsidiary loop usually services a work station and includes a three position switch 25 for routing the trolleys between the main rail and each pair of subsidiary loops or directly between subsidiary loops of a given pair and two position switches 27 for routing the trolleys between the main rail and an unpaired subsidiary loop or a diversion rail 31.
FIG. 2 illustrates an isolated section of the conveyorized transport system shown in FIG. 1 and more particularly shows in detail the cooperation between the main rail 12, the propulsion track 10 and the pair of subsidiary loops 16, 32 servicing a pair of work stations 33, 35 positioned adjacent each subsidiary loop. The trolleys 14 ride on the main rail 12 and are propelled by one of the pushers 15 toward the subsidiary loops 16, 32 in the direction of flow indicated by the arrow drawn on track 10. Each subsidiary loop 16, 32 includes a looping rail 28, a stop assembly 38 and an elevator 54. The stop assembly 38 is one such as described in U.S. Pat. No. 4,667,602 issued on May 26, 1987 to Vaida et al. and which is commonly assigned to the assignee of the present application. The stop 38 is used as a gate to index and advance a single one of a number of trolleys collecting at the stop 38 to advance it down the inclined rail 28 toward the elevator.
The three position switch 25 having an actuator apparatus 18 for moving a section of rail 24 between laterally aligned gaps 29 in each of the subsidiary loops 16, 32 and the main rail 12, routes individual trolleys between the loops 16, 32 and the main rail 12. The actuator apparatus 18 is controlled by the computer 8 and selectively energizes the actuator 18 to alternatively position the rail section 24 thereby bridging and bridge one of the gaps 29 and effecting trolley transfer to the main rail from one of the subsidiary loops or from the main rail to either of the subsidiary loops. For a more complete description of the actuator apparatus operation, reference made be had to U.S. Pat. No. 4,615,273. Once a trolley is transferred onto the looping rail 28, it travels downwardly on the rail toward one of the work stations 33, 35 under the force of gravity and is further aided in its travel down the rail 28 by forward movement imparted to the trolley by the pusher 15 as it is moved off of and away from the transfer rail segment 24. The trolley travels down the rail 28 and arrives at the stop 38 where a series of trolleys 14b-d may collect at a stop upper gate. A downstream gate located at the other end of the stop 38 allows a single trolley 14e to be isolated from the remaining trolleys 14b-d so that an operator 42 has easy access to work pieces 46 carried by hanger 48 on the isolated trolley and in turn performs a work operation on such work pieces.
After the work operation is performed on work pieces 46, the operator releases the isolated trolley from the downstream gate of the stop 38 by pushing a button on control box 50 to cause the downstream gate to open and allow isolated trolley 14e to roll under the force of gravity down looping rail 28 toward the elevator 54. The trolley is then loaded onto a slotted track car carried by the elevator 54, and when the master computer 8 senses a break in a parade of trolleys on the main rail 12 it directs the elevator 54 to raise the trolley 14 upwardly toward the main rail. When the elevator car reaches the top, a next pusher 15 arrives and engages a crown located on the top portion of the trolley 14 and pushes the trolley from the slotted track elevator car onto the transfer rail 24 positioned in the gap 29 of the subsidiary loop adjacent the elevator. From the transfer rail section, the trolley 14 can either be transferred back to the beginning of the subsidiary loop 16, to main rail 12, or to the opposite subsidiary loop 32.
In accordance with the invention, FIG. 3 shows a transfer slide assembly 70 fixed to the lower free end of the subsidiary rail 28 and functions to advance a single trolley 14 from the rail 28 into an elevator car 1 positioned adjacent the rail end. The transfer slide assembly of the present invention is comprised of a body 72 having a central longitudinal axis L and a slide 74 connected to a piston rod 78 of a double acting dual chamber pneumatic actuator 75 for moving a slide 74 in small strokes of approximately 3 to 4 inches away from and toward the body 72. The slide 74 is secured to the piston rod 78 through a slide depending portion 80 having an aperture for receiving the piston rod 78. The end of the piston rod is threaded at 82 and utilizes two adjusting nuts which may selectively position the depending portion 80 on the threaded portion 82 of the piston rod 78 to vary the stroke length is desired. The body 72 is fixed to the rail 28 by screws 86 threadably engaging the body 72 through openings formed in the rail 28 and has a body depending portion 76 rigidly mounting the dual acting actuator 75 such that the piston rod 82 slides relative to the stationary actuator secured to the body portion.
One feature of the invention is the particularly compact and multipurpose design of the body 72. As shown in FIG. 4, the body 72 forms a segment of the rail 28 and provides a housing for the slide 74 while a depending portion 84 of the body 72 fixes the actuator 75 to the transfer slide assembly 70. The body depending portion 84 has a through counterbore formed throughout its width and defines a first larger diameter opening D-1 receiving the housing of the actuator 75 and a second smaller diameter D-2 opening receiving a threaded neck portion 172 of the actuator 75. A portion of the threaded neck portion 172 protrudes beyond the depending portion 84 such that a nut 174 threadably engages the exposed neck portion and when tightened draws the actuator 75 within the opening diameter D-1 to clamp it against the shoulder formed by the differing diameters. In addition, the free end of the body 72 is bifurcated at 178 so that the depending portion 80 of the slide 74 extends through the slot formed by the bifurcated end portions of the body 72 thus allowing the aperture in the slide depending portion 80 to be positioned adjacent the actuator 75 and in line with the rod 82.
Referring now to FIGS. 4 and 5, the body 72 of the transfer slide assembly 70 is shown attached to the rail 28 at its lowermost free end. A cutout 90 is formed in the rail 28 extending longitudinally from its free end along a segment of the length of rail 28. As shown in FIG. 5, the rail 28 is preferably formed from a hollow steel pipe and the cutout 90 therefore defines a lower C-shaped portion 94 having an inner curved surface 92. The body 72 has two correspondingly curved support surfaces 96 and 98 bearing against portions of the surface 92 to vertically position the body 72 on the rail 28. In addition, the body 72 has two flat surfaces 100 and 102 each of which extends in planes parallel to the axis L and each of which underlies two, laterally extending body arm portions 104 and 106. Each of the surfaces 100 and 102 also support the body 72 on flat, longitudinally extending upper surfaces 93 and 95 of the C-shaped portion 94 of the rail 28 formed by the cutout 90 and which flat surfaces also extend in planes parallel to the axis L. The screws 86 engaging within threaded openings in the body 72 and which pass through apertures formed in the bottom of the C-shaped portion 94 of the rail 28, secure the body 72 on the rail 28 such that it is vertically supported on both the flat surfaces 93, 95 and by portions of the inner curved surface 92. Thus, when the screws 86 are tightened, the body surfaces 100, 102, 96 and 98 are drawn into simultaneously engagement with the respectively confronting surfaces of the rail 28 thereby securing the body 72 against rotational and longitudinal movement relative to the rail 28.
As shown in FIG. 5, each laterally extending arm portion 104 and 106 of the body 72 also has an upper surface respectively labelled 108 and 110 extending longitudinally along the body parallel to the axis L. The upper surfaces 108 and 110 are contiguous with two upstanding body portions 112 and 114 defining two spaced apart tracks. The outer surface of each of the upwardly extending portions 112 and 114 forms an angle A equal to approximately 135 degrees with each of the corresponding one of upper surfaces 108 and 110. The body upper surfaces 108 and 110 being disposed at such an angle relative to the upwardly extending body portions 112 and 114, provide a surface upon which the trolley 14 may be guided. In addition, the tracks 112 and 114 as shown in FIGS. 7a-c served to space and guide rollers 116 of the trolley 14 along the body 72 thereby preventing or ceasing trolley side sway once the trolley engages with the body 72.
The body 72 has an internal cavity 118 extending longitudinally along the central axis L and is defined by two, parallel spaced apart surfaces 120 and 122 transversely connected by a bottom surface 124 oppositely facing a cavity opening 125 to define a generally U-shaped cavity within the body 72. The cavity 118 is sized and shaped to receive the elongate slide 74 within its generally U-shaped confines. As shown in FIGS. 6 and 6a, the slide 74 carries two laterally and outwardly extending portions or guides 126 and 128 formed on opposite side faces of the slide 74. Each guide 126, 128 has in transverse cross section a truncated peak configuration engaging correspondingly shaped recesses 130 and 132 formed respectively in each of the confronting surfaces 120 and 122 defining the cavity 118 of the body 72. As is shown in FIG. 6a, the slide 74 has a width B which dimension is slightly smaller in size than the cavity width C shown in FIG. 5 by an amount equal to approximately six one thousandths of an inch. Similarly, a slight clearance equal to approximately two hundredths of an inch exists between the juxtaposed surfaces of the corresponding guides 126, 128 and recesses 130, 132 thus permitting relative movement therebetween. While the guides 126, 128 and recesses 130, 132 cooperate with one another to constrain the slide 74 from moving upwardly out of the cavity 118, it should be undertood that the slide 74 is preferably mounted within the cavity 118 such that slide bottom surface 134 contacts with and bears on the body transverse surface 124 as the slide 74 reciprocates along the axis L of the body 72. In addition, the body 72 and the slide 74 are formed from generally hard and rigid synthetic material such as, for example DELRIN, having a low frictional characteristic thus permitting slidable engagement between the slide 74 and the body 72.
When the slide 74 is fully extended as shown in FIG. 3, the slide depending portion 80 is supported by piston rod 78 while a portion of the slide 74 adjacent guides 126, 128 remains within and is supported by the body 72. Conversely, when the slide 74 is in the retracted position as shown in FIG. 4, the guides 126, 128 are received within the recesses 130, 132 extending into a rear portion 73 formed integrally with the body 72. The cavity 118 formed within the body 72 is continuous with the rear portion 73 such that the portion of the slide 74 extending into the rear portion 73 is supported by the lower cavity surface 124 and is laterally confined by the side walls 120 and 122 which likewise are coextensive with the surface 124.
The slide 74 shown in FIGS. 6 and 6a has a pusher 136 located at the end of the slide 74 adjacent the guides 126, 128 and has a vertically extending face 138 for contacting with a trolley. The support provided by the rear portion 73 is important because when the slide 74 is moved into the retracted position shown in FIG. 4, the pusher 136 is received within a slot 91 formed in the rail 28 and extending longitudinally beyond the edge of the cutout 90 such that the pusher 136 protrudes above the surface of the rail 28 along longitudinal length D of the slot 91. Thus, it should be appreciated that the stroke of the pusher 136 begins at a point along the distance D from the edge of the cutout 90 in the rail 28 and continues its advance along the body 72 until the slide 74 is extended to its outermost position.
As previously discussed, the transfer slide assembly 70 of the present invention loads a trolley 14 into the elevator car 1 for carriage upwardly to the mail rail 12 by advancing it from a position adjacent the free end of the rail 28 into the elevator car 1. The elevator 54 comprises a pneumatic lift (not shown) connected to the elevator car 1 riding on an inclined track between upper and lowermost positions. As is shown in FIG. 7c, the elevator car 1 consists generally of a split rail 148 having a slot 142 defining two laterally extending portions 151 and 153 of the elevator car 1. When the elevator car 1 is moved by the pneumatic lift to the lowermost elevator position by a command by the master computer 8, the slot 142 and the slide 74 become coaligned with one another in a plane which includes the longitudinal axis L of the body 72. Each trolley 14 carries an upwardly extending protrusion or crown 144 fixed to a transversely extending portion 115 of the trolley 14. The upwardly extending crown 144 is T-shaped and has a web thickness smaller in dimension than that of the width of the slot 142. A laterally extending flange 146 is connected to the top end of the web and defines a flange width of substantially greater dimension than that of the width of the slot 142. The web of the crown 144 is capable of being received within the slot 142 and a guide or an apron 150 having an outwardly tapered extension of the slot 142 is positioned at the open end of the elevator car 1 to facilitate the moving of the web into the slot 142.
In FIGS. 7a-c, the general operation of a transfer slide assembly is shown cooperating with a trolley 14 having been once it is released from the lower gate of the stop 38 in the subsidiary loop 16. The trolley typically travels down the rail 28 under the force of gravity toward the transfer slide assembly 70 on the angularly oriented rollers 116 which ride on the upper curved surface of the rail 28 such that an under surface 117 of the transversely extending portion 115 of the trolley 14 is spaced from the uppermost curved surface of the rail 28 by a distance represented as E in FIG. 7a. The pusher 136 extends upwardly beyond the upper curved surface of the rail 28 at a height represented by the dimension F being of a significantly smaller magnitude than that of the dimension E. Thus, it should be appreciated that the under surface 117 of the transverse portion 115 of the trolley 14 passes over the pusher 136 with a clearance equal to the difference between the dimensions E and F when the trolley travels along the surface of the rail portion labelled D as represented in FIG. 4.
Referring now to FIG. 7b, the trolley 14 is shown having travelled off of the upper surface of the rail 28 and onto the longitudinally extending surfaces 108 and 110 of the body 72. Since the longitudinally extending surfaces 108 and 110 are oriented below the curved upper surface of the rail 28 upon which trolley 14 rides, the trolley 14 when it rolls off of the curved surface of the rail 28 drops downwardly onto the spaced apart longitudinally extending surfaces 108 and 110 and therefore experiences a height differential. The dimension G generally represents the drop experienced by the rollers 116 from the upper surface of the rail 28 downwardly to the body surfaces 108 and 110. Since the rollers 116 are inclined relative to the vertical plane V at an angle A' equal to approximately 45 degrees, the rollers 116 and surfaces 108 and 110 are disposed orthogonally with one another thus providing corresponding flush surfaces upon which the rollers 116 engage. Once the rollers 116 drop onto the surfaces 108 and 110, the trolley under surface 117 is no longer elevated above the pusher 136 as it was previously when the rollers 116 were supported on the upper surface of the rail 28. Rather, the pusher 136 now positioned behind the transverse portion 115 of the trolley 14 extends upwardly beyond the under surface 117 such that a portion of the pusher face 138 is engagable with the transversely extending portion 115 of the trolley 14. It should be understood that the drop dimension G must be greater in magnitude than the difference between dimensions E and F to insure that the pusher is engagable with the portion 115 of the trolley 14.
As is shown in FIG. 7c, the apron or guide 150 which extends outwardly from the elevator car 1 is positioned symmetrically about the longitudinal axis L of the body 72 when the elevator car 1 is in the lowermost position. The apron 150 and the laterally extending portions 151, 153 of the split rail 148 are contiguous with one another and form a support surface engagable with the lower surface of the flange 146 of the trolley 14. When the trolley 14 is supported on the body surfaces 108 and 110, and the trolley car 1 is oriented in its lowermost position, the lower surface of the flange 146 is spaced slightly above the supporting surface formed by the apron 150 and the laterally extending portions 151, 153 such that the flange 146 passes above the supporting surface without interfering with it. Thus, a trolley 14 travelling along the rail 28 drops downwardly onto the surfaces 108 and 110 of the body 72 and continues moving forwardly to initially position the web of the crown 144 within the slot 142 of the apron 150.
At this point, however, the crown 144 does not advance into the elevator car 1 beyond the apron 150 because a thin, flexible, C-shaped metal leaf spring 160 extends downwardly from transverse portions 162 of the elevator car 1 and slightly interferes with the path of the flange 146 into the elevator car 1. However, the spring being flexible is capable of being deflected upwardly by the flange 146 when the slide 74 pushes the trolley 14 into the elevator car 1. Once the flange 146 is received within the car 1, however, the spring 160 provides a sufficient downward biasing force to hold the flange 146 of the trolley 14 in place against the portions 151, 153 while it is being moved upwardly thus eliminating the need to use stops or other fastening devices while the trolley is upwardly moved. It should thus be appreciated that the trolley travelling along the rail 128 and onto the body 72, positions the crown 144 only within the apron 150 and not within the remaining portion of the elevator car 1. It is only when the trolley is advanced against the bias of the spring 160 by the pusher 136 that the crown 144 is completely received within the elevator car 1.
The actuator 75 is energized when a switch 164 is activated by the insertion of a trolley within the car 1. As is shown in FIG. 3, the switch 164 is mounted within the car 1 such that when the flange 146 deflects the spring upwardly, it also pushes upwardly the normally downwardly biased arm 250 of the switch 164. The switch 164 is connected to the master computer 8 and indicates to the computer 8 that the trolley 14 is in place within the car 1 and ready for carriage upwardly to the main rail 12. The actuator 75 is then energized by a command from the computer 8 which activates an electrically controlled valve and prompts the piston rod 78 to advance toward the elevator car 1. The pusher 136 thus engages the back face of the transversely extending portion 115 of the trolley 14 and thus forces the flange 146 between the spring 160 and the portions 151, 153 of the elevator car 1. The engaging surface of the leaf spring 160 is curved upwardly toward the transverse portion 162 of the car 1 such that the leading upper edge of the flange 146, which preferably is tapered for camming engagement, gradually engages the lower surface of the spring 160 to bias it upwardly as the trolley is advanced into the elevator car 1 by the pusher 136.
The slide 74 is substantially longer in length than the body surfaces 108, 110. This feature enables the pusher 136 to extend outwardly beyond the outer end of the body 72 in order to advance the trolley 14 off of the body surface 108, 110 and move it into the elevator car 1. A stop plate 166 is fixed to the lower end of the inclined elevator track and provides an abutment face against which the trolley 14 may be advanced thus assuring complete registry of the trolley 14 within the car 1. It should be appreciated that once the trolley 14 is advanced off of the body 72 by the pusher 136, it becomes suspended by the portions 151, 153 of the split rail 148 and therefore the slide 74 does not support the trolley weight once the trolley 14 is advanced into the elevator car 1.
Referring now to FIGS. 8 and 8a, an alternate embodiment of a slide 74' is shown. The slide 74' in FIG. 8 has been modified to incorporate a stainless steel wire torsion spring 180 housed within a portion of the slide 74'. In addition, the face 138' of the pusher 136' is oriented at an angle I equal to approximately 20 degrees relative to the vertically extending plane V transversely intersecting the slide. A bore 182 is formed in the slide 74' and extends transversely through the slide along with a slot 184 also formed in the slide 74' coextensively with the bore 182 and provides a passage between the bore 182 and the outer surface of the slide 74'. Along each side wall 188 and 190 of the slide 74' are formed shallow indentations 192 and 194 having depth equal to approximately the thickness of the wire forming the spring 180. The indentations 192 and 194 recess the spring 180' inwardly from the surfaces 188 and 190 so that the slide 74' reciprocates within the cavity 118 without the spring interfering with the cavity walls 120 and 122 of the body 72.
The spring 180 is comprised of a coil portion 200, arm portions 206 extending upwardly from each end of the coil portion and a bent loop portion 204 extending between the other ends of each of the arm portions. The arm portions 206 are capable of pivoting about a transversely extending axis J from an upper position shown in solid line in FIG. 8 to a lowermost position shown by the phantom line. To limit this movement to the illustrated range, the indentations 192 and 194 each have at least one abutment face 196 for limiting the downward displacement of the spring arms 206 as they are pivoted about the axis J. The bent loop portion 204 of the spring 180 is normally biased against the face 138' by the resilient force of the spring coil portion 200 utilizing a tab 202 received within the slot 184 to prevent the coil 200 from freely rotating within the bore 182 and thereby generating torque within the coil.
The arms 206 and the tab 202 are generally coaligned with one another when the spring is in its relaxed state. Thus, the spring 180 is inserted within the slide 74' by sliding the coil portion 200 and the arms 206 coaligned with the and tab 202 laterally into the bore 182 and the slot 184. Once the spring 180 is so positioned within the slide 74' the loop portion 204 is pulled forwardly up beyond the peak of the pusher 136' and thereafter is released to engage with the face 138. Since the loop portion 204 is somewhat resilient, the inner U of the loop 204 is capable of being flexed forward over the peak of the pusher 136' and then returning into engagement with the face 138'.
As shown in FIG. 9, the loop portion 204 of the spring 180' extends above the under surface 117 of the trolley 14 when the trolley travels along the rail 28. However, the transverse body portion 115 of the trolley 14 will push the loop portion 204 of the spring 180 downwardly against the bias of the coil portion 200 as the trolley 14 rolls down the rail 28 and over the spring 180. As is shown in FIG. 9a once the trolley body portion 115 moves past the spring 180, the spring is no longer depressed by the under surface 117 of the trolley 14 and returns under the bias of the coil 200 back into its generally upright position against the face 138'. Since the trolley 14 now rests on the body surfaces 108 and 110, it now may be positively engaged by the loop portion 204 of the spring 180 to move it into the elevator car 1 as discussed previously. It should be appreciated that the portion of the spring 180 extending above the pusher 136' in FIG. 8 is supported against bending by four parallel spaced apart segments of the loop 204 which abut the face 138' as a trolley is pushed by the loop portion 204 thereby offering increased strength to the spring where it is otherwise unsupported by the surface 138'.
Referring now to FIGS. 10-13, another embodiment of the transfer slide assembly is shown. The operation of the transfer slide assembly 70' in this embodiment is identical to the operation previously discussed with reference to FIGS. 1-7. However, certain structural modifications have been made to the slide 74" and the body 72' in this embodiment.
As is shown in FIGS. 10 and 11, the body 72' of the transfer slide assembly 70' is attached to the rail 28 at its lower free end. The cutout 90 in the rail 28 allows the body 72' to be supported by the surfaces 93 and 95 of the lower C-shaped portion 94 of the rail 28 as has been previously discussed. The cavity 118' formed along the axis L of the body 72' and the rear portion 73' is modified in that the parallel spaced apart surfaces 120' and 122' do not have recesses extending parallel to the axis but rather have outwardly protruding angled portions 130' and 132' extending longitudinally throughout the length of the body 72'. Also, the lower end of the slide 74" has in transverse cross section a dovetail configuration extending along its length and defined essentially by two tail portions 126' and 128' correspondingly sized and shaped to cooperate with two angled portions 130' and 132' such that the dovetail may be received within the cavity 118' when it is slid longitudinally between the bottom surface 124' and the angled portions 130' and 132'.
The confronting surfaces of each of the angled and tail portions 130', 132', and 126', 128' are provided with a slight clearance therebetween thus allowing these interengaged portions to slide relative to each other without substantial interference resulting from frictional engagement. However, the slide bottom surface 134' does contact with and bear on the body transverse surface 124' as the slide 74" reciprocates along the axis L of the body 72'. In addition, since both the body 72' and the slide 74" are preferably formed from a generally rigid synthetic material, the engagement between the surfaces 124' and 134' has a low friction characteristic thereby assisting the slidable engagement of the surfaces 124' and 134'. It should thus be appreciated from FIG. 10 that because the dovetail on the slide 74" is coextensively supported along the length of the body 72', the rear portion 73' can be shorter since a substantial portion of the dovetail is still supported within the body 72'.
The laterally extending arm portions 104' and 106' of the body 72' in this embodiment are each defined by the intersection of one of the upper surfaces 108' and 110' with one of the underlying surfaces 100' and 102'. Angle A" in FIG. 11 represents the angle of intersection between these surfaces and is equal to approximately 45 degrees which angle corresponds to the vertical inclination of the trolley rollers 116 thus allowing the rollers 116 to engage correspondingly oriented support surfaces. Since the upper surfaces 108' and 110' directly intersect with the underlying surfaces 100' and 102' rather than being spaced from one another by an intermediate portion, the surfaces 108' and 110' can be spaced a greater distance below the upper surface of the rail 28. This feature is important because it allows the upwardly extending portions 112' and 114' to have greater lengths thereby creating a more effective track by which each trolley is guided on the body 72'.
Referring now to FIGS. 12 and 13, the slide 74" shown has a modified pusher 136" with side surfaces 270 and 280 tapering from the face 138" rearwardly toward the slide free end. Each of the surfaces 270 and 280 is disposed symmetrically about the body axis L and extends upwardly above the surface of the rail 28 to present the rollers 116 of an approaching trolley with the body axis L. Thus, it should be appreciated that the pusher 136", while in its retracted position shown in FIG. 10, serves also as a guide to align an otherwise swinging trolley in a parallel relationship with the upwardly extending portions 112' and 114' of the body 72' so that the rollers 116 of the trolley 14 seat evenly upon the surfaces 108' and 110' when the trolley drops from the rail 28 downwardly onto the body 72'.
By the foregoing transfer slides embodying the present invention have been disclosed. However, it should be understood that numerous modifications and substitutions may be made without departing from the spirit of the invention. For example, in a slight modification of the illustrated embodiments the inclined face 136' shown in FIG. 8 may be provided in the embodiment of the slide in FIG. 5 showing a face 136 without any inclination relative to the vertical plane intersecting it. Accordingly, the invention has been described by way of illustration rather than limitation.
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A transfer slide is used in a conveyor system to advance a trolley from one position to another position and includes a body fixed to a free end of a rail and has a cavity formed substantially throughout its length. The body has longitudinally extending surfaces spaced apart from one another by an opening communicating with the cavity which surfaces provide a rolling surface upon which a trolley travels. A slide is received within the cavity of the body and reciprocates within the body in response to the reciprocating movements of an actuator means connected with the slide. The slide has a pusher device extending upwardly from the body and above the rail and which pusher device is engageable with the trolley to push it from the initial position to a final position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a magnetic recording medium and to a method for its preparation, and is particularly directed to an improved method for dispersing magnetic powder into a resinous binder to achieve improved residual magnetic flux density B r , improved squarness ratio R s , and a better packing density.
2. Description of the Prior Art
In the manufacture of magnetic recording media, magnetic powder is treated by means of various kinds of dispersants or surfactants in order to improve the dispersion of the magnetic powder in the magnetic coating material. Surfactants such as fatty acids, metallic salts of fatty acids (metallic soaps) or the like have been used. However, when these materials are used in a magnetic medium, their surface activity is not sufficient and therefore do not improve the dispersion greatly.
In other examples of the prior art, there has been proposed a method in which the magnetic powder is treated preliminarily by lecithin. In this proposal, however, ordinary lecithin as available on the market was used, this being a raw lecithin which includes a large quantity of impurities.
There has also been proposed a method by N. Kazino et al. in Japanese Laid Open Specification No. 309/1976, a method which uses a lecithin prepared in such a manner that ordinary lecithin is extracted with acetone to remove neutral fats or fatty acids. Even with the acetone extracted lecithin, however, the degree of dispersion of magnetic powder achieved is insufficient.
SUMMARY OF THE INVENTION
From our experimental work, we have ascertained that the typical raw lecithin on the market, and the acetone purified lecithin contain only about 10% or 20% pure lecithin at most, respectively. We have also determined that since these lecithins contain a large amount of impurities, they are difficult to apply over the entire surface of magnetic powder particles as a monomolecular layer. Furthermore, since the surface activity of such relatively impure materials is insufficient, the dispersion becomes insufficient. In other words, lecithin compositions containing such relatively small amounts of pure lecithin do not effectively cause adsorption of lecithin molecules to the surface of magnetic powder.
The present invention provides a magnetic recording medium including a non-magnetic base, a magnetic layer carried by the base and composed of magnetic powder particles dispersed in a resinous binder, the magnetic powder particles being covered on substantially their entire surfaces with a monomolecular layer composed substantially of lecithin. The improved lecithin composition which is selectively adsorbed on the surface of the particles contains at least 30% pure lecithin and is substantially devoid of fats, free fatty acids, cephalin and proteins.
The method of preparation basically consists of mixing the magnetic powder and an organic solvent with a purified lecithin composition having a purity of greater than 30% in an amount sufficient to cover substantially the entire surface of the magnetic powder particles with a monomolecular layer consisting essentially of lecithin, mixing the thus treated magnetic powder particles with a synthetic resin binder to form a magnetic paint, and applying the magnetic paint on a non-magnetic base to form a magnetic layer.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention will be readily apparent from the following description of certain preferred embodiments thereof, taken in conjunction with the accompanying drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure, and in which:
FIG. 1 is a graph showing the absorption spectrum of a choline-reinecke salt in acetone;
FIG. 2 is a graph showing the variation in absorbance with the concentration of high purity lecithin used in the present invention;
FIG. 3 is a graph showing the variation of absorbance with concentration of choline chloride in acetone solution;
FIG. 4 is a graph showing the amount of adsorption of lecithin on gamma ferric oxide as a function of the original concentration;
FIG. 5 is a graph showing the relationship between equilibrium concentration and ratio of equilibrium concentration to adsorption of lecithin on gamma ferric oxide;
FIG. 6 is a diagrammatic illustration of the lecithin molecule;
FIG. 7 is a graph plotting adsorption and desorption amounts of lecithin against equilibrium concentration;
FIG. 8 is a graph relating residual magnetic flux density with concentration of the dispersant;
FIG. 9 is a graph showing the relation between the purity of the additive and the amount which should be added to form a monomolecular layer of lecithin;
FIG. 10 is a graph showing the relationship between residual magnetic flux density and the purity of lecithin employed; and
FIG. 11 is a graph showing the relationship between squarness ratio and the purity of the lecithin employed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the present invention, we use a lecithin of high purity which is at least 30%, and is preferably at least 50%. It has been found that using 4 parts per 100 parts magnetic powder (PHP) of a lecithin having a purity of 30%, more than 2.5 PHP of a lecithin of 50% purity, and more than 1.5 PHP in the case of a lecithin having a purity of 91%, a monomolecular layer, composed substantially entirely of lecithin can be applied on substantially the entire surface of the magnetic powder particles.
A lecithin having an extremely high purity of more than 30%, and preferably of 50% or more can be obtained by purifying a commercial lecithin available on the market, or by suitably processing a raw lecithin such as egg lecithin or soybean lecithin, or by using a synthetic lecithin. A suitable method of producing a lecithin of high purity by purifying raw lecithin was disclosed by M. C. Pangborn in Journal of Biological Chemistry, vol. 188, page 471 (1951). The following examples set forth various methods of producing high purity lecithin.
EXAMPLE 1
Egg lecithin (raw lecithin) marketed by Ajinomoto Company, Inc., in an amount of 350 grams was extracted with 3 liters of acetone to remove neutral fat and fatty acid material and leave a lecithin precipitate containing phospholipids and proteins which was thereupon dried. The yield of this precipitate, acetone purified lecithin was 200 grams. Next, this precipitate was extracted with 95% ethanol. The lecithin precipitate was dissolved in the ethanol and separated from impurities such as proteins, cephalin and the like. The amount of the precipitate was 100 grams. Then, a water solution of 50% cadmium chloride was added dropwise to the ethanol solution of lecithin to produce a white colloidal precipitate consisting of a complex salt of lecithin and cadmium chloride. This precipitate was washed with acetone, separated by filtration, and vacuum dried at a temperature below 40° C. Next, this complex salt was passed through a separatory funnel where it was dissolved in 100 cc of chloroform. The above solution was then mixed with 100 to 150 cc of 30% ethanol, shaken and permitted to stand. The cadmium chloride was dissolved into the ethanol and the lecithin remained in the chloroform. The ethanol layer is lower in specific gravity than the chloroform layer, so that after standing, the mixture separated into an ethanol upper layer and a chloroform lower layer. The chloroform layer was then removed from the lower end of the separatory funnel and the chloroform solution was again treated with ethanol, the process being repeated three times. Completion of the extraction was determined by the absence of a white precipitate of silver chloride when adding silver nitrate to a portion of the ethanol solution. Next, the chloroform solution of lecithin was dried by evaporation in a rotary evaporator. A transparent yellow lecithin of high purity was obtained in an amount of 15 grams. The purity of lecithin obtained by this purification was ascertained to be 91% according to an analysis method to be described later.
To permit easy understanding of the following lecithin purification method, the flow chart will be helpful.
______________________________________raw lecithin (starting material) ↓acetone purified lecithin neutral fat and fatty ↓ acid being removedethanol extraction cephalin and protein ↓ fraction being removed.lecithin-cadmium chloridecomplex salt ↓decomposition of complexsalt ↓chloroform solution of lecithin ↓high purity lecithin______________________________________
The high purity lecithin was mixed with magnetic powder in an organic solvent consisting of methyl ethyl ketone (MEK) or cyclohexanone, the mixing and dispersion thereof being carried out for 7 hours in a ball mill to produce a uniform suspension. The composition of this suspension (hereinafter referred to as composition "A") was as follows:
______________________________________gamma Fe.sub.2 O.sub.3 (21.1 sq. m./g/) 300 parts by weighthigh purity lecithin 4.5 parts by weight (1.5 PHP)MEK 300 parts by weight______________________________________
The above composition "A" was mixed with 50 parts by weight of "VYHH" resin sold by Union Carbide, which is a vinyl chloride-vinyl acetate copolymer and serves as a binding agent. It was also combined with a solution of 300 parts MEK by weight and milled in a ball mill for 20 hours to obtain a magnetic paint. This magnetic paint was applied to a non-magnetic base composed of polyethylene terephthalate film (Mylar), dried, subjected to calendering, and slitted to produce a magnetic recording tape.
EXAMPLE 2
A high purity lecithin was obtained by the process set forth in Example 1. Composition "A" was formed similarly as in Example 1, except that the amount of high purity lecithin was 6 PHP. An amount of 300 parts by weight of MEK was applied to the composition and mixed together for 1 hour in a ball mill, and thereafter was allowed to stand for 1 hour. Then, a supernatant solution of 300 parts by weight was removed to eliminate excess lecithin, i.e., the non-adsorbed lecithin. This composition was subjected to the treatments mentioned in Example 1 to produce a magnetic coating, and the coating was applied to a non-magnetic base to obtain a magnetic record medium.
The purity of the high purity lecithin described above was measured by colorimetric method described by M. H. Hack in the Journal of Biological Chemistry, vol. 169, page 137, 1947). In this method, a choline component available only in lecithin was separated and the thus separated amount is colorometrically determined to determine the amount of lecithin.
Structurally, lecithin has the structural formula (1) as set forth below which includes a choline chain having formula (2): ##STR1## where ROCO and R'OCO are fatty acid residues from palmitic acid, stearic acid, oleic acid and the like.
The extraction of the choline component and its colorimetric determination were performed as follows. First, the lecithin was weighed and put in a 20 cc flask with a stopper into which a one normal (1 N) potassium hydroxide aqueous solution was applied in an amount of 5 cc in perform a hydrolysis reaction for 17 hours at 37° C. Thereafter, 4.5 N HCl was applied to dissolve the choline contained in the hydrolysis product and the dissolved choline was filtered to remove precipitates of impurities such as proteins which are insoluble in HCl aq. solution. The filter cake was treated with additional amounts of 1.5 N HCl for dissolution in an extraction so that the choline compound compound would not remain in the filter cake. A solution of the completely extracted choline compound was treated with ammonium reineckate NH 4 [Cr(NH 3 ) 2 (SCN) 4 ]. There was produced a precipitate of choline-reineckate which was removed and cleansed with ethanol. Before the quantitative analysis, the choline-reineckate precipitation was carried out at a temperature of 20° to 25° C. Since the precipitate has little solubility in ethanol, the ethanol was used under cool conditions to minimize the amount of dissolution which occurred. The thus obtained choline-reineckate was dissolved in 5 cc of acetone. This solution hereinafter referred to as solution "B" was pink in color and its absorbance Abs was determined by colorimetry. FIG. 1 shows the absorption characteristic of this reference solution. As shown in FIG. 1, the absorption spectrum has a peak at a wavelength of about 526 nm so that the absorbance of the acetone solution "B" was measured relative to a light having a wavelength of 526 nm.
FIG. 2 shows the results obtained from measuring the absorbence of the high purity lecithin according to Example 1 by means of 1 cm cell. The absorbance Abs in this curve was measured according to the equation:
Abs=-log T
where T is the light transmittance of the object to be measured.
The measured absorbance was compared with the reference absorbance spectrum to obtain the purity of the lecithin. The reference absorbance was obtained by reacting a commercial choline specimen (choline chloride) to produce a precipitate of choline chloride-reineckate by the same method used in the production solution "B" and the thus produced precipitate was dissolved in 5 cc of acetone and its absorbance was measured by the same method. The result is shown in FIG. 3. The abscissa represents the amount of choline chloride. The amount of choline chloride can be converted into the amount of lecithin by multiplying a suitable conversion factor. Since the molecular weight of choline chloride is 137.5 and that of lecithin is 793 and assuming that the fatty acid groups are both stearic acid groups, a conversion factor of 5.77 is obtained. If the relation between the amount of choline chloride and absorbance is converted to the relation between the amount of lecithin and absorbance, the weight of lecithin per unit of absorbance was 42.2 mg. The value of weight of lecithin per unit of absorbance according to Example 1 was 46.5 mg so that the purity of this lecithin corresponds to 91% of the choline specimen. Since the purity of the choline specimen can be regarded as about 100%, the purity of the high purity lecithin can be taken to be about 91%. In this connection, the purity of a raw egg lecithin on the market measured by the same method was 4.3%, and the purity of the lecithin purified by acetone was 7.1%. The purity of a raw soybean lecithin on the market was found to be 9.2% and that of its acetone purified product was 20%, which were both considerably lower than required. For this reason, the lecithin content of the compositions of the present invention have purities of at least 30%, and preferably 50% or more.
We will now describe the dispersion effect achieved in the present invention. First, we shall consider the adsorptive condition of lecithin on magnetic powder which is the basis of evaluating the dispersion effect. Magnetic powder consisting of gamma Fe 2 O 3 in an amount of 50 grams and high purity lecithin of a predetermined amount were mixed together with MEK in an amount of 100 cc in a ball mill for 7 hours to produce a uniform suspension. After the lecithin had been adsorbed on the magnetic powder, the suspension was separated into solid and liquid phases using a centrifugal separator, and the supernatant solution was removed in a predetermined amount. The solvent of this removed portion was vaporized and the amount of lecithin was determined by the above-described colorimetric method. Since this amount of lecithin gives the equilibrium concentration C of adsorption, the amount of adsorption, Γ, to magnetic powder can be obtained from the original concentration, C o , the volume of lecithin solution, V, and the powder weight, w, by means of the following equation:
Γ=V(C.sub.o -C)/w
The measured results of the amount of adsorption at various concentrations of high purity lecithin (91% purity) are given in the following table.
TABLE 1______________________________________Lec- C.sub.o (Orig. C(Equi.ithin concentration) concentration) Γ(Adsorption)(PHP) (g/100 cc) (g/100 cc) (g/g Γ Fe.sub.2 O.sub.3) C/Γ______________________________________0.5 0.25 0 0.0050 01 0.50 0 0.0100 01 0.50 0 0.0100 02 1.00 0 0.0200 02 1.00 0 0.0200 03 1.50 0.0420 0.0292 1.443 1.51 0.0512 0.0292 1.754 2.00 0.285 0.343 8.315 2.50 0.620 0.0376 16.56 3.00 1.020 0.0396 25.87 3.50 1.472 0.0406 36.3______________________________________
From the foregoing table, with a high purity of lecithin of 91% purity, when the original concentration C o is in the range of 0.25 to 1.0 g/100 cc, or the amount of lecithin added to the magnetic powder is 2 PHP or less, the equilibrium concentration C is zero, i.e., the added lecithin is all adsorbed to the magnetic powder and no lecithin remains in the solvent. Therefore, it is concluded that the lecithin molecules have strong surface activity and are irreversibly adsorbed.
FIG. 4 shows the relation between the amount of adsorption and the original concentration, C o . From this figure, it will be seen that there is a linear relationship and an irreversible adsorption is achieved in the range where the original concentration C o is low. It also should be noted that if the concentration is increased, a saturated adsorption occurs.
The monomolecular adsorption step can be expressed by the Langmuir equation as follows:
Γ=ΓsKC/(1+KC)
or
C/Γ=1/Γs K+C/Γs
where Γs is the amount of saturated adsorption and K is a constant determined by the system. (4)
From the above equation it will be seen that during the process of monomolecular adsorption to the solid surface, the relationship concentration to adsorption becomes linear and the reciprocal of the gradient is the amount of saturated adsorption. Applying the equations to adsorption data of the above-described high purity lecithin-gamma ferric oxide system of this invention, the adsorptive characteristics of the high purity lecithin were determined. FIG. 5 shows the relationship and the applicability of the Langmuir formula. As apparent from FIG. 5, a satisfactory linearity is obtained and so a monomolecular adsorption is produced in the concentration range shown in FIG. 5.
On the other hand, it is well known that the lecithin molecule can form an oriented monomolecular layer of BLM layer (black lipid membrane or bilayer lipid member which is composed of two oriented monomolecular layers). It is also known that the lecithin molecule is composed of a hydrophilic group having a dimension of 5 Angstroms and a lipophilic group of 25 Angstroms, as shown in FIG. 6. In the drawing of FIG. 6, one of the lipophilic hydrocarbon chains is omitted because it is not visible from that position. Accordingly, on the surface of a solid such as gamma ferric oxide, the hydrophilic group is oriented toward the solid surface and the lipophilic group is oriented toward the organic solvent. When the adsorption is carried out in such a manner, the area of solid surface covered by one molecule, or occupied cross sectional area S o is in the range from 45 to 110 square Angstroms. In other words, the monomolecular layer of a lecithin molecule is quite compressible and can have a relatively wide range of adsorption density from a sparse condition to a dense condition. The adsorption condition and the condition of monomolecular layers formed on the surfaces of gamma ferric oxide particles were investigated according to the amount of saturated monomolecular adsorption obtained from the measured results of FIG. 5. As will be apparent from FIG. 5, the gradient or slope of the line is 25.0 and the saturated adsorption is 40 mg per gram of gamma ferric oxide. The molecular weight of lecithin is 793 and the specific surface area S of gamma ferric oxide powder used was 21.1 m 2 /g. Therefore, the occupied cross sectional area S o of the lecithin-gamma ferric oxide system is calculated as follows: ##EQU1## where N A is Avogadro's number.
The value of the occupied cross sectional area is quite small within the above-mentioned wide range of occupied cross sectional area so that a relatively dense monomolecular layer is formed on the surface of the magnetic particles. According to Table 1, in order to adsorb lecithin onto the surface of gamma ferric oxide particles with the amount of adsorption so as to obtain the ideal effect of surface activity, the amount of lecithin should be 5 PHP or more and the original concentration C o should be 2.5 g/100 cc or more, corresponding to a value close to the amount of saturated adsorption.
The amount of adsorption of acetone purified lecithin (5 PHP) to gamma ferric oxide was measured with the result that equilibrium concentration after the adsorbing process was zero and no lecithin was detected in the solution. This means that all the lecithin was adsorbed to the magnetic powder with the result that its amount of adsorption was calculated to be 3.55 mg/g Fe 2 O 3 which is less than 10% of the value shown in Table 1. The occupied cross sectional area S o of adsorbed molecules to magnetic powder may be considered the same as that of pure lecithin so that the actual surface coverage of magnetic powder by lecithin molecules is also less than 10%. In the case of using a raw egg lecithin on the market which has previously been used as a dispersant, the surface coverage of pure lecithin was only about 5% of that obtained when the high purity (91%) lecithin of the present invention was used. As a result, the excellent surface activity effect inherent in lecithin was not observed.
As noted previously, it is advisable to limit the amount of lecithin in the formulation so that it does not exceed the amount of saturated adsorption. Otherwise the magnetic characteristic can be adversely affected by excess lecithin which changes the particle surface hydrophilic to cause flocculation.
The existence of irreversible adsorption was ascertained in the following manner. First, 100 cc of MEK solution containing 3 g high purity (91%) of lecithin which substantially corresponds to the amount of its saturated adsorption in FIG. 4 was mixed with 50 g magnetic powder (Fe 2 O 3 ) in a ball mill for 7 hours and the actual lecithin concentration of this solution was colorimetrically determined by the aforementioned method. Next, the solution was diluted by MEK and put in a slowly rotating ball for a 2 hour mixing. After the equilibrium condition was reached, the concentration of the supernatant solution was measured. By repeating the above process until the concentration was about 1/100 of the original concentration when the lecithin concentration at the solution side was regarded substantially as zero, the desorption behavior of the lecithin was measured. The solution to be diluted was partially removed in advance by almost the same amount as that supplied in diluent in each diluting operation so that during each slow agitation operation, the ratio to solution to solid was kept substantially constant, and the mixing condition was not affected by dilution. The measured results of desorption of lecithin in the lecithin-gamma ferric oxide system are shown in the following table.
TABLE 2__________________________________________________________________________ Equi. Lecithin concent- Removed Added Lecithin Lecithin in Total Adsorp-Sample ration Solvent Solvent Solvent in V.sub.o in V.sub.1 Solvent tionNo. C(g/100cc) V.sub.1 (cc) V.sub.2 (cc) V.sub.o (cc) (g) (g) (g).sub.R Γ(×10.sup.-3)__________________________________________________________________________101 1.020 0 0 100 1.020 0 1.020 39.6102 0.484 5 100 195 0.939 0.051 0.990 40.2103 0.285 70 100 225 0.641 0.339 1.031 39.4104 0.144 115 100 210 0.302 0.328 1.020 39.6105 0.0695 100 100 210 0.146 0.144 1.008 39.8106 0.0425 100 100 210 0.0893 0.0695 1.021 39.5107 0.0230 100 100 210 0.0483 0.0425 1.022 39.6108 0.0112 100 170 270 0.0302 0.0230 1.027 39.5__________________________________________________________________________ ##STR2##
In the above table, the equilibrium concentration C corresponds to that of a mixture having an amount of solvent V 0 , and the solvent amount V 0 corresponds to an amount of mixture which is added to an amount of solvent V 2 after solvent V 1 is removed from the mixture prior to dilution. The amount of lecithin R in the total solvent indicates the sum of the lecithin amounts in the removed solvent and the lecithin amount in the added solvent.
FIG. 7 illustrates the above results, indicating both the adsorption and desorption steps. As apparently shown by FIG. 7, the amount of adsorption at the desorption step was maintained at substantially 100% of the level of saturated adsorption, or about 39.6 mg/g gamma ferric oxide for all these cleaning operations. Therefore, even with the removal of excess lecithin contained in the solvent, the surface coverage of the magnetic powder is substantially 100%.
The following table, Table 3, shows the measured results obtained with regard to magnetic recording characteristics of various samples. Samples--Nos. 1 to 8 were prepared by adding the amount of high purity lecithin indicated into the solution "A" with no calendering process being applied. Samples 9 to 12 used acetone purified lecithin, and Samples Nos. 13 to 15 used raw egg lecithin. Sample No. 16 had no lecithin and Sample No. 5' is the lecithin of Sample 5 which had been applied with a calendering process.
TABLE 3______________________________________ In-Sam- Leci- creaseple thin Bm Br of Br Rs Hc P ρNo. (PHP) (gauss) (gauss) (%) (%) (Oe) (%) (%)______________________________________1 0.5 1480 1210 -- 81.0 320 38.0 38.82 1.0 1650 1370 -- 83.0 315 37.0 38.93 1.5 1650 1370 -- 83.0 315 33.0 40.94 2.0 1600 1370 2.2 83.0 310 32.4 40.75 2.5 1700 1420 -- 83.5 310 28.5 42.56 3.0 1830 1540 12.4 84.0 310 27.0 42.97 4.0 1780 1480 8.8 83.3 310 25.8 42.68 5.0 1910 1600 18.5 84.0 310 22.9 43.19 2.0 1600 1280 -4.5 80.0 320 36.8 38.110 3.0 1700 1390 1.5 82.1 310 32.7 39.511 4.0 1640 1360 0 82.9 315 30.5 39.912 5.0 1630 1360 0.7 83.8 310 28.0 40.313 2.0 1600 1340 0 83.0 310 33.4 40.114 3.0 1650 1370 0 83.0 310 27.7 42.415 5.0 1620 1350 0 83.5 310 26.2 41.316 0 1420 1100 -- 78.0 320 45.0 34.95' 5.0 1940 1640 -- 84.4 305 19.6 45.0______________________________________
The packing density ρ and the porosity P were obtained from the following equations:
ρ(%)=[(Wc/Sm) (φ/ρp)/Va]×100
P(%)={1-Wc/Sm{[φ/ρp]+(1-φ)/ρB}/Va}×100
where Va=Sm·t
Sm=area
t=thickness of magnetic coating film
Wc=weight of coating film on area Sm
φ=powder weight per unit coating weight
ρp=density of magnetic powder=4.66
ρB=density of binder and lecithin system (binder density=1.35, lecithin density=1.10)
As will be apparent from Table 3, the magnetic recording medium using high purity lecithin has an improved maximum flux density B m , residual magnetic flux density B r , squareness ratio R s and packing density ρ. In Table 3 there is shown an increased rate of B r as compared with the use of raw egg lecithin. The porosity P becomes large in the case of raw lecithin. Thus is believed to be resulted from the bubbling effect of cephalin-protein fractions as impurities. In this connection, the measured results of magnetic characteristics obtained are shown in Table 4 with the added amounts of cephalin and protein fractions being changed, and with no lecithin being present.
TABLE 4______________________________________Amount ofCephalin-Protein P R.sub.s H.sub.c B.sub.m B.sub.r(PHP) (%) (%) (Oe) (gauss) (gauss)______________________________________5 29.3 79.3 310 1690 13403 35.4 78.7 310 1550 12202 35.9 78.5 310 1550 12201 40.9 76.9 310 1480 1140______________________________________
It should be noted from Table 4 that the porosities are large while the values of squareness ratio, maximum magnetic flux density, and residual magnetic flux density are low compared with those in the case of high purity lecithin.
FIG. 8 shows the relation between concentration of dispersant and the residual magnetic flux density wherein curve 1 was obtained with a high purity (91%) lecithin according to this invention, and curves 2 to 4 were of acetone purified lecithin, unpurified lecithin, and the cephalin-protein fraction, respectively.
Table 5 shows the measured results obtained from magnetic recording media of samples 17 to 20 prepared after the excess lecithin had been removed in a solvent according to Example 2.
TABLE 5__________________________________________________________________________ IncreaseSample Lecithin Dilution B.sub.m B.sub.r of B.sub.r R.sub.s H.sub.c P ρNo. (PHP) Condition (gauss) (gauss) (%) (%) (O.sub.e) (%) (%)__________________________________________________________________________17 5.0 1 1716 1367 18.4 79.3 303 27.7 40.518 5.0 2 1652 1299 12.5 78.6 305 26.5 41.119 5.0 4 1771 1418 22.8 80.1 307 28.4 40.120 5.0 16 1703 1364 18.1 80.1 307 27.6 40.521 0 -- 1287 881 -23.7 68.4 325 48.6 32.622 5.0 1 1591 1155 0 72.6 290 29.7 39.3__________________________________________________________________________
The dilution condition indicates the dilution multiplying factor, the No. 1 indicating that no dilution was carried out. Sample No. 21 illustrates a case in which no lecithin was added, and Sample No. 22 is the case where raw lecithin was used.
From Table 5 it will be seen that even in magnetic recording media prepared by removing excess lecithin in the solvent, the variation of characteristics does not appear and every sample shows an increase of B r .
It was further ascertained that when excess lecithin in the solvent is removed, the wear resistance is improved as compared to the case where the lecithin is not removed. This was determined by moving a magnetic medium for a given time under wear conditions, and measuring the weight before and after movement to determine the amount of fallen powder. This measurement was carried out with respect to a magnetic tape prepared in the manner of Example 1 with high purity lecithin being added in an amount of 1.1 PHP and with a magnetic tape prepared as in Example 1 without the excess lecithin removing process and the amount of high purity lecithin being 4.5 PHP. As apparent from the results of Table 1, when the added amount is 1.1 PHP, the entire amount of lecithin is adsorbed onto the surface of the magnetic powder while when the added amount is 4.5 PHP, the excess lecithin remains in the solvent and excess lecithin remains in the magnetic tape in a binder. In measuring the relative amounts of fallen powder with respect to the two tapes, if the amount of fallen powder was taken as 1 for the lecithin of 1.1 PHP, then the relative amount for the lecithin of concentration 4.5 PHP is 2.
The gamma Fe 2 O 3 used in the above examples was an acicular powder having a long axis of from 0.7 to 0.8 microns, and an axis ratio of 8 to 10. It had a saturation magnetization of 72 emu/g and a specific surface area of 21.1 square meters per gram. However, various kinds of magnetic powder can be used such as Fe 3 O 4 , gamma Fe 2 O 3 or Fe 3 O 4 containing cobalt or other elements, iron oxides having intermediate oxidized states between gamma Fe 2 O 3 and Fe 3 O 4 , iron oxide containing an element such as cobalt and having an oxidized state between gamma Fe 2 O 3 and Fe 3 O 4 , or ferromagnetic powder such as CrO 2 (ferromagnetic chromium dioxide) or metals or alloys such as iron, iron-cobalt, iron-cobalt-nickel, or the like. In addition, mixtures of these various materials can be used and these examples are not meant to be limiting.
As the binder agent, there may be used various kinds of well known thermoplastic and thermosetting resins such as vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinylidene chloride copolymers, cellulose derivatives such as nitrocellulose, butadiene-acrylonitrile copolymers, polyester resins, epoxy resins, polyurethane resins, or mixtures thereof. If necessary, the binder may include a curing agent such as a polyisocyanate compound.
The magnetic layer may also include other conventional additives such as lubricants such as silicone oil, graphite, molybdenum disulfide, fatty acid esters, hydrocarbons, or the like. In addition, antistatic agents such as carbon black, quartenary ammonium salts, or the like can also be added. The composition may also include abrasive particles such as alumina or Cr 2 O 3 or the like.
As the solvent for the composition "A" for dilution or for coating purposes, we can use one or more solvents such as MEK, cyclohexanone, toluene, tetrahydrofuran, isopropyl alcohol, and butyl acetate. The only requirement is the solvent a capability of dissolving lecithin.
In the examples, the purity of the high purity lecithin was 91%. However, it is also possible to use a lecithin having a purity of 30% or more and to add sufficient amounts so as to substantially cover the whole surface of the magnetic powder particles with a monomolecular layer which is substantially entirely lecithin because of the selective adsorption. In this connection, FIG. 9 shows the relationship between the degree of purity and the amount to be added, in which the cross hatched area indicates the range in which the monomolecular layer can be effectively formed. From FIG. 9, it will be seen that the monomolecular layer can be formed by using 1.5 PHP where the purity is 90% or more, about 2.5 PHP for a purity of 50%, and 4 PHP or more where the purity is about 30%.
The minimum concentration of high purity lecithin should be at least 30% and preferably 50% or more because of the relationship between the purity of lecithin and its Br and Rs, respectively as shown in FIGS. 10 and 11.
As described in the foregoing, the monomolecular layer of lecithin can be surely formed on the surface of the magnetic powder, and consequently the magnetic and mechanical characteristics of the resulting record member can be improved.
It will be evident that a number of changes and variations can be effected without departing from the scope of the novel concepts of the present invention.
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A magnetic recording medium is produced using a highly purified lecithin which is selectively adsorbed upon magnetic powder particles so as to coat substantially the entire surface of such particles with a monomolecular layer, thereby providing a magnetic record medium of improved magnetic properties.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to integrated circuit devices, and, more particularly, to baluns and transformers manufactured on integrated circuit chips.
[0003] 2. Description of Related Art
[0004] Increasingly, due to reliability, performance and cost considerations, devices that previously resided on a printed circuit board (PCB) are being integrated into an integrated circuit (IC) chip. Transformers, inductors, and baluns are examples of devices that have migrated to the IC chip.
[0005] Due to the relatively noisy environment on an IC chip, many signals on a chip are typically differential or double-ended signals. Differential signals offer good common-mode rejection of noise; noise typically affects both halves of the differential signal in the same manner, and since information is contained in the difference of both signal halves, the difference does not change appreciably despite the noise that has been added to both halves.
[0006] A balun is an example of a device that accepts a single-ended signal and transforms it into a differential signal and vice versa. The term balun suggests its function: conversion of balanced (differential) signals to unbalanced (single-ended) signals. Signals on PCBs are typically single-ended signals. Since IC chips use differential signals, baluns have been placed on PCBs to transform a single-ended signal into a differential signal. Baluns have also been placed on IC chips. However, present designs suffer from asymmetrical parasitic characteristics (e.g., asymmetric parasitic capacitances and resistances) and poor magnetic coupling. The asymmetrical parasitic characteristics cause a differential signal to be asymmetrical. Symmetry in a differential signal is very important to the proper functioning of many differential circuits. Furthermore, poor magnetic coupling results in inefficient energy transfer.
[0007] A transformer is another example of a device that has on-chip uses. For example, a transformer can be used to match impedances between amplifier stages while providing DC isolation between the stages. A transformer for differential signals also needs to offer good magnetic coupling as well as symmetrical parasitic characteristics. Present designs do not offer relatively good parasitic characteristics and good magnetic coupling.
[0008] Thus, there is a need for baluns and transformers that provide improved symmetry and magnetic coupling.
SUMMARY OF THE INVENTION
[0009] A method for producing an on-chip signal transforming device is described. The method includes providing a substrate and laying a first conductive layer above the substrate, wherein the first conductive layer has a plurality of interleaved inductors. The method then includes laying a second conductive layer above the substrate, wherein the second conductive layer has at least one inductor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is illustrated by way of example, and not limitation, in the figures of the accompanying drawings in which like references denote similar elements, and in which:
[0011] [0011]FIG. 1 a illustrates an electrical circuit representation of a balun;
[0012] [0012]FIG. 1 b illustrates a balun according to one embodiment of the present invention;
[0013] [0013]FIG. 2 illustrates a balun according to yet another embodiment of the present invention;
[0014] [0014]FIG. 3 a illustrates a balanced transformer according to one embodiment of the present invention;
[0015] [0015]FIG. 3 b illustrates an electrical circuit representation of transformer 300 ;
[0016] [0016]FIG. 3 c illustrates two amplifiers coupled by a balanced line transformer;
[0017] [0017]FIG. 4 a illustrates another balun according to one embodiment of the present invention, which has the capability to transform a differential signal to a single ended signal and vice-versa; and
[0018] [0018]FIGS. 4 b ( 1 - 3 ), and 4 c illustrate three layers used to make the inductors of the balun illustrated in FIG. 4 a.
DETAILED DESCRIPTION
[0019] Methods and apparatus for integrated transformers and baluns are described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, one skilled in the art will appreciate that the present invention may be practiced in a variety of circuits, especially radio frequency circuits, without these specific details. In other instances, well-known operations, steps, functions and devices are not shown in order to avoid obscuring the invention. Repeated usage of the phrases “in one embodiment,” “an alternative embodiment,” or an “alternate embodiment” does not necessarily refer to the same embodiment, although it may.
[0020] [0020]FIG. 1 a illustrates an electrical circuit representation of a balun. Balun 100 includes inductors 114 and inductors 108 and 110 . Inductors 108 and 110 are dc (direct current) decoupled from and magnetically coupled with inductor 114 permitting the transfer of energy. Balun 100 can convert the signal of unbalanced transmission line 102 into to a signal of balanced transmission lines 104 and 106 . Balun 100 can also convert a signal of balanced transmission lines 104 and 106 to a signal of unbalanced transmission line 102 . One advantage of the balanced portion is that external noise affects the lines of the balanced transmission equally without appreciably affecting the potential difference in lines 104 and 106 . While the electric circuit representation for a balun has been known for a long time, the designs for integrated baluns and transformers of the present invention have heretofore been unkown.
[0021] [0021]FIG. 1 b illustrates a balun according to one embodiment of the present invention. Balun 100 includes two interleaved inductors 108 and 110 in metal layer 108 ′ and vertically displaced spiral inductor 114 in metal layer 114 ′, all of them above substrate 116 . Making inductors 108 and 110 interleaved causes each of the inductors to have substantially equivalent parasitic characteristics; in other words they are symmetrical. Furthermore, having the interleaved inductors stacked above inductor 114 provides for relatively better magnetic coupling in comparison to a lateral coupling arrangement in which interleaved inductors of a primary winding are placed adjacent to and in the same layer as the inductor of a secondary winding.
[0022] While in the above description, balun 100 has interleaved inductors 108 and 110 above spiral inductor 114 , in an alternative embodiment spiral inductor 114 is above interleaved inductors 108 and 110 .
[0023] [0023]FIG. 2 illustrates a balun according to yet another embodiment of the present invention. Balun 200 includes two interleaved inductors 208 and 210 in metal layer 208 ′ and vertically displaced spiral inductor 214 in metal layers 214 ′ and 214 ″, all of them above substrate 216 . A first portion of inductor 214 is in layer 214 ′ and a second portion of inductor 214 is in layer 214 ″. Having an inductor which has twice the number of windings of inductor 114 split among two layers results in an inductor with a larger inductance, which can be desirable in some instances because it results in larger magnetic coupling.
[0024] [0024]FIG. 3 a illustrates a transformer according to one embodiment of the present invention. Transformer 300 includes stacked interleaved inductors 308 and 314 in metal layers 308 ′ and 314 ′ respectively. Interleaved inductor 308 includes spiral inductors 308 a and 308 b . Interleaved inductor 314 includes spiral inductors 314 a and 314 b . The stacked interleaved structure provides good magnetic coupling between inductors 308 and 314 and symmetric parasitic characteristics between 308 a and 308 b , as well as between 314 a and 314 b . FIG. 3 b illustrates an electrical circuit representation of transformer 300 . A transformer such as transformer 300 is desirable because it can be used, for example, to match impedances between amplifier stages while providing DC (direct current) isolation between the stages. FIG. 3 c illustrates two amplifiers coupled by a balanced line transformer. Because of the DC isolation between amplifier 320 and amplifier 324 , amplifer 320 's output can be set to a bias voltage V A and amplifier 324 's input can be set to a different bias voltage V B .
[0025] [0025]FIG. 4 a illustrates another balun according to one embodiment of the present invention, which has the capability to transform a differential signal to a single ended signal and vice-versa. Transformer 400 includes inductors 408 , 410 and 414 . As shown in FIG. 4 b 1 , the inductors 408 and 410 are interleaved to provide good magnetic coupling between them. According to one embodiment, they are disposed in the same layer except at areas 420 a - 1 , and 420 a - 2 were one inductor crosses over the other. In one embodiment illustrated in FIG. 4 b 2 , inductor 408 is entirely disposed on metal layer 408 ′, with inductor 410 crossing inductor 408 using vias 422 that electrically connect to another metal layer 410 ′ above or below the metal layer 408 .′ In the embodiment shown in FIG. 4 b 2 , inductor 408 makes two right angle turns at the cross over area 420 a - 1 , and although not shown in FIG. 4 b 2 , inductor 410 also makes two right angle turns at the cross over area 420 a - 2 . In the embodiment shown in FIG. 4 b 3 , inductor 410 crosses over inductor 408 at an angle, such as, for example, 45 degrees or some other angle. Further, as shown in FIG. 4 c inductor 414 is stacked on a different metal layer 414 ′, disposed adjacent to one of layers 408 ′ and 410 ′, and allows inductor 414 to couple to each of inductors 408 and 410 .
[0026] In a modified embodiment, inductors 408 and 410 can be disposed in separate metal layers 408 ′ and 410 ′, respectively. In the embodiment, since the inductors are on separate layers, a cross over is not required, although turns within a layer can be made within a layer to equalize coupling between inductors 408 and 410 .
[0027] Thus, methods and apparatus for integrated baluns and transformers have been described. Although the present invention has been described with reference to specific exemplary embodiments, it will be evident to one of ordinary skill in the art that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention as set forth in the claims. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
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A method for producing an on-chip signal transforming device. The method includes providing a substrate, and laying a first conductive layer above the substrate, wherein the first conductive layer has a plurality of interleaved inductors. The method then includes laying a second conductive layer above the substrate, wherein the second conductive layer has at least one inductor.
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This application is a continuation of Ser. No. 515,646, filed July 20, 1983, now abandoned.
DESCRIPTION
The present invention relates to new amino derivatives of benzylidene-pyrrolo[2,1-b]quinazolines and benzylidene-pyrido[2,1-b]quinazolines, to a process for their preparation and to pharmaceutical compositions containing them.
The invention provides compounds having the following general formula (I) ##STR1## wherein m represents zero or 1;
n represents 1 or 2;
R 1 represents:
(a) hydrogen; C 3 -C 4 alkenyl; or C 1 -C 6 alkyl, unsubstituted or substituted by one or more substituents chosen from halogen, hydroxy and phenyl; or
(b) formyl; or C 2 -C 8 alkanoyl, unsubstituted or substituted by one or more substituents chosen from halogen, C 1 -C 2 alkoxy and phenyl;
X completes a single bond or it represents:
(a') a branched or straight C 1 -C 12 alkylene or C 2 -C 12 alkenylene chain unsubstituted or substituted by one or more substituents chosen from halogen and phenyl;
(b') phenylene, unsubstituted or substituted by 1 to 4 halogen atoms;
(c') cyclohexylene or cyclohexenylene;
R 2 represents:
(a") a group --CH 2 Z, wherein Z represents chlorine, bromine or iodine;
(b") a group ##STR2## wherein each of R 7 and R 8 may be independently hydrogen or C 1 -C 6 alkyl or R 7 and R 8 , taken together with the nitrogen atom, form an unsubstituted N-pyrrolidinyl, morpholino or piperidino ring or a N-piperazinyl ring, which is unsubstituted or substituted by C 1 -C 4 alkyl or by phenyl or by C 1 -C 2 alkoxycarbonyl;
(c") carboxy or C 1 -C 7 alkoxycarbonyl, unsubstituted or substituted by a group ##STR3## wherein R 7 and R 8 are as defined above; R 3 represents a hydrogen atom or a C 1 -C 6 alkyl group;
each of R 4 , R 5 and R 6 independently represents a hydrogen or a halogen atom, C 1 -C 6 alkyl, halo-C 1 -C 4 alkyl, hydroxy, C 1 -C 6 alkoxy, C 3 -C 4 alkenyloxy, formyloxy, C 2 -C 8 alkanoyloxy, carboxy, C 1 -C 7 alkoxycarbonyl, wherein the alkoxy moiety is unsubstituted or substituted by a group ##STR4## wherein R 7 and R 8 are as defined above, nitro or a group ##STR5## wherein each of R 9 and R 10 independently represents a hydrogen atom, a C 1 -C 6 alkyl group, formyl or C 2 -C 8 alkanoyl; or any two adjacent R 4 , R 5 and R 6 , taken together, form a C 1 -C 3 alkylenedioxy group.
The scope of the invention includes also the pharmaceutically acceptable salts of the compounds of formula (I), all the possible isomers (e.g. Z and E isomers and optical isomers) and the mixtures thereof as well as the metabolites and the metabolic precursors of the compounds of formula (I).
The alkyl, alkenyl, alkylene, alkenylene, halo-alkyl, alkoxycarbonyl, alkenyloxy, alkoxy, alkanoyl and alkanoyloxy groups may be branched or straight chain groups.
The numbering used to identify the positions in the compounds of formula (I) is the conventional one, as is shown in the following Examples:
(A) when n=1: ##STR6##
(B) when n=2: ##STR7##
A C 3 -C 4 alkenyl group is, for example, allyl or 2-methyl-allyl.
A C 1 -C 6 alkyl group is preferably a C 1 -C 4 alkyl group, in particular methyl, ethyl, propyl and isopropyl.
A halogen atom is, for example, fluorine, chlorine or bromine, preferably it is fluorine or chlorine. A C 1 -C 7 alkoxycarbonyl group is preferably a C 1 -C 5 alkoxycarbonyl group, in particular, methoxycarbonyl and ethoxycarbonyl.
A C 2 -C 8 alkanoyl group is for example acetyl, propionyl, butyryl, valeryl and isovaleryl, preferably acetyl. A halo-C 1 -C 4 alkyl group is for example a C 1 -C 4 alkyl group substituted by one to 3 halogen atoms, e.g. chlorine, fluorine and bromine, in particular it is trifluoromethyl. P A C 1 -C 6 alkoxy group is for example a C 1 -C 4 alkoxy group, in particular methoxy and ethoxy.
A C 1 -C 3 alkylenedioxy group is for example methylenedioxy and ethylenedioxy.
A branched or straight C 1 -C 12 alkylene chain is, preferably, a branched or straight C 1 -C 6 alkylene chain, in particular, for example, --CH 2 --, ##STR8##
A branched or straight C 2 -C 12 alkenylene chain is, preferably, a branched or straight C 2 -C 6 alkenylene chain, in particular, for example, --CH═CH--, ##STR9##
A C 2 -C 8 alkanoyloxy group is, for example, acetoxy, propionyloxy and butyryloxy, preferably it is acetoxy.
When one or more of R 1 , R 7 and R 8 is a C 1 -C 6 alkyl group, the alkyl group is preferably a C 1 -C 4 alkyl group, in particular methyl, ethyl, propyl and isopropyl.
When one or more of R 3 , R 4 , R 5 and R 6 is a C 1 -C 6 alkyl group, the alkyl group is preferably methyl or ethyl.
When one or more of R 4 , R 5 and R 6 is a C 1 -C 6 alkoxy group, the alkoxy group is preferably methoxy, ethoxy, propoxy and isopropoxy.
More preferred compounds of the invention are the compounds of formula (I), wherein
m is 1;
n is 1;
R 1 is hydrogen or C 1 -C 4 alkyl, unsubstituted or substituted by phenyl;
X completes a single bond; or X is C 1 -C 6 alkylene or C 2 -C 6 alkenylene, both of them being unsubstituted or substituted by 1 up to 3 chlorine atoms;
R 2 is piperidinomethyl, morpholinomethyl, (1-pyrrolidinyl)-methyl or (1-piperazinyl)-methyl, wherein the piperazinyl ring is unsubstituted or substituted by C 1 -C 4 alkyl, phenyl or by C 1 -C 2 alkoxycarbonyl; or R 2 is carboxy or C 1 -C 5 alkoxycarbonyl, unsubstituted or substituted by a N,N-dimethylamino or a N,N-diethylamino group;
R 3 is hydrogen or methyl;
each of R 4 , R 5 and R 6 , independently is hydrogen, fluorine, chlorine, C 1 -C 2 alkyl, hydroxy, C 1 -C 3 alkoxy, acetoxy, carboxy or any two adjacent R 4 , R 5 and R 6 , taken together, form a methylenedioxy group; and the pharmaceutically acceptable salts thereof.
Examples of pharmaceutically acceptable salts are either those with inorganic bases, such as sodium, potassium, calcium and aluminium hydroxides or with organic bases, such as lysine, triethylamine, triethanolamine, dibenzylamine, methylbenzylamine, tris-(hydroxymethyl)-aminomethane, piperidine, N-ethylpiperidine, N,N-diethylaminoethylamine, N-ethylmorpholine, β-phenethylamine, N-benzyl-β-phenethylamine, N-benzyl-N,N-dimethylamine and the other acceptable organic amines, as well as the salts with inorganic acids, e.g. hydrochloric, hydrobromic, nitric and sulphuric acids and with organic acids, e.g. citric, tartaric, maleic, malic, fumaric, methanesulphonic and ethanesulphonic acids.
Examples of particularly preferred compounds of the invention are:
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid;
N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(4-fluoro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2,3-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2-methoxy-3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2,5-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2,5-dimethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2,3-dichloro-2-propenoic acid;
(E)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid;
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid;
N-[3-(2,4-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid;
N-[3-(2-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3-trifluoromethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3,4-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2,3-diethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3,4,5-trimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3,4-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]amino-oxoacetic acid;
N-[3-(4-carboxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3,4-methylenedioxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-(6-benzylidene-11-oxo-6,7,8,9-tetrahydro-11H-pyrido[2,1-b]quinazolin-3-yl)-amino-oxoacetic acid;
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl-acetic acid;
3-benzylidene-6-N-(3-morpholino-propionyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-9-one;
3-benzylidene-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
and the pharmaceutically acceptable salts thereof, in particular the sodium, triethanolamine and tris-(hydroxymethyl)-aminomethane salts and the hydrochlorides of the basic esters (e.g. those with 2-diethylamino-ethanol) and the C 1 -C 6 alkyl esters thereof, in particular the methyl, ethyl, isopropyl and n-butyl esters.
The compounds of formula (I) can be obtained by a process comprising:
(a) reacting a compound of formula (II) ##STR10## wherein n, R 1 , R 3 , R 4 , R 5 and R 6 are as defined above, with a compound of formula (III)
R.sub.2 --X--COY (III)
wherein X and R 2 are as defined above and Y represents a halogen atom, hydroxy or a group --OCOOR 9 , wherein R 9 represents benzyl, phenyl or C 1 -C 6 alkyl, so obtaining a compound of formula (I) wherein m is 1, or
(b) reacting a compound of formula (II), as defined above, with a compound of formula (IV) ##STR11## wherein X is as defined above, except a single bond, so obtaining a compound of formula (I), wherein m is 1, R 2 is carboxy, and X is as defined above, except a single bond; or
(c) reacting a compound of formula (II), as defined above, with a compound of formula (V)
R.sub.2 --X--Z (V)
wherein X, Z and R 2 are as defined above, so obtaining a compound of formula (I) wherein m is zero; or
(d) reacting a compound of formula (VI) ##STR12## wherein m, n, X, R 1 , R 2 and R 3 are as defined above or a salt thereof, with an aldehyde of formula (VII) ##STR13## wherein R 4 , R 5 and R 6 are as defined above; and if desired, converting a compound of formula (I) into another compound of formula (I) and/or if desired, converting a compound of formula (I) into a pharmaceutically acceptable salt and/or, if desired, converting a salt into a free compound and/or, if desired, separating a mixture of isomers into the single isomers.
In a compound of formula (III) Y is preferably chlorine, bromine, hydroxy or a group --OCOOC 2 H 5 ; more preferably it is chlorine and bromine.
The reaction between a compound of formula (II) and a compound of formula (III), wherein X and R 2 are as defined above and Y is halogen, preferably chlorine or bromine, or a group --OCOOR 9 , wherein R 9 is as defined above, may be carried out, for example, in an organic solvent such as dichloroethane, dichloromethane, chloroform, dimethylformamide, dimethylacetamide in the presence of a base such as pyridine, triethylamine, N-methyl-piperidine, N,N-dimethylaniline at a temperature varying between about 0° C. and about 100° C. preferably between 0° C. and about 40° C.
The reaction between a compound of formula (II) and a compound of formula (III), wherein X and R 2 are as defined above and Y is hydroxy, may be carried out, for example, in the presence of a dehydrating agent such as N,N-carbonyldiimidazole, N,N-dicyclohexylcarbodiimide, N-hydroxypiperidine, N-hydroxy-succinimide in an organic solvent such as dimethylformamide, dimethylacetamide, dichloromethane, dioxane, tetrahydrofuran, acetonitrile, at a temperature varying between 0° C. and about 120° C., preferably between room temperature and about 80° C.
The reaction between a compound of formula (II) and a compound of formula (IV) may be carried out, for example, in a solvent such as dichloromethane, dichloroethane, chloroform, tetrahydrofuran, dimethylformamide, dimethylacetamide, at a temperature varying betweeen room temperature and about 100° C., preferably between room temperature and about 70° C.
The reaction between a compound of formula (II) and a compound of formula (V) may be carried out, for example, in the presence of a base such as Na 2 CO 3 , K 2 CO 3 , NaH, NaNH 2 in a solvent such as dimethylformamide, dimethylacetamide, dioxane, tetrahydrofuran and their mixtures, at a temperature varying between room temperature and about 100° C.
Preferred salts of a compound of formula (VI) are those with inorganic bases such as sodium and potassium salts as well as the salts with inorganic acids e.g. hydrochloric, hydrobromic, hydroiodic and sulphuric acid.
The reaction of a compound of formula (VI) or a salt thereof with an aldehyde of formula (VII) is preferably carried out in the presence of a basic condensing agent such as sodium ethoxide, sodium methoxide, sodium hydride, sodium amide or sodium hydroxide, in a solvent selected, e.g., from the group consisting of methanol, ethanol, isopropanol, dioxane, water and their mixtures, at a temperature preferably ranging between about 0° C. and about 120° C.
A compound of formula (I) may be converted, as stated above, into another compound of formula (I) by known methods; for example, a C 1 -C 7 alkoxycarbonyl group may be converted into a free carboxy group by hydrolysis, e.g. basic hydrolysis, using, for example, sodium or potassium hydroxide, in a solvent, such as water, dioxane, dimethylformamide or a lower aliphatic alcohol and their mixtures, and operating at a temperature ranging from the room temperature to about 100° C.; the same reaction may be also carried out e.g. by treatment with lithium bromide in dimethylformamide at a temperature higher than 50° C. or by treatment with hydrochloric or hydrobromic or hydroiodic or sulphuric acid in acetic acid at temperature higher than 50° C.
A free carboxy group may be converted into a C 1 -C 7 alkoxycarbonyl group unsubstituted a substituted by a ##STR14## group, wherein R 7 and R 8 are as defined above, by conventional methods, for example, by reacting the acid with a suitable C 1 -C 7 alkyl alcohol in the presence of a Lewis acid such as gaseous hydrochloric acid, 98% sulphuric acid, boron trifluoride etherate, at a temperature varying from room temperature and the reflux temperature.
Alternatively the esterification of a free carboxy group in a compound of formula (I) may be effected by converting the carboxylic acid into the corresponding halocarbonyl, preferably chlorocarbonyl, derivative, by reaction, e.g. with the desired acid halide, for example oxalyl chloride, thionyl chloride, PCl 3 , PCl 5 or POCl 3 , either in the absence of solvents or in an inert organic solvent such as benzene, toluene, xylene, dioxane, dichloroethane, methylene chloride or tetrahydrofuran, at a temperature ranging preferably from about 0° C. to about 120° C., and then reacting the resulting halocarbonyl derivative with a suitable C 1 -C 7 alkyl alcohol in an inert solvent such as benzene, toluene, xylene, dioxane, dichloroethane, methylene chloride or tetrahydrofuran, at temperatures varying between about 0° C. and about 120° C., preferably in the presence of a base such as triethylamine or pyridine.
Furthermore a compound of formula (I) wherein R 1 is hydrogen may be converted into a compound of formula (I) wherein R 1 is C 3 -C 4 alkenyl or C 1 -C 6 alkyl, unsubstituted or substituted as defined above, for example, by reaction with a suitable C 3 -C 4 alkenyl halide or C 1 -C 6 alkyl halide, unsubstituted or substituted as defined above, in the presence of a base such as Na 2 CO 3 , K 2 CO 3 , NaH, NaNH 2 , in a solvent such as dimethylformamide, dimethylacetamide, dioxane, tetrahydrofuran and their mixtures, at a temperature varying between room temperature and about 100° C.
A compound of formula (I) wherein R 1 is hydrogen may be converted into a compound of formula (I) wherein R 1 is formyl by heating with formic acid at a temperature varying between about 50° C. and about 100° C. A compound of formula (I) wherein R 1 is hydrogen may be converted into a compound of formula (I) wherein R 1 is C 2 -C 8 alkanoyl, unsubstituted or substituted as defined above, by reaction, for example, with a suitable C 2 -C 8 alkanoyl halide or anhydride in the presence of a base such as pyridine or triethylamine either in a solvent such as dimethylformamide, dioxane, tetrahydrofuran or without a solvent, at a temperature varying between about 50° C. and about 150° C.
A compound of formula (I) wherein m is zero and R 1 is formyl or C 2 -C 8 alkanoyl, unsubstituted or substituted as defined above, may be converted into a compound of formula (I), wherein m is zero and R 1 is hydrogen, e.g., by acid hydrolysis using, for example, hydrochloric, hydrobromic or hydroiodic acid in aqueous solution in the presence, if necessary, of an organic cosolvent such as dioxane or acetic acid, operating at a temperature varying between room temperature and reflux temperature or by basic hydrolysis, using, for example, sodium hydroxide or potassium hydroxide in aqueous solution in the presence, if necessary, of an organic cosolvent such as dioxane or a lower alkyl alcohol, operating at a temperature varying between room temperature and reflux temperature.
A compound of formula (I) wherein R 2 is a group --CH 2 Z, wherein Z is a as defined above, may be converted into a compound of formula (I) wherein R 2 is a group ##STR15## wherein R 7 and R 8 are as defined above, by reaction with a compound of formula ##STR16## wherein R 7 and R 8 are as defined above, in an inert organic solvent such as dioxane, dimethyformamide, dimethylacetamide, at a temperature varying between the room temperature and the reflux temperature, preferably between the room temperature and about 100° C.
Also the optional salification of a compound of formula (I) as well as the conversion of a salt into the free compound and the separation of a mixture of isomers into the single isomers may be carried out by conventional methods.
For example the separation of a mixture of optical isomers into the individual isomers may be carried out by salification with an optically active base and subsequent fractional crystallization.
Thus, the separation of a mixture of geometric isomers may be carried out, for example, by fractional crystallization.
The compounds of formula (II), wherein R 1 is hydrogen, may be prepared, for example, by reducing a compound of formula (VIII) ##STR17## wherein n, R 3 , R 4 , R 5 and R 6 are as defined above, with a suitable reducing agent such as stannous chloride or sodium borohydride. The reduction of a compound of formula (VIII) with stannous chloride may be carried out, for example, in concentrated hydrochloric acid, using if necessary an organic cosolvent such as acetic acid, dioxane, tetrahydrofuran, at a temperature varying between room temperature and the reflux temperature, preferably between room temperature and about 60° C.
The reduction of a compound of formula (VIII) with sodium borohydride may be carried out, for example, in C 1 -C 4 aliphatic alcohols, preferably isopropyl alcohol, tetrahydrofuran, dimethylformamide, dimethylacetamide, water and their mixtures, operating at a temperature varying between room temperature and about 60° C.
The compounds of formula (II) wherein R 1 is formyl or a group of C 2 -C 8 alkanoyl, unsubstituted or substituted as defined above, may be prepared, for example, by reacting a compound of formula (II) wherein R 1 is hydrogen, respectively, with formic acid at a temperature varying between about 50° C. and about 100° C. or with a suitable C 2 -C 8 alkanoyl halide or anhydride in the presence of a base such as pyridine or triethylamine either in a solvent such as dimethylformamide, dioxane, tetrahydrofuran or without a solvent, at a temperature varying between about 50° C. and about 150° C.
The compounds of formula (II) wherein R 1 is a group C 3 -C 4 alkenyl or C 1 -C 6 alkyl, unsubstituted or substituted as defined above, may be prepared, for example, by reacting a compound of formula (II), wherein R 1 is formyl or C 2 -C 8 alkanoyl, unsubstituted or substituted as defined above, with a suitable C 3 -C 4 alkenyl halide or C 1 -C 6 alkyl halide, in the presence of a base such as Na 2 CO 3 , K 2 CO 3 , NaH, NaNH 2 in a solvent such as dimethylformamide, dimethylacetamide, dioxane, tetrahydrofuran and their mixtures, at a temperature varying between room temperature and about 100° C., and then hydrolyzing the formyl or C 2 -C 8 alkanoyl moiety e.g. by treatment with a mineral acid such as hydrochloric, hydrobromic or hydroiodic acid in aqueous media at a temperature varying between room temperature and about 100° C.
The compounds of formula (VI) may be prepared, for example, by reacting a compound of formula (IX) ##STR18## wherein n, R 1 and R 3 are as defined above, with a compound of formula (III), (IV) or (V), so obtaining respectively compounds of formula (VI), wherein m is 1; or m is 1, R 2 is carboxy and X is as defined above, except a single bond; or m is zero.
The reaction between a compound of formula (IX) and a compound of formula (III), (IV) or (V) may be carried out, for example, using the same experimental conditions as described above for the reaction between a compound of formula (II) and a compound of formula (III), (IV) or (V).
Alternatively the compounds of formula (VI), wherein R 1 is C 3 -C 4 alkenyl or C 1 -C 6 alkyl, unsubstituted or substituted as defined above, may be prepared, for example, by reacting a compound of formula (VI) wherein R 1 is hydrogen with a suitable C 3 -C 4 alkenyl halide or C 1 -C 6 alkyl halide, in the presence of a base such as Na 2 CO 3 , K 2 CO 3 , NaH, NaNH 2 in a solvent such as dimethylformamide, dioxane, tetrahydrofuran and their mixtures, at a temperature varying between room temperature and about 100° C.
The compounds of formula (VIII) may be prepared, for example, by reacting a compound of formula (X) ##STR19## wherein n and R 3 are as defined above, with an aldehyde of formula (VII), using the same experimental conditions described above for the reaction between a compound of formula (VI) and an aldehyde of formula (VII).
The compounds of formula (IX) wherein R 1 is hydrogen may be prepared, for example, by treatment of a compound of formula (X) with a reducing agent such as stannous chloride or sodium borohydride as described above for the reduction of the compounds of formula (VIII).
The compounds of formula (IX) wherein R 1 is different from hydrogen may be prepared, for example, from the compounds of formula (IX) wherein R 1 is hydrogen, using the same chemical processes described above for the preparation of the compounds of formula (II) wherein R 1 is different from hydrogen.
The compounds of formula (X) may be prepared by known methods, for example, according to the methods described in published UK Patent Application No. 2103207A.
The compounds of formula (III), (IV), (V) and (VII) are known compounds and may be prepared by conventional methods: in some cases they are commercially available products.
The compounds of formula (I) have antiallergic activity and are therefore useful in the prevention and treatment of all the affections of allergic origin, e.g. bronchial asthma, allergic rhinitis, hay fever, urticaria and dermatosis. The antiallergic activity of the compounds of the invention is shown, e.g., by the fact that they are active in the following biological tests:
in vitro
(1) test of A 23187 induced SRS production from rat peritoneal cells, according to M. K. Bach and J. R. Brashler (J. Immunol., 113, 2040, 1974);
(2) test of antigen induced SRS production from guinea-pig chopped lung, according to W. E. Brocklehurst (J. Physiol., 151, 416, 1960);
in vivo
(3) test of the IgG mediated passive peritoneal anaphylaxis in the rat, according to H. C. Morse, K. J. Bloch and K. F. Austen (Journal Immunology, 101, 658, (1968); and
(4) test of the IgE mediated passive cutaneous anaphylaxis (PCA) in the rat, according to A. M. J. N. Blair (Immunology, 16, 749, 1969).
The results of these biological tests show that the compounds of the invention are active, for example, as inhibitors of the immunological release of allergic mediators, e.g. histamine, from the mast cells and as inhibitors of the production and/or release of anaphylactic mediators such as "slow reacting substances" (SRS) in the peritoneal and the pulmonary system, induced by challenge with an ionophore or with an antigen.
An important property of the compounds of this invention is that they are active as antiallergic agents also when administered orally.
As preferred example of compound having antiallergic activity the following can be mentioned:
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid.
In view of their high therapeutic index the compounds of the invention can be safely used in medicine.
For example, the approximate acute toxicity (LD 50 ) of the compound:
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid,
in the mouse, determined with single administration of increasing doses and measured on the seventh day after the treatment is per os higher than 800 mg/kg.
Analogous toxicity data have been found for the other compounds of the invention.
The compounds of the invention may be administered to humans in conventional manner, for instance, orally or parenterally at a daily dosage preferably from about 0.5 to about 15 mg/kg, or by inhalation, preferably at a daily dosage from about 0.5 to about 100 mg, preferably 0.5 to 25 mg, or by topical application, (for example for the treatment of urticaria and dermatosis), e.g. by a cream containing about from 0.5 to 5 mg, preferably 1-2 mg, of the active principle per 100 mg of cream.
The nature of the pharmaceutical compositions containing the compounds of this invention in association with pharmaceutically acceptable carriers or diluents will, of course, depend upon the desired route of administration.
The compositions may be formulated in the conventional ways with the usual ingredients. For example, the compounds of the invention may be administered in the form of aqueous or oily solutions or suspensions, aerosols, as well as powders, tablets, pills, gelatine capsules, syrups, drops, suppositories, or creams, or lotions for topical use.
Thus, for oral administration, the pharmaceutical compositions containing the compounds of this invention, are preferably tablets, pills or gelatine capsules which contain the active substance together with diluents, such as lactose, dextrose, sucrose, mannitol, sorbitol, cellulose; lubricants, for instance, silica, talc, stearic acid, magnesium or calcium stearate, and/or polyethylene glycols; or they may also contain binders, such as starches, gelatine, methylcellulose, carboxymethylcellulose, gum-arabic, tragacanth, polyvinylpyrrolidone; disaggregating agents, such as starches, alginic acid, alginates, sodium starch glycolate; effervescing mixtures; dyestuffs, sweeteners; wetting agents such as lecithin, polysorbates, laurylsulphates; and, in general, non-toxic and pharmacologically inactive substances used in pharmaceutical formulations.
Said pharmaceutical preparations may be manufactured in known manner, for example, by means of mixing, granulating, tabletting, sugar-coating, or film-coating processes.
For the treatment of allergic asthma, the compounds of the invention are also administered by inhalation. For such use, suitable compositions may comprise a suspension or solution of the active ingredient, preferably in the form of a salt, such as the sodium salt or the salt with triethanolamine or with tris-(hydroxymethyl)-aminomethane, in water, for administration by means of a conventional nebulizer.
Alternatively, the compositions may comprise a suspension or a solution of the active ingredient in a conventional liquified propellant, such as dichlorodifluoromethane or dichlorotetrafluoroethane to be administered from a pressurized container, i.e., an aerosol dispenser.
When the medicament is not soluble in the propellant, it may be necessary to add a co-solvent, such as, ethanol, dipropylene glycol, isopropyl myristate, and/or surface-active agent to the composition, in order to suspend the medicament in the propellant medium and such surface-active agents may be any of those commonly used for this purpose, such as non-ionic surface-active agents, e.g., lecithin.
The compounds of the invention may also be administered in the form of powders by means of a suitable insufflator device and in this case the fine particle sized powders of the active ingredients may be mixed with a diluent material such a lactose.
Furthermore, the compounds of this invention may also be administered by intradermal or intravenous injection in the conventional manner.
In addition to the internal administration, the compounds of this invention may find use in compositions for topical application, e.g., as creams, lotions or pastes for use in dermatological treatments.
For these compositions the active ingredient may be mixed with conventional oleaginous or emulsifying excipients. The following examples illustrate but do not limit the present invention.
EXAMPLE 1
6-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 268°-270° C. (3.1 g), was reacted with ethyl oxalyl chloride (3.2 g) in dimethylacetamide (30 ml) in the presence of pyridine (3 ml) at room temperature for 16 hours.
The reaction mixture was then diluted with ice water and the precipitate was filtered and washed with water: crystallization from dimethylformamide gave N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, ethyl ester, m.p. 248°-250° C. (3 g), which was dissolved in dimethylformamide (150 ml) and treated with 5% aqueous NaOH (150 ml) at room temperature for 5 hours.
The precipitate, N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, sodium salt, m.p. >300° C., was filtered and washed with water, then it was dissolved in formic acid and the solution was diluted with water to give a precipitate which was filtered and washed with water until netural. Crystallization from formic acid gave 1.4 g of N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, m.p. 220°-225° C.,
NMR (DMSO d6) δ ppm: 3.22 (m) (2H, C-2 protons), 4.11 (m) (2H, C-1 protons), 7.25-7.80 (m) (6H, --CH═ and phenyl protons), 7.75 (dd) (1H, C-7 -proton), 8.02 (d) (1H, C-8 proton), 8.20 (d) (1H, C-5 proton), 11.0 (bs) (1H, --NH--CO--).
By proceeding analogously the following alkyl esters and acids were prepared:
N-(6-benzylidene-11-oxo-6,7,8,9-tetrahydro-11H-pyrido[2,1-b]quinazolin-3-yl)-amino-oxoacetic acid, ethyl ester, m.p. 193°-195° C.;
N-(6-benzylidene-11-oxo-6,7,8,9-tetrahydro-11H-pyrido[2,1-b]quinazolin-3-yl)-amino-oxoacetic acid, m.p. 350° C. dec.,
NMR (CF 3 COOD+DMSO d6) δ ppm: 2.14 (m) (2H, C-8 protons), 3.05(m) (2H, C-7-protons), 4.16 (m) (2H, C-9 protons), 7.58 (m) (3H) and 7.74 (m) (2H) and 8.05 (m) (2H) (--CH═, phenyl protons and C-2proton), 8.33 (d) (1H, C-1 proton), 8.78 (bs) (1H, C-4 proton);
N-(3-benzylidene-1-methyl-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, ethyl ester, m.p. 232°-235° C.;
N-(3-benzylidene-1-methyl-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, m.p. 221°-225° C.;
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-7-yl)-amino-oxoacetic acid, ethyl ester, m.p. 270°-272° C.; and
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-7-yl)-amino-oxoacetic acid, m.p. 239°-242° C.,
NMR (DMSO d6) δ ppm: 3.24 (m) (2H, C-2 protons), 4.17 (t) (2H, C-1 protons), 7.33-7.78 (m) (7H, --CH═, C-5 proton and phenyl protons), 8.10 (dd) (1H, C-6 proton), 8.65 (d) (1H, C-8 proton), 10.99 (s) (1H, --NH--CO--).
EXAMPLE 2
6-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one (2.5 g) was reacted with 3-carbometoxy propionyl chloride (1.95 g) in dimethylacetamide (110 ml) in the presence of pyridine (2 ml) at room temperature for 18 hours. The reaction mixture was then diluted with ice water and the precipitate was filtered and washed with water to give 3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-propanoic acid methyl ester, m.p. 288°-291° C. (3.3 g) which was dissolved in dimethylformamide (120 ml) and treated with 5% aqueous NaOH (32.5 ml) at room temperature for 3 hours. The precipitate, 3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-propanoic acid, sodium salt, m.p. >300° C., was filtered and washed with water, then it was dissolved in formic acid and the solution was diluted with water to give a precipitate which was filtered and washed with water until neutral to give 2.07 g of 3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-propanoic acid, m.p. 250°-255° C. dec., NMR (DMSO d6) δ ppm., 2.62 (bs) (4H, --COCH 2 CH 2 --COOH), 3.18 (m) (2H, C-2 protons), 4.08 (t) (2H, C-1 protons), 7.30-7.70 (m) (7H, C-5 and C-7 protons and phenyl protons), 7.98 (d) (1H, C-8 proton), 8.07 (t) (1H, --CH═), 10.31 (ds) (1H, --NHCO--).
By proceeding analogously the following alkyl esters and acids were prepared:
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl-acetic acid, ethyl ester, m.p. 227°-229° C.;
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl-acetic acid, m.p. 307°-310° C.;
(E)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, m.p. 315°-320° C.;
(E)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, ethyl ester, m.p. 298°-300° C.;
3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, methyl ester, m.p. 284°-287° C.;
3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, m.p. 384°-387° C.;
4-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, methyl ester, m.p. 280°-285° C.;
4-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, m.p. 310°-315° C.;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-4,5-dichloro-benzoic acid, methyl ester;
3-benzylidene-6-N-ethoxycarbonyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 285°-288° C.;
3-benzylidene-6-N-methoxycarbonyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-4,5-dichloro-benzoic acid;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]propanoic acid, ethyl ester;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-propanoic acid;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-methyl-propanoic acid, ethyl ester;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-methyl-propanoic acid;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-butanoic acid, ethyl ester;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-butanoic acid;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-ethyl-butanoic acid, ethyl ester;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-ethyl-butanoic acid;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-phenyl-acetic acid, ethyl ester; and
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-phenyl-acetic acid.
EXAMPLE 3
6-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one (2 g) was reacted with phthalic anhydride (4.6 g) in tetrahydrofuran (150 ml) under stirring at the reflux temperature for 14 hours. After cooling the precipitate was filtered and washed with tetrahydrofuran and then with water to give 1.6 g of 2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, m.p. 302°-308° C.,
NMR (CDCl 3 --CF 3 COOD) δ ppm: 3.61 (bt) (2H, C-2 protons), 4.65 (t) (2H, C-1 protons), 7.4-8.0 (m) (7H; phenyl and C-4 and C-5 benzoyl protons), 8.0-8.5 (m) (6H; --CH═, C-5 and C-7 and C-8 protons, C-3 and C-6 benzoyl protons).
By proceeding analogously the following compounds were prepared:
cis-2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-1-cyclohex-4-ene-carboxylic acid, m.p. 245°-248° C.;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-cyclohex-1-ene-carboxylic acid;
cis-2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-cyclohexane-carboxylic acid; and
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-3,4,5,6-tetrachloro-benzoic acid.
EXAMPLE 4
6-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one (3 g) was reacted with maleic anhydride (4.55 g) in tetrahydrofuran (220 ml) under stirring at the reflux temperature for 14 hours.
After cooling the precipitate was filtered and washed with tetrahydrofuran and then with water: crystallization from dimethylformamide gave 2.8 g of (Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, m.p. 210°-230° C.,
NMR (CDCl 3 +CF 3 COOD) δ ppm: 3.53 (m) (2H, C-2 protons), 4.57 (m) (2H, C-1 protons), 6.51 (d) (1H, α-propenoyl proton), 6.78 (d) (1H, β-propenoyl proton), 7.58 (broad peak) (5H, phenyl protons), 8.00-8.40 (m) (4H, --CH═ and C-5, C-7 and C-8 protons); J H αHβ =12.5 Hz.
By proceeding analogously the following compounds were prepared:
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2,3-dimethyl-2-propenoic acid;
4-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-butanoic acid;
5-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-pentanoic acid; and
4-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-3,3-dimethyl-butanoic acid.
EXAMPLE 5
6-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one (2 g) was reacted with 2,3-dichloro-maleic anhydride (3.46 g) in tetrahydrofuran (130 ml) under stirring at the reflux temperature for 3 hours. After cooling the solution was evaporated in vacuo to dryness: the residue was suspended in hot ethyl acetate and filtered. Crystallization from CH 2 Cl 2 -ethyl acetate gave 1 g of (Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2,3-dichloro-2-propenoic acid, m.p. 160°-165° C. (dec.),
NMR (DMSO d6) δ ppm: 3.23 (m) (2p, C-2 protons), 4.14 (m) (2p, C-1 protons), 7.35-7.80 (m) (7H, C-5 and C-7 protons and phenyl protons), 8.07 (d) (1H, C-8 proton), 8.08 (bs) (1H, --CH═), 11.15 (s) (1H, CONH).
EXAMPLE 6
By proceeding according to Example 1, using suitable 6-amino-3-substituted benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-ones, the following compounds were prepared:
N-[3-(2-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester; m.p. 248°-251° C.;
N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 230°-233° C.;
N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 288°-290° C.;
N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 260°-262° C.;
N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 242°-244° C.;
N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 265°-268° C.;
N-[3-(4-fluoro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 240°-243° C.;
N-[3-(2-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 230°-233° C.;
N-[3-(2,3-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 170°-175° C.;
N-[3-(3,4-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 273°-275° C.;
N-[3-(4-nitro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(4-amino-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(3-trifluoromethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 245°-250° C.;
N-[3-(3,4-methylenedioxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 275°-280° C.;
N-[3-(2,5-dimethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 257°-259° C.;
N-[3-(2,4-dimethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]-quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(2-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 212°-214° C.;
N-[3-(3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 223°-226° C.;
N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 253°-256° C.;
N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 252°-255° C.;
N-[3-(3-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 244°-247° C.;
N-[3-(2-methoxy-3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 212°-216° C.;
N-[3-(2,5-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 264°-267° C.;
N-[3-(3,5-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(2,4-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(3,4,5-trimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 285°-288° C.;
N-[3-(2,3,4-trimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(2-ethoxy-3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(2,3-diethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 174°-177° C.;
N-[3-(2-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(3-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(4-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(2-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(3-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(4-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(3,4-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(2,4-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 244°-246° C.;
N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester, m.p. 234°-237° C.;
N-[3-(4-N,N-dimethylamino-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, ethyl ester;
N-[3-(2-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 235°-240° C. dec.;
N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 232°-235° C.;
N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 253°-256° C.;
N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 246°-248° C.;
N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]amino-oxoacetic acid, m.p. 195°-205° C. dec.;
N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 236°-240° C.;
N-[3-(4-fluoro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 246°-248° C.;
N-[3-(2-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 300°-310° C. dec.;
N-[3-(2,3-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 253°-255° C.;
N-[3-(3,4-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 250°-260° C. (dec.);
N-[3-(2-methoxy-3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]amino-oxoacetic acid, m.p. 228°-230° C. dec.;
N-[3-(2,5-dimethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]amino-oxoacetic acid, m.p. 347°-349° C.;
N-[3-(2,4-dimethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxacetic acid, m.p. 215°-220° C.;
N-[3-(3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-6-yl]-amino-oxoacetic acid, m.p. 238°-240° C.;
N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 240°-245° C. dec.;
N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 226°-229° C.;
N-[3-(3-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 236°-240° C.;
N-[3-(2,3,4-trimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2,4-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2-ethoxy-3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2,3-diethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 220°-222° C.;
N-[3-(2-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(4-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3,4-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2,4-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 205°-215° C. (dec.);
N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 222°-226° C.;
N-[3-(3,5-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(2-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(4-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3,4-methylenedioxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 225°-229° C.;
N-[3-(4-nitro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(4-amino-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid;
N-[3-(3-trifluoromethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 250°-265° C. (dec.);
N-[3-(2,5-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 238°-243° C. dec.;
N-[3-(3,4,5-trimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 221°-225° C.;
N-[3-(4-methoxycarbonyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 282°-285° C.;
N-[3-(4-carboxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid, m.p. 240°-250° C. dec.; and
N-[3-(4-N,N-dimethylamino-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-amino-oxoacetic acid.
EXAMPLE 7
By proceeding according to Example 2, using suitable 6-amino-3-substituted benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-ones, the following compounds were prepared:
N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(2,3-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
N-[3-(2,5-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl-acetic acid;
3-{N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]aminocarbonyl}-propanoic acid;
3-{N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
3-{N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
3-{N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
3-{N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
3-{N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
3-{N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
3-{N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
(E)-3-{N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3{-N-[3-(3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(3-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(E)-3-{N-[3-(2-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
2-{N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
2-{N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbony}-propanoic acid;
2-{N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbony}-propanoic acid;
2-{N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
2-{N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
2-{N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
2-{N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
2-{N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-propanoic acid;
2-{N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-methyl-propanoic acid;
2-{N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-methyl-propanoic acid;
2-{N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-methyl-propanoic acid;
2-{N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-methyl-propanoic acid;
2-{N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-methyl-propanoic acid;
2-{N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-methyl-propanoic acid;
2-{N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-methyl-propanoic acid; and
2-{N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-methyl-propanoic acid.
EXAMPLE 8
By proceeding according to Example 3, using suitable 6-amino-substituted benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-ones, the following compounds were prepared:
2-{N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-benzoic acid;
2-{N-[3-(3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-benzoic acid;
2-{N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-benzoic acid;
2-{N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-benzoic acid;
2-{N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydrio-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-benzoic acid;
2-{N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-benzoic acid;
2-{N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-benzoic acid;
2-{N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-benzoic acid;
cis-2-{N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-1-cyclohex-4-ene-carboxylic acid;
cis-2-{N-[3-(3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-1-cyclohex-4-ene-carboxylic acid;
cis-2-{N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-1-cyclohex-4-ene-carboxylic acid;
cis-2-{N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-1-cyclohex-4-ene-carboxylic acid;
cis-2-{N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-1-cyclohex-4-ene-carboxylic acid;
cis-2-{N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-1-cyclohex-4-ene-carboxylic acid;
cis-2-{N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-1-cyclohex-4-ene-carboxylic acid; and
cis-2-{N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-1-cyclohex-4-ene-carboxylic acid.
EXAMPLE 9
By proceeding according to Examples 4 and 5, using suitable 6-amino-3-substituted benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-9-ones, the following compounds were prepared:
(Z)-3-{N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-2-{N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(3-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(2-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid;
(Z)-3-{N-[3-(2-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-methyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-fluoro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2-ethoxy-3-methoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,3-diethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-chloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3,4-methylenedioxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,6-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3,4-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-nitro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-amino-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-propoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(4-isopropoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,4-dichloro-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2-methoxy-3-ethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3-N,N-dimethylamino-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,3,4-trimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3,4,5-trimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,3-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3,4-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,5-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,4-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3,5-dimethoxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,5-dimethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(2,4-dimethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid;
(Z)-3-{N-[3-(3-trifluoromethyl-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid; and
(Z)-3-[N-(3-benzylidene-1-methyl-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2,3-dichloro-2-propenoic acid.
EXAMPLE 10
3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, methyl ester (0.85 g) dissolved in dimethylformamide (40 ml) was added to a suspension of 50% NaH (0.18 g) in dimethylformamide (5 ml) and the mixture was stirred at room temperature for 1 hour and then reacted with methyl iodide (0.54 g) at room temperature for 17 hours. The reaction mixture was diluted with ice water and then acidified with acetic acid: the precipitate was filtered and purified over a flash column using chloroform-ethyl acetate 3:1 as eluant. A further purification from isopropyl ether gave 3-[N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, methyl ester, m.p. 200°-202° C. (0.42 g), which was dissolved in dimethylformamide (20 ml) and treated with 5% aqueous NaOH (3.6 ml) at room temperature for 2 hours. The precipitate, 3-[N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, sodium salt, m.p. >300° C., was filtered and then dissolved in formic acid: the solution was diluted with water to give a precipitate which was filtered and washed with water until neutral. Crystallization from dichloromethane-methanol gave 0.2 g of 3-[N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, m.p. 302°-304° C., NMR (CDCl 3 ) δ ppm.: 3.38 (m) (2H, C- 2 protons), 3.61 (s) (3H, CH 3 ), 4.32 (t) (2H, C-1 protons), 7.14 (dd) (1H, C-7 proton), 7.32 (t) (1H, C-5 benzoyl proton), 7.35-7.85 (m) (7H, C-4 and C-6 benzoyl protons and phenyl protons), 7.88 (bs) (1H, --CH═), 8.00 (bd) (1H, C-5 proton), 8.13 (d) (1H, C-8 proton), 8.15 (bs) (1H, C-2 benzoyl proton).
By proceeding analogously the following compounds were prepared:
N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, NMR (CDCl 3 ) δ p.p.m.: 3.30 (m) (2H, C-2 protons), 3.45 (s) (3H, CH 3 ), 4.28 (t) (2H, C-1 protons), 7.2-7.6 (m) (7H; C-5, C-7 and phenyl protons), 7.85 (t) (1H,═CH--), 8.28 (d) (1H, C-8 proton).
N-ethyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid;
N-benzyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid;
N-methyl-N-(6-benzylidene-11-oxo-6,7,8,9-tetrahydro-11H-pyrido[2,1-b]quinazolin-3-yl)-amino-oxoacetic acid;
N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl-acetic acid;
3-[N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-propanoic acid;
(Z)-3-[N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid;
N-dichloromethyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid;
(Z)-3-[N-dichloromethyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid;
(Z)-3-[N-ethyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid;
(E)-3-[N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid;
2-[N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-propanoic acid; and
(Z)-3-[N-methyl-N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]-quinazolin-6-yl)-aminocarbonyl]-2,3-dichloro-2-propenoic acid.
EXAMPLE 11
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)aminocarbonyl]-benzoic acid (2 g) dissolved in hot dimethylformamide (30 ml) was treated with NaHCO 3 (0.4 g) dissolved in a little water for 30 minutes at room temperature. After dilution with ice water the precipitate was filtered and washed with water to give 1.8 g of 2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, sodium salt, m.p. >300° C.
By proceeding analogously the following compounds were prepared:
cis-2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-1-cyclohex-4-ene-carboxylic acid, sodium salt, m.p. >300° C.;
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, sodium salt, m.p. >300° C.
EXAMPLE 12
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid (1.22 g) was heated in anhydrous methanol (190 ml) containing boron trifluoride etherate (1.58 ml) at reflux temperature for 8 hours. The reaction mixture was concentrated to a small volume in vacuo and the precipitate was filtered and washed with water until neutral to give 1.1 g of (Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, methyl ester, m.p. 233°-235° C.
By proceeding analogously the following compounds were prepared:
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, ethyl ester;
3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-propanoic acid, ethyl ester;
2-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-benzoic acid, ethyl ester; and
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2,3-dichloro-2-propenoic acid, ethyl ester.
EXAMPLE 13
6-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one (2 g) was reacted with 3-piperidino-propionyl chloride, hydrochloride (3.66 g) in dimethylacetamide (120 ml) in the presence of pyridine (2.8 ml) at room temperature for 18 hours. The reaction mixture was then diluted with isopropyl ether (1 l) and the sticky precipitate was dissolved in water.
After neutralization with Na 2 HPO 4 the aqueous solution was extracted with chloroform: evaporation of the organic phase in vacuo to dryness and crystallization from chloroform-methanol gave 1.9 g of 3-benzylidene-6-N-(3-piperidino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 230°-234° C., NMR (CDCl 3 +CF 3 COOD) δ ppm.: 1.68 (m) (6H; C-3, C-4 and C-5 piperidinyl protons), 2.62 (m) (8H; C-2 and C-6 piperidinyl protons and --COCH 2 CH 2 N<), 3.72 (tt) (2H, C-2 protons), 4.22 (t) (C-1 protons), 7.28-7.62 (m) (5H, phenyl protons), 7.62 (dd) (1H, C-7 proton), 7.80 (t) (1H, --CH═), 7.90 (d) (1H, C-5 proton), 8.18 (1H, C-8 proton).
EXAMPLE 14
6-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one (2.3 g) was reacted with chloroacetyl chloride (1.35 g) in dimethylacetamide (100 ml) in the presence of pyridine (1.9 ml) at room temperature for 3 hours.
The reaction mixture was diluted with ice water and the precipitate was filtered and washed with water to give 3-benzylidene-6-N-chloroacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 281°-284° C. dec. (2.4 g), which was reacted with morpholine (0.63 g) in dimethylacetamide (90 ml) in the presence of anhydrous potassium carbonate (1 g) under stirring at 60° C. for 4 hours. After cooling the precipitate was filtered and washed with water: crystallization from acetone-ethanol gave 1.4 g of 3-benzylidene-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 223°-225° C.,
NMR (CDCl 3 ) δ ppm.: 2.70 (m) (4H, C-3 and C-5 morpholinyl protons), 3.23 (s) (2H, --CO--CH 2 --N<), 3.28 (dt) (2H, C-2 protons), 3.82 (m) (4H, C-2 and C-6 morpholinyl protons), 4.25 (t) (2H, C-1 protons), 7.33-7.70) (m) (6H, C-7 proton and phenyl protons), 7.70-7.92 (m) (2H, ═CH-- and C-5 proton) 8.23 (d) (1H, C-8 proton).
By proceeding analogously the following compounds were prepared:
3-benzylidene-6-N-piperidinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-benzylidene-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 252°-254° C.;
3-benzylidene-6-N-[(1-pyrrolidinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 205°-207° C.;
3-benzylidene-6-N-[(1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-benzylidene-6-N-(N',N'-diethylamino-acetyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 191°-193° C.;
3-benzylidene-6-N-(N'-isopropylamino-acetyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-benzylidene-6-N-[(4-ethoxycarbonyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 250°-252° C.;
3-benzylidene-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 241°-244° C.;
3-benzylidene-6-N-[3-(1-pyrrolidinyl)-propanoyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-benzylidene-6-N-[3-(4-methyl-1-piperazinyl)-propanoyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-benzylidene-6-N-[3-(4-ethoxycarbonyl-1-piperazinyl)-propanoyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-benzylidene-6-N-[3-(4-ethyl-1-piperazinyl)-propanoyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-benzylidene-6-N-[3-(1-piperazinyl)-propanoyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one; and
3-benzylidene-6-N-[(4-phenyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one.
EXAMPLE 15
By proceeding according to Example 14, starting from suitable substituted-benzylidene derivatives, the following compounds were prepared:
3-(2-methyl-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-methyl-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-methyl-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2-methoxy-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]-quinazoline-9-one;
3-(3-methoxy-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-methoxy-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-fluoro-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2-chloro-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-chloro-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-chloro-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2-ethoxy-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-ethoxy-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-9-one;
3-(4-ethoxy-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2,3-dimethoxy-benzylidene)-6-N-morpholinoactyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3,4-dichloro-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2,5-dimethoxy-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2-methoxy-3-ethoxy-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2,6-dichloro-benzylidene)-6-N-morpholinoacetyl-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-chloro-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-methyl-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2,6-dichloro-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-methyl-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-chloro-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-methoxy-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-methoxy-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-ethoxy-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-ethoxy-benzylidene)-6-N-(3-morpholino-propanoyl)-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(2-methyl-benzylidene)-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-ethoxy-benzylidene)-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-methyl-benzylidene)-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-chloro-benzylidene)-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(3-methoxy-benzylidene)-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-methoxy-benzylidene)-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
3-(4-ethoxy-benzylidene)-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one; and
3-(2,6-dichloro-benzylidene)-6-N-[(4-methyl-1-piperazinyl)-acetyl]-amino-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one.
EXAMPLE 16
6-N-trifluoroacetyl-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 320°-323° C., (1.8 g) was reacted with ethyl bromoacetate (2,4 g) in dimethylformamide (75 ml) in the presence of anhydrous potassium carbonate (1.95 g) under stirring at room temperature for 25 hours and then at 60° C. for 3 hours. After cooling, dilution with ice water and acidification with acetic acid, the precipitate was filtered and washed with water. Crystallization from CH 2 Cl 2 -methanol gave 6-N-ethoxycarbonylmethyl-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 222°-224° C., (1.2 g), which was dissolved in dimethylformamide (70 ml) and treated with 2N NaOH (7.5 ml) at room temperature for 3 hours. Dilution with acetone gave a precipitate, the N-carboxymethyl-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, sodium salt, m.p.>300° C., which was filtered, dissolved in water and treated with acetic acid. Filtration of the precipitate and purification with acetic acid gave 0.6 g of 6-N-carboxymethyl-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 290°-293° C.
By processing analogously the following compounds were prepared:
6-N-(2-carboxy-ethyl)-amino-3-benzylidene-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
6-N-carboxymethyl-amino-3-(3-methyl-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
6-N-carboxymethyl-amino-3-(3-ethoxy-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
6-N-carboxymethyl-amino-3-(4-methyl-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
6-N-carboxymethyl-amino-3-(4-ethoxy-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
6-N-carboxymethyl-amino-3-(3-methoxy-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
6-N-carboxymethyl-amino-3-(4-methoxy-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one;
6-N-carboxymethyl-amino-3-(2,6-dichloro-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one; and
6-N-carboxymethyl-amino-3-(4-chloro-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one.
EXAMPLE 17
N-(9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, ethyl ester, m.p. 198°-200° C. (1.2 g) was reacted with benzaldehyde (0.84 g) in methanol (20 ml), in the presence of sodium methoxide (0.86 g) under stirring at 60° C. for 6 hours. After cooling the reaction mixture was concentrated in vacuo and diluted with ethyl ether: the precipitate was filtered, washed with ether and dissolved in water. Acidification with acetic acid gave a precipitate which was filtered and washed with water: crystallization from formic acid gave 0.4 g of N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, m.p. 220°-225° C.
EXAMPLE 18
6-nitro-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one (10 g) was reacted with 4-carboxy-benzaldehyde (7.78 g) in methanol (400 ml) in the presence of sodium methoxide (8.2 g) under stirring at 60° C. for 7 hours.
After cooling the precipitate was filtered and washed with methanol then it was dissolved in water. The aqueous solution was acidified with acetic acid and the precipitate was filtered and washed with water: crystallization from dimethylformamide gave 3-(4-carboxy-benzylidene)-6-nitro-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 299° C. dec. (7.6 g), which was suspended in dimethylformamide (1050 ml) and reacted with methyl iodide (6.7 g) in the presence of anhydrous K 2 CO 3 (4.95 g) under stirring at room temperature for 3 hours. The reaction mixture was diluted with ice water and the precipitate was filtered and washed with water until neutral, to give 3-(4-methoxycarbonyl-benzylidene)-6-nitro-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 264°-266° C. (7.8 g), which was reacted with SnCl 2 .2H 2 O (23 g) in acetic acid (275 ml) and 35% HCl (53 ml) under stirring at 60° C. for 2.5 hours: after cooling the precipitate was filtered and washed with 2N HCl and water and finely dispersed in 2N NaOH. The precipitate was filtered and washed with water until neutral to give 6-amino-3-(4-methoxycarbonyl-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 292°-295° C. (5.9 g), which was treated with 35% HCl (120 ml) in acetic acid (240 ml) under stirring at 100° C. for 4 hours. After cooling the precipitate was filtered and washed with acetone to give 6-amino-3-(4-carboxy-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, hydrochloride m.p. 295°-300° C. (5.2 g), which was suspended in water and treated with Na 2 HPO 4 until pH 6: the precipitate was filtered and washed with water to give 6-amino-3-(4-carboxy-benzylidene)-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazoline-9-one, m.p. 336°-339° C., (4.4 g) which was reacted with maleic anhydride (7.8 g) in dimethylacetamide (50 ml) at 100° C. for 6 hours. After cooling and dilution with ice water the precipitate was filtered and washed with water. Crystallization from dimethylformamide-methanol gave 3,2 g of (Z)-3-{N-[3-(4-carboxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2-propenoic acid, N.M.R. (CDCl 3 --CF 3 COOD) δ p.p.m.: 3.63 (m) (2H, C-2 protons), 4.68 (t) (2H, C-1 protons), 6.60 (d) and 6.83 (d) (2H, α- and β-propenoyl protons), 7.65-8.55 (m) (5H, --CH═ and phenyl protons).
By proceeding analogously the following compound was prepared:
(Z)-3-{N-[3-(4-carboxy-benzylidene)-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-aminocarbonyl}-2,3-dichloro-2-propenoic acid.
EXAMPLE 19
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl]-2-propenoic acid (1 g) was dissolved in chloroform (60 ml) and triethylamine (2.3 ml).
To the solution, at -10° C., ethyl chloroformate (1.6 ml) and then 2-(diethylamino)-ethanol (1.5 ml) were added dropwise. The reaction mixture was kept at 0° C. for 3 hours and then at room temperature for 20 hours.
After washing with water the organic solution was evaporated in vacuo to dryness: crystallization of the residue from diisopropyl ether gave 0.6 g of (Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, 2-(diethylamino)-ethyl ester.
By proceeding analogously the following compounds were prepared:
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, 2-(dimethylamino)-ethyl ester;
(E)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, 2-(diethylamino)-ethyl ester;
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2,3-dichloro-2-propenoic acid, 2-(diethylamino)-ethyl ester;
(E)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2-propenoic acid, 2-(dimethylamino)-ethyl ester;
(Z)-3-[N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-aminocarbonyl]-2,3-dichloro-2-propenoic acid, 2-(dimethylamino)-ethyl ester;
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, 2-(diethylamino)-ethyl ester; and
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, 2-(dimethylamino)-ethyl ester.
EXAMPLE 20
Tablets, each weighing 200 mg and containing 100 mg of the active substance were manufactured as follows:
______________________________________Compositions (for 10,000 tablets)______________________________________N--(3-benzylidene-9-oxo-1,2,3,9- 1000 gtetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acidLactose 710 gCorn starch 237.5 gTalc powder 37.5 gMagnesium stearate 15 g______________________________________
N-(3-benzylidene-9-oxo-1,2,3,9-tetrahydro-pyrrolo[2,1-b]quinazolin-6-yl)-amino-oxoacetic acid, lactose and a half of the corn starch were mixed; the mixture was then forced through a sieve of 0.5 mm openings. Corn starch (18 g) was suspended in warm water (180 ml). The resulting paste was used to granulate the powder. The granules were dried, comminuted on a sieve of sieve size 1.4 mm, then the remaining quantity of starch, talc and magnesium stearate was added, carefully mixed and processed into tablets using punches of 8 mm diameter.
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Amino derivatives of benzylidene-Pyrrolo[2,1-b] Quinazolines are provided, together with pharmaceutical compositions containing them. The compounds and the compositions have pharmaceutical utility and are particularly useful as anti allergy agents.
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RELATED APPLICATION
This application claims priority of U.S. Provisional Application No. 60/164,090, filed on Nov. 6, 1999, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method of use for measuring the geometry of a foot in the position the foot will be in when inside of a shoe. More particularly, the present invention relates to an apparatus having a foam impression block specially formed into the shape the target foot wear will have. Moreover, the present invention relates to methods of using such an apparatus for measuring the plantar contour and instep of a foot in the position the foot will be in when inside of a shoe.
2. Description of the Related Art
A number of methods currently exist to measure the geometry of the plantar contour of a foot. The accurate measurement of the plantar contour is used in the manufacture of custom insoles. The prior art methods include plaster casting, optical scanning, contact sensor measurement, as well as foam impression measurement. These methods require the foot to be in a planar position. However, some shoes, such as high heels or other shoes with a slope, distort the plantar contour and instep due to the shifting of the user's body weight. Accordingly, the insoles made using these prior art methods do not account for such distortions. Moreover, these prior art methods are not well suited for home use.
The optical scanning methods and contact sensor measurement methods utilize expensive equipment. These methods provide an accurate and complete measurement of the foot. But, the size, expense and complexity of the equipment necessary for these methods makes them not suitable for use in all locations. Moreover, these methods do not permit accurate measurement of the geometry of the foot in the position it will be in when inside of a shoe.
Plaster casting methods require the measurement to be performed by a person other then the one being measured. This method provides an accurate and complete measurement of the foot but can be very messy and time consuming. Thus, plaster casting methods are not suitable for use in a person's home or by one's self. Moreover, these methods do not permit accurate measurement of the geometry of the foot in the position it will be in when inside of a shoe.
Foam impression measurement methods and apparatus utilize an easily deformable foam block. A person steps onto the block, thus crushing the foam in the locations of higher pressure. In this manner, the foam block deforms in the approximate shape of the persons' plantar contour. While this prior art method may be suitable for home use, it produces a sub-optimal characterization of the foot for a number of reasons. First, the foam block is uniform in thickness from heel to toe. This causes the toes to be forced upward as the foot is pressed into the foam because the toes of the foot have substantially less pressure on them than the region of the foot from the heel to the metatarsal heads. Forcing the toes upward can cause a number of problems including, hyper-extension of the plantar fascia, lowering of the correct arch height, and improper measurement of the forefoot and heel. Second, under full body weight, the foot expands allowing for a larger than normal foot impression. Additionally, the prior art does not provide for measurement of the instep. Moreover, the current foam materials and methods do not permit accurate measurement of the geometry of the foot in the position it will be in when inside of a shoe.
In the manufacture of custom insoles, the use of the plaster casting and foam impression methods also require the use of a scanning system. The scanning system may act directly on the negative impression within the foam or plaster. Scanning systems that act directly on negative impressions are known in the art. These laser scanning systems consist of a laser with a line generating optic. The laser projects a line at a know incident angle onto the negative impression. A camera is used to read the position of the laser line on the negative impression. Alternatively, the scanning system may act on a positive plaster model made from the negative impression within the plaster or foam. Scanning systems that act directly on the positive impressions are also known in the art. One such scanning system, provided by U.S. Pat. No. 4,876,758, specially constructed array of pin-like sensors. In either circumstance, the scanning system is used to digitize the measured contour. The digitized contour is provided to a computer controlled milling machine. The milling machine uses the digitized information to manufacturing a custom insole matching the digitized contour. Accordingly, the apparatus and methods of the present invention provide for cheaper and easier means to provide custom manufactured insoles to a customer.
Accordingly, it is an object of the present invention to provide foot measurement apparatus and methods, which overcome the limitations set forth above.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an apparatus for measuring a plantar contour. The apparatus has a foam impression block, and a carrier having a heel. The block has a toe thickness, a length and a heel thickness. The toe thickness is less than the heel thickness. The block is disposed upon the carrier such that the heel thickness and the heel are adjacent one another.
It is a further object of the present invention to provide an apparatus for measuring a plantar contour and an instep. The apparatus has a foam impression block and a carrier. The carrier has a heel and a plurality of straps. The block has a toe thickness, a length and a heel thickness wherein the toe thickness is less than the heel thickness. The block is disposed upon the carrier such that the heel thickness and the heel are adjacent one another. The plurality of straps are disposed upon the carrier and are adapted to wrap around the instep such that a plurality of sizing graduations disposed upon each of the straps are readable.
It is also an object of the present invention to provide a method for measuring the plantar contour of a foot. The method having the steps of: (1) placing the plantar contour over a foam impression block disposed upon a carrier having a heel wherein the block has a toe thickness, a length and a heel thickness, the toe thickness is less than the heel thickness, and the block is disposed upon the carrier such that the heel thickness and heel are adjacent one another; (2) aligning the toes with the toe thickness; and (3) urging the plantar contour into the block to deform the block.
It is a further object of the present invention to provide a method for measuring the plantar contour and instep of a foot. The method having the steps of: (1) placing the plantar contour over a foam impression block disposed upon a carrier having a heel and a plurality of straps, wherein the block has a toe thickness, a length and a heel thickness, the toe thickness is less than the heel thickness, the block is disposed upon the carrier such that the heel thickness and the heel are adjacent one another, and the plurality of straps are disposed upon the carrier are adapted to wrap around the foot; (2) aligning the toes of the foot with the toe thickness; (3) urging the plantar contour into the block to deform the block; (4) wrapping the straps around the instep such that a plurality of sizing graduations disposed upon each of the straps are readable; and (5) noting the sizing graduation indicated by each of the straps.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side perspective view of a first embodiment of the foam block of the present invention.
FIG. 2 is a rear perspective view of a second embodiment of the foam block of the present invention.
FIG. 3 is a front perspective view of a third embodiment of the foam block of the present invention.
FIG. 3 a is a side view of a foot being placed on an embodiment of the foam block of FIG. 1 .
FIG. 3 b is a side view of a foot being placed on an alternate embodiment of the container of FIG. 2 .
FIG. 3 c is a rear view of a foot being placed on the container of FIG. 3 b.
FIG. 4 is a side perspective view of a foot being placed on the foam block of FIG. 1 .
FIG. 5 is a side perspective view of the foot fully deforming the foam block of FIG. 1 .
FIG. 6 is a side perspective view of the foot being removed from the deformed foam block of FIG. 1 .
FIG. 7 is a rear perspective view of the deformed foam block of FIG. 1 after the foot has been removed.
FIG. 8 is a front perspective view of the deformed foam block of FIG. 2 showing an instep measurement embodiment.
FIG. 9 is a rear perspective view of the foam block of FIG. 2 showing a wedge correction embodiment.
FIG. 10 a is a side view of a first metatarsal support embodiment of the present invention.
FIG. 10 b is a side view of a second metatarsal support embodiment of the present invention.
FIG. 11 a is a rear view of a foot being placed into a dual density embodiment of the present invention.
FIG. 11 b is a side view of the dual density embodiment of FIG. 11 a.
FIG. 12 is a perspective view of the heel guide embodiment of the present invention.
FIG. 13 is a perspective view of the clear embodiment of the container of the present invention.
FIG. 14 is a top view of a scanning mark embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures and more particularly to FIG. 1, a foam impression block is shown and is generally designated by the number 10 . Block 10 is made from pressure sensitive materials, which compress when a person's foot is pressed into the block. Preferably, block 10 comprises a foam casting material having low density, high flexural modulus and low shear strength. Accordingly, block 10 provides a material, which is easily deformed, with little or no memory, and retains the deformed shape indefinitely. Expanded phenolic materials such as those commonly used for insulation and ultra low density expanded polystyrene are suitable for block 10 . In the preferred embodiment, block 10 is expanded phenolic material.
Block 10 has a hardness or density from about 2 to about 25 pounds per square inch (hereinafter“psi”). Selection of the correct foam density depends on factors such as body weight, lifestyle or desired usage (e.g., sport, casual, or formal). For example, a density of about 2 psi is selected for casting a foot in block 10 while in the sitting position, a density of about 5 psi is selected for casting a foot in block 10 while in standing position, and a density of about 10 psi is selected for taking a dynamic casting of a foot in block 10 as described hereinbelow.
Shown in FIG. 1, block 10 has a toe thickness 14 , a heel 16 , a heel thickness 18 , and a length 19 . In one embodiment, toe thickness 14 and heel thickness are the same. In the preferred embodiment, toe thickness 14 , heel thickness 18 and length 19 provide the block with a wedge-like shape. In this embodiment, toe thickness 14 is less than heel thickness 18 , which minimizes any tendency for the toes of a person's foot to lift up while being pressed into block 10 . For instance in a first embodiment, heel thickness 18 is in a range from about 20 mm to about 35 mm and toe thickness 14 is in a range from about 10 mm to about 15 mm. In the preferred embodiment, heel thickness 18 is approximately 35 mm and toe thickness 14 is approximately 10 mm.
Block 10 is disposed upon the top of carrier 21 . Carrier 21 includes a heel 16 disposed on the bottom of the carrier. Heel 16 provides carrier 21 with a shape similar to a woman's shoe 5 . Block 10 is disposed upon carrier 21 such that heel thickness 18 and heel 16 are adjacent to one another.
Heel 16 improves the accuracy of the measurement of a person's foot using block 10 . Heel 16 and carrier 21 by more closely approximating the position and shape a foot assumes when wearing the desired shoe. An alternate embodiment of heel 16 , shown in FIG. 2, the slope of a man's shoe is approximated. In this embodiment, heel 16 and carrier 21 form an integral container 22 . In yet another embodiment of heel 16 , shown in FIG. 3, the slope of a sneaker or tennis shoe is approximated. In this embodiment, heel 16 and carrier 21 form integral container 22 . In yet another embodiment, block 10 is provided with heel 16 having an adjustable height. The height of heel 16 is adjustable from (1) a heel height less than the toe height, providing a negative slope to block 10 ; (2) a heel height equal to the toe height, providing no slope to block 10 ; (3) a heel height more than the toe height, providing a positive slope to block 10 . Preferably, container 22 is shaped so as to approximate the visual appearance of the exterior of a sole of a shoe. Moreover, the inside of container 22 is shaped having side-walls 22 - 1 at about a ninety degree angle with respect to its bottom surface 22 - 2 as shown in FIG. 11 a , or having side-walls 22 - 1 with a radius with respect to its bottom 22 - 2 as shown in FIG. 3 c.
In an alternate embodiment of FIGS. 3 b and 3 c , container 22 includes a vertical guide portion 34 . Portion 34 extends upwardly from container 22 above the level of block 10 . Accordingly, portion 34 aids the user to align the foot with regards to block 10 .
In an alternative embodiment, carrier 21 and/or container 22 act to provide flexure to block 10 . In this embodiment shown in FIG. 3 a , carrier 21 includes a biasing section 23 . Biasing section 23 is positioned between heel 16 and toe portion 17 . Preferably, biasing section 23 is positioned between heel 16 and foot pivot point portion 13 . Biasing section 16 elastically flexes or biases under the weight of the user shown as position 23 - 1 and returns to its original position after use shown as position 23 - 2 . Accordingly, biasing section 23 further improves the accuracy and support of the measurement of a person's foot in a weighted position using block 10 . In another alternate embodiment, the amount of flexure in biasing section 23 is adjustable. The amount of flexure in biasing section 23 is adjustable either along the length of the foot, along the width of the foot, or along a combination of the length and width.
It should be recognized that combinations of heel 16 , carrier 21 and/or biasing section 23 which more closely approximates the position of the foot wearing the shoe is included within the scope of the present invention.
By way of example, the use of block 10 to measure a person's plantar contour is described below with reference to the embodiment of block 10 shown in FIG. 1 . The user positions one foot over block 10 with their toes toward toe thickness 14 and their heel towards heel thickness 18 and moves their foot towards block 10 in the direction shown by arrow A, shown in FIG. 4 . Next, the user applies weight to that foot in the direction shown by arrow A until block 10 is fully deformed, shown in FIG. 5 . The user's foot, with weight applied thereon, will conform to the shape the foot has when wearing a shoe having a heel height substantially equal to the height of heel 16 . Thus, block 10 will deform in the shape the user's foot will assume when wearing the shoe. Next, the user removes that foot from deformed block 10 in the direction shown by arrow B, shown in FIG. 6. A fully deformed block 10 , having the shape of the person's foot will conform to when wearing the shoe, is shown in FIG. 7 .
In an alternative embodiment of the present invention, block 10 has been modified to provide for measurement of the instep or top surface of the foot. This information is often also required to properly fit footwear. A person with a“high instep” would require a shoe that is deeper and may prevent the person from properly fitting into snugger fitting footwear. Further, by knowing the instep of a subject foot and knowing the internal geometry of a particular shoe, it is possible to determine if the shoe will fit properly. This information is vital when manufacturing custom plantar contours. For instance, if it is known via measurement using the present invention that there will be 2 mm of extra space in the shoe, it is possible to tailor the characteristics of the plantar contours to take up this extra space.
A plurality of straps 80 are used to characterize the instep, as shown in FIG. 8 . Each strap 80 has a plurality of graduations 81 on its top surface indicating instep range. Each strap 80 is disposed upon carrier 21 or container 22 and is run over the top of the foot, and the instep range is read off of graduations 81 . As an additional feature, straps 80 secure block 10 to the person's foot such that the person can walk with the block secured to their foot. Thus, straps 80 enable dynamic casting of the foot. The shifting in body weight and the changing of foot size, which occur as a result of walking, will therefore be captured by block 10 . Dynamic casting of the foot requires block 10 to have a density of at least 3 psi.
It is oftentimes desirable to make adjustments to the position of the foot. For instance, it is often desirable to manipulate the angle that the plantar contour of the foot has with respect to the floor to correct for excessive pronation, supination or the like. In this instance block 10 , as shown in FIG. 9, is further provided with a support 30 . Support 30 is insertable between block 10 and support 21 to correct for pronation or supination of the foot or for difference in the length of the leg. Alternately, support 30 is insertable into a slot 31 defined within container 22 . In another embodiment, support 30 is formed within carrier 21 /container 22 . Support 30 further improves the accuracy of the measurement of a person's foot by more closely approximating the position and shape their foot will assume when wearing the desired shoe having a desired level of pronation or supination correction.
In alternate embodiments, support 30 is a metatarsal support under block 10 shown in FIG. 10 a or on block 10 as shown in FIG. 10 b . Support 30 , as a metatarsal support, further improves the accuracy of the measurement of a person's foot by more closely approximating the position and shape their foot will assume when wearing the desired shoe having a desired level of metatarsal support.
In yet another alternate embodiment shown in FIGS. 11 a and 11 b support 30 is provided by the selective use of various density foams within block 10 . In this instance, block 10 includes a region 10 - 1 having a first density and a region 10 - 2 having a second lower density. Region 10 - 1 , being of higher density, ensures that the heel of the user is properly centered within block 10 . Support 30 further improves the accuracy of the measurement of a person's foot by more closely approximating the position and shape their foot will assume when properly centered. For instance, in a preferred embodiment region 10 - 1 has a density of 5 psi and region 10 - 2 has density of 3 psi. In this embodiment, the higher density of region 10 - 1 ensures that the foot is properly centered within the lower density region 10 - 2 .
It should be recognized that support 30 which aids to adjust the foot within block 10 to more closely approximate the correct position of the foot wearing the shoe are included within the scope of the present invention.
It is desirable for container 22 to be used for more than one shoe size. In the embodiments where support 30 is secured within container 22 , the foot must be properly aligned over the support. Thus, a heel guide 44 shown in FIG. 12 is provided. Heel guide 44 enables container 22 to be used for more than one shoe size. Heel guide 44 is adapted to be removably coupled to container 22 in one or more positions such that the guide properly positions the foot of the user within the container. In a preferred embodiment, heel guide 22 includes studs 45 and container 22 includes recesses 46 . Studs 45 are adapted couple with recesses 46 to removably secure heel guide 44 to container 22 . Studs 45 are positioned on guide 22 and recesses 46 are positioned on container 22 so as to approximate the desired range of shoe sizes.
Shown in FIG. 3, a thin compliant medium 85 , such as, but not limited to, terry cloth, is placed on top surface block 10 . The foot is pressed into compliant medium 85 , which in turn compresses block 10 . Compliant medium 85 acts to prevent any of block 10 from adhering to the user's foot.
It is oftentimes desirable to mark specific points on the bottom of foot where problems, such as a metatarsal head, exists. In this instance, it is desirable for container 22 to be of optically clear material as shown in FIG. 13 . Optionally, only a portion of container 22 to be of optically clear material, such as bottom surface 22 - 2 . Preferably, clear container 22 includes a reference grid 60 disposed thereon. Optionally, reference grid 60 is a Harris mat, a pedo bar graph, a grid that relates to computer display software for corrections or the like. Clear container 22 therefor enables the user to remove block 10 from container 22 , to place their foot on reference grid 60 and precisely mark any existing problem spots.
As described above, the plantar contour measured by block 10 is often used in the manufacture of custom insoles. The process of converting the contour on block 10 into the custom insole often times requires using a scanner to digitize the contour directly from block 10 . In this instance, it is desirable for carrier 21 and/or container 22 to include one or more scanning reference marks 33 as seen in FIGS. 12 and 14. Mark 33 assists the optical scanner in the fast and accurate centering of the container and measured plantar contour.
Optionally, container 22 and/or carrier 21 includes mechanisms to secure block 10 therein. For example, in a first embodiment an adhesive is used to secure block 10 within container 22 . In alternate embodiments, indentations 70 (shown in FIG. 10 a ) or slots 71 (shown in FIG. 10 b ) are formed in container 22 . Indentations 70 and/or slots 71 allow removal of block 10 prior to deformation of the block. However, once deformed by the user, block 10 expands into indentations 70 and/or slots 71 to secure the block in container 22 .
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims.
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An apparatus and method for measuring a plantar contour having a foam impression block and a carrier. The apparatus has a foam impression block including a front portion and a rear portion and a carrier including a height adjuster. The block is associated with the carrier such that the rear portion and the height adjuster are adjacent one another.
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BACKGROUND OF THE INVENTION
This invention relates to composite film materials and methods for their preparation. More particularly it relates to composite films and methods of manufacture wherein highly crystalline polymeric materials (e.g., those having a mass crystallinity greater than about 60%) are non-adhesively bonded to polyester film, even though said polymeric materials have heretofore been essentially non-bondable to polyester. As used herein the term "mass crystallinity" means the mass fraction (in percent) of a material that is crystalline (Encyclopedia of Polymer Science and Technology, Vol. 4, pp 472 (1966).
Multilayer composite film structures which employ non-adhesive bonding of their various layers are known. Thus see U.S. Pat. Nos. 3,188,265 and 3,188,266. These patents describe two layer composite film structures having a polyester film layer and a polyethylene film layer. The structures are prepared by laminating the two film layers together heating and then irradiating the laminate with electromagnetic radiation (e.g., ultraviolet light) in the wavelength range of about 1800-4000 angstroms. After irradiation the two layers are self-unified and are not mechanically separable from each other.
U.S. Pat. No. 3,188,266 further discloses that a third layer may be incorporated into the composite structure. The third layer comprises a solid body which has one of its surfaces adherently bonded to the polyethylene layer. The resulting structure can then be employed in an adhesive tape or sheet, a coated abrasive, a coated fabric or other coated or laminated polymer construction.
While the two and three layer constructions disclosed in these patents have proven to be useful in bonding polymers having a mass crystallinity of less than about 60% to polyester, it was discovered that those polymeric materials having a mass crystallinity of more than about 60% (sometimes referred to hereinafter as highly crystalline materials) did not form strong bonds to polyester when bonded by the technique described therein.
Consequently other techniques were employed in order to bond these materials to polyester. These techniques included, for example, either (i) priming the polyester surface or (ii) treating the polyester surface with corona discharge before joining the two materials together. They also included the use of adhesives to bond the materials to each other. However, none of these techniques has proven entirely satisfactory. Often the resulting bond between the materials was not very strong with the result that they frequently delaminated under even minimal stress conditions.
Additionally these techniques required the use of special equipment and/or processing steps. Still further the primers and adhesives often contained solvents which presented environmental, health and safety problems.
Moreover, the utility of certain of these composite film structures was limited. Such structures are often used in food packaging. Thus migrating solvents present in the primers and adhesives were undesirable. If the solvents could be removed from such composite structures, however, then the potential health and safety problems attendant with their use would be eliminated.
Coextrusion techniques have also been employed to bond highly crystalline materials to polyester. In such techniques, the two polymers are coextruded onto each other and the two layer structure then irradiated with ultraviolet light. However, the two layers typically have not adhered well to each other.
THE PRESENT INVENTION
It has now been discovered that highly crystalline polymers can be non-adhesively bonded to polyester to form multilayered composite films. This result is achieved by utilizing an intermediate or first polymeric layer between a polyester support and an outer or second layer of highly crystalline material. The resulting films are resistant to delamination as exemplified by the strength of the interfacial bonds therebetween. That is, the interfacial bond between the support and the first layer is so strong that the two layers require more than about 90 grams per centimeter of width (g/cm width) tensile stress before they are mechanically separable. The interfacial bond between the first layer and the second layer is even stronger. Thus the bond between these two layers cannot be mechanically broken.
The composite films of the invention also eliminate the need for primers, solvents, adhesives and corona discharge preparation techniques. They are easily prepared and eliminate the environmental, health and safety hazards which may be associated with said primers, etc.
The films of the invention also exhibit excellent resistance to greases such as animal, vegetable and mineral oils, and improved resistance to the passage of gasses such as water vapor, oxygen, nitrogen, carbon dioxide, etc. than do the aforementioned prior art composite films.
In accordance with the present invention there is provided a multilayer composite film structure comprising
a support of polyester film;
a first layer on said support, said first layer comprising an organic polymer which is transparent to electromagnetic radiation in the wavelength range of about 1800 to 4000 angstroms and whose skeletal chain substantially comprises saturated carbon-to-carbon linkages and has a mass crystallinity of less than about 60%, and wherein when said support and said first layer are placed in face-to-face contact with each other, heated and irradiated with said electromagnetic radiation, said support and said first layer form an interfacial bond to each other which has bond strength of at least about 90 g/cm width; and
a second layer on said first layer, said second layer comprising an organic polymer which is transparent to said electromagnetic radiation and has a mass crystallinity of greater than about 60%; and wherein when said first and second layers are placed in face-to-face contact with each other and heated, said first and second layers form an interfacial bond to each other which is so strong that said layers cannot be mechanically separated from one another.
Also provided herein is a novel method of preparing the composite film structures of the invention.
The composite film structures of the present invention are particularly useful as packaging materials especially those which undergo processing at elevated temperatures (e.g., greater than 100° C.) and/or elevated pressures (e.g., greater than 1 atmosphere). Such materials include packages for foods (e.g., frozen vegetables, etc.) and medical instruments. Additionally the film structures of the present invention are permanently heat sealable to various materials including, for example, high density (i.e., ρ greater than about 0.94 g/cm 3 ) polyethylene.
BRIEF DESCRIPTION OF THE DRAWING
The invention is described in more detail hereinafter with reference to the accompanying drawings wherein like reference characters refer to the same parts throughout the several views and in which:
FIG. 1 shows a side view of one embodiment of the composite film structure of the invention; and
FIG. 2 shows a modification of the composite film structure of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring now specifically to FIG. 1, the multilayered composite film structure 10 comprises a polyester support 12, a first layer 14 and a second layer 16. The first layer 14 is in intimate face-to-face contact with both support 12 and second layer 16 and forms strong interfacial bonds with each.
The support 12 comprises a polyester film. Preferably said film is biaxially oriented and heat-set and is at least about 10 microns thick most preferably it comprises poly(ethylene terephthalate). However, other polyesters such as poly(1,4-cyclohexylenedimethylene terephthalate) and poly(ethylene naphthalate), may make up the support 12.
The material used in support 12 may be prepared from the reaction of the appropriate dicarboxylic acid with ethylene glycol. Alternatively the acid may be converted to the ester and then allowed to react with the glycol by ester interchange. Generally, the amount of glycol employed is in excess to the stoichiometric amount required to react with acid. Minor amounts (e.g., up to 10 mole percent) of other dicarboxylic acids such as isophthalic, phthalic, 2,5-or 2,7-naphthalenedicarboxylic, succinic, sebacic, adipic, azelaic, suberic, pimelic, glutaric, etc., or a diester thereof may be substituted for the acid without deleteriously affecting the properties of the resultant polyester. Additionally, minor amounts (e.g., up to 10 mole percent) of other glycols such as 1,3-propanediol, 1,4-butanediol etc. may be substituted for the ethylene glycol.
The thickness of support 12 is not critical to the present invention. However, preferably support 12 is at least about 0.00125 cm thick.
First layer 14 comprises an organic polymer whose skeletal chain substantially comprises saturated carbon-to-carbon linkages. Additionally, this organic polymer is not highly crystylline (i.e., it has a mass crystallinity of less than about 60%) and is transparent to electromagnetic radiation in the wavelength range of about 1800 to 4000 angstroms. Preferably the polymer is branched although a linear polymer is also useful. It is also preferred that the polymer used in layer 14 contain a maximum of about 0.01 percent by weight antioxidant and slip agent.
Preferably the organic polymer used in layer 14 is selected from the group consisting of polyethylene; copolymers of ethylene and (i) acrylic acid, (ii) ethyl acrylate and (iii) vinyl acetate; and terpolymers of ethylene, methacrylic acid and vinyl acetate.
Particularly preferred materials for use as layer 14 are the low density (i.e., ρ of less than about 0.925 g/cm 3 ) and medium density (i.e., ρ in range of about 0.925 to 0.94 g/cm 3 ) polyethylenes. A specific example of one useful low density polyethylene is Union Carbide Corporation type DFD 3300 polyethylene. A specific example of one useful medium density polyethylene is Gulf Chemical Company type 2604M polyethylene.
Other representative examples of materials useful as layer 14 are the copolymers of ethylene and acrylic acid such as type 2735.12 commercially available from the Dow Chemical Company; metal salt copolymers of ethylene and acrylic acid such as "Surlyn-A" commercially available from the E. I. duPont de Nemours and Company; and terpolymers of ethylene, methacrylic acid and vinyl acetate such as the "Elvax" acid terpolymer resins commercially available from E. I. duPont de Nemours and Company.
The thickness of layer 14 is not critical to the present invention. Typically the thickness of said layer is in the range of about 0.00125 to 0.005 cm thick. Preferably the thickness of said layer is in the range of about 0.00125 to 0.0025 cm thick. Most preferably the thickness of said layer is about 0.0025 cm thick.
Layer 16 of the composite film structure of the invention comprises a highly crystalline polymeric material. This material has a mass crystallinity of at least about 60% and is transparent to electromagnetic radiation in the wavelength range of about 1800 to 4000 Angstroms.
Preferably the materials employed in layers 14 and 16 are mutually compatible and exhibit a similar melt index. Thus, it is preferred that the materials of these two layers have a melt index in the range of about 2 to 5 g/10 min. Moreover, it is preferred that these materials each be extrusion coatable.
A particularly useful material for use in layer 16 is high density polyethylene (i.e., ρ of at least about 0.94 g/cm 3 ). These polyethylenes do not form strong interfacial bonds to polyester when bonded thereto by prior art techniques. Representative examples of commercially available high density polyethylenes include types 5320.03 and 5320.12 polyethylene available from the Dow Chemical Company and types DPD 7070, DMDJ 7006 and DMDJ 7904 polyethylene available from the Union Carbide Corporation.
The thickness of layer 16 is not critical to the present invention. Typically the thickness of said layer is in the range of 0.00125 to 0.0075 cm. Preferably the thickness of said layer is in the range of about 0.00125 to 0.0025 cm. Most preferably the thickness of said layer is about 0.0025 cm.
The composite films of the invention may be prepared by a number of techniques. Thus, for example, one may (i) coextrude layer 16 with layer 14 and then coextrude the combination onto support 12 (ii) heat the composite structure for about 10 seconds at to about 130° C. and (iii) irradiate interfacial area 13 with electromagnetic radiation (e.g., ultraviolet light) in the wavelength range of about 1800 to 4000 angstroms. Irradiation of interfacial area 13 is accomplished by irradiating composite 10 through layers 14 and 16. The irradiation and heating steps are of an intensity and for a time sufficient to provide an interfacial bond strength between support 12 and layer 14 of at least about 90 g/cm or width. The other interfacial bond (i.e., that between layer 14 and layer 16), on the other hand, is so strong that layers 14 and 16 cannot thereafter be mechanically separated.
The length of time which the composite must be irradiated is dependent upon the light source utilized and distance that the composite is from said source. One particularly useful set of irradiation conditions comprise irradiating the composite for about 10 seconds at a distance of from 3 to 5 centimeters from a model G25T8, 25 watt germicidal ultra-violet light commercially available from the General Electric Company. The process for irradiation with ultraviolet light is described in more detail in U.S. Pat. No. 3,188,266 at column 5, lines 1 to 60, incorporated herein by reference.
Other methods of preparing the composite are also useful. Thus the layer 14 can be applied to support 12 (e.g., by extrusion, coextrusion or solvent coating techniques) and this structure heated and irradiated as described above. Layer 16 may then be applied to layer 14 and heated as described above. Still other methods of preparation are possible as will be apparent from this disclosure.
The multilayer composite film structure of the present invention may be employed as such, or alternatively, it may be further modified. Thus, referring specifically to FIG. 2, there is shown a modification of multilayer composite structure 10 wherein another layer 14 has been applied to the opposite side of support 12. The interfacial area of the other layer 14 and support 12 has been exposed to heat and electromagnetic radiation as described above. The resulting four layered structure is then laminated to a metalized polyester comprising a layer 20 of aluminum and a layer 22 of poly(ethylene terephthalate) to produce a six layered finished product.
The present invention is further exemplified by the following examples wherein the stated melt indices of the polymers were determined according to ASTM D1238.
EXAMPLES 1-5
Composite film structures according to the present invention were prepared by coextrusion techniques. Each composite structure consisted of, in order, a support of biaxially oriented and heat-set poly(ethylene terephthalate) (0.0013 cm thick), a 0.0025 cm thick first layer of a low density (ρ=0.918 g/cm 3 ) polyethylene having a mass crystallinity less than about 60% and being commercially available from the Union Carbide Corporation as DFD 3300 (melt index of 3.5 g/10 min) and a 0.00635 cm thick second layer of high density polyethylene having a mass crystallinity of more than about 60%. The resulting film structures were heated to about 130° C. and exposed to electromagnetic radiation in the wavelength range of from about 1800 to 4000 angstroms for about 10 seconds. A Model G25T8, 25 watt germicidal ultraviolet light commercially available from the General Electric Company was used for the irradiation. It was located about 4 centimeters from the composite film structure.
The strength of (i) the interfacial bond between the support and the first layer (i.e., the first interfacial bond) and (ii) the interfacial bond between the first layer and the second layer (i.e., the second interfacial bond) of the resulting composites was determined. The test for determining the bond strength involved immersing about 1.25 cm of one end of each sample into an aqueous solution of NH 4 OH (58% by weight) for 24 hours at about 20° C. This caused the first interfacial bond to separate in the immersed area but did not affect the second interfacial bond (e.g., there was no separation of this bond). The second interfacial bond could not be mechanically separated.
The tensile strength of the first interfacial bond was then determined on an Instron tensile tester Model TM available from the Instron Corporation of Canton, Massachussetts. A 2.5 cm wide by 15 cm long specimen was cut from each of the composite films to be tested. The portion of the support which had separated from the first layer was inserted into one of the jaws of the tester and the portion of the first layer plus second layer which had separated from the support was inserted into the other jaw of the tester. The jaws were then pulled away from each other at a speed of 12.5 cm/min and the maximum force necessary to separate the bond recorded. The results of these tests together with the materials (and some of their characteristics) used as the second layer are set forth in Table 1. In each case the interfacial bond strength of the bond between the first layer and the support had a value of greater than about 90 g/cm width.
TABLE 1__________________________________________________________________________ FIRST INTERFACIAL SECOND LAYER SECOND INTERFACIAL BOND STRENGTH MANUFACTURER DENSITY MELT INDEX BOND STRENGTHEXAMPLE (g/cm width) & TYPE (g/cm.sup.3) (g/10 min) (g/cm width)__________________________________________________________________________1 142 Dow Chemical 0.954 8.0 Mechanically Company inseparable Type 5320.032 134 Union Carbide 0.962 6.0 Mechanically Corporation Type inseparable DMDJ 70063 143 Union Carbide 0.942 -- Mechanically Corporation inseparable Type DPD 70704 116 Union Carbide 0.953 4.0 Mechanically Corporation inseparable Type DMDJ 79045 134 Dow Chemical 0.950 12.0 Mechanically Company inseparable Type 5320.12__________________________________________________________________________
EXAMPLES 6-9
Composite film structures according to the present invention were prepared as described in Examples 1-5. In Examples 6 and 7 the first layer comprised a medium density polyethylene (ρ=0.934 g/cm 3 , melt index of 1.0 g/10 min.) having a mass crystallinity of less than about 60% and being commercially available from the Gulf Chemical Company as type 2604 M. In Examples 8 and 9 the first polymeric material was a copolymer of ethylene and acrylic (ρ=0.938 g/cm 3 , melt index of 5.5 g/10 min) and having a mass crystallinity of less than about 60% and being commercially available from the Dow Chemical Company as type 2375.12. In all cases the second layer comprised a high density polyethylene having a mass crystallinity of more than about 60%.
The strength of the two interfacial bonds was determined according to the procedure set forth in Examples 1-5. The results of these tests together with the materials (and some of their characteristics) used as the second layer are set forth in Table 2.
TABLE 2__________________________________________________________________________ FIRST INTERFACIAL SECOND LAYER SECOND INTERFACIAL BOND STRENGTH MANUFACTURER DENSITY MELT INDEX BOND STRENGTHEXAMPLE (g/cm width) & TYPE (g/cm.sup.3) (g/10 min) (g/m width)__________________________________________________________________________6 125 Dow Chemical 0.954 8.0 Mechanically Company Inseparable Type 5320.037 89-107 Union Carbide 0.953 4.0 Mechanically Corporation Inseparable Type DMDJ 79048 169 Union Carbide 0.953 4.0 Mechanically Corporation Inseparable Type DMDJ 79049 107 Dow Chemical 0.950 12.0 Mechanically Company Inseparable Type 5320.12__________________________________________________________________________
EXAMPLES 10-13
The following examples demonstrate the inability of high density polyethylene to form a strong interfacial bond to polyester when no first layer is employed therebetween. In these examples, film structures were prepared by extrusion coating a layer (0.0089 cm thick) of high density polyethylene having a degree of crystallinity greater than about 60% onto a support layer (0.0013 cm thick) of biaxially oriented and heat-set poly(ethylene terephthalate). The resulting film structures were heated to 130° C. and exposed to electromagnetic radiation in the wavelength range of from about 1800 to 4000 angstroms as described in Examples 1-9.
The strength of the interfacial bond between the layer of high density polyethylene and the support of poly(ethylene terephthalate) was determined as described in Examples 1-9. The results of these tests together with the nature of the high density polyethylene (and some of their properties) used are set forth in Table 3. In each case the tensile strength of the bond between the high density polyethylene layer and the poly(ethylene terephthalate) support had a value of less than about 90 g/cm of width. Moreover each of these bonds readily delaminated at the interfacial bond when subjected to the test.
TABLE 3______________________________________ MeltInterfacial Bond IndexStrength Manufacturer Density (g/10)Ex. (g/cm width) & Type (g/cm.sup.3) min)______________________________________10 17.9 Dow Chemical 0.954 8 Company Type 5320.0311 10.7 Union Carbide 0.942 -- Corporation Type DPD 707012 17.9 Union Carbide 0.953 4 Corporation Type DMDJ 790413 71.4 Dow Chemical 0.950 12 Company Type 5320.12______________________________________
EXAMPLES 14-15
The following examples illustrate the improved resistance of the composite films of the invention to moisture vapor transmission and oxygen transmission. Composite film structures were prepared as described in Examples 1-9. In Example 14 the composite film structure comprised a 0.0013 cm thick support of poly(ethylene terephthalate), a 0.004 cm thick first layer of medium density polyethylene (type 2604M, ρ of 0.934 g/cm 3 , 1.0 g/10 min melt index, commercially available from Gulf Chemical Company), and a 0.0017 cm thick second layer of high density polyethylene (ρ of 0.954 g/cm 3 , 8.0 g/10 min melt index, commercially available from the Dow Chemical Company). This was an example of the invention.
In Example 15 the composite film structure comprised a 0.0013 cm thick support of poly(ethylene terephthalate) and a 0.0019 cm thick layer of medium density polyethylene (Gulf type 2604M). This was an example of a prior art composite film. The results of the tests are given in Table 4.
As can be seen the composite films of the invention are more resistant to the passage of water vapor and oxygen.
TABLE 4______________________________________ Moisture Vapor Transmission Oxygen TransmissionExample (g/m.sup.2 /24 hour) (cc/m.sup.2 /24 hour atm)______________________________________14 4.8 8.115 6.2 11.2______________________________________
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A multilayer composite film structure comprising (i) a support of polyester film, (ii) a first layer of organic polymer having a mass crystallinity of less than about 60%, and (iii) a second layer of organic polymer having a mass crystallinity of greater than about 60% is provided. A method for non-adhesively bonding normally non-bondable polymeric materials to polyester is also provided.
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FIELD OF THE INVENTION
The present invention is directed to probe structures for testing of electrical interconnections to integrated circuit devices and other electronic components and particularly to testing of integrated circuit devices with rigid interconnection pads and multi-chip module packages with high density interconnection pads.
BACKGROUND OF THE INVENTION
Integrated circuit (IC) devices and other electronic components are normally tested to verify the electrical function of the device and certain devices require high temperature burn-in testing to accelerate early life failures of these devices. Wafer probing is typically done on a single chip site at temperatures ranging from 25° C.-125° C. while burn-in is typically done on diced and packaged chips at temperatures ranging from 80° C. to 150° C. Wafer probing and IC chip burn-in at elevated temperatures of up to 200° C. has several advantages and is becoming increasingly important in the semiconductor industry. Simultaneous testing of multiple chips on a single wafer has obvious advantages for reducing costs and increasing production throughput and is a logical step towards testing and burn-in of an entire wafer.
The various types of interconnection methods used to test these devices include permanent, semi-permanent, and temporary attachment techniques. The permanent and semi-permanent techniques that are typically used include soldering and wire bonding to provide a connection from the IC device to a substrate with fan out wiring or a metal lead frame package. The temporary attachment techniques include rigid and flexible probes that are used to connect the IC device to a substrate with fan out wiring or directly to the test equipment.
The permanent attachment techniques used for testing integrated circuit devices such as wire bonding to a lead frame of a plastic leaded chip carrier are typically used for devices that have low number of interconnections and the plastic leaded chip carrier package is relatively inexpensive. The device is tested through the wire bonds and leads of the plastic leaded chip carrier and plugged into a test socket. If the integrated circuit device is defective, the device and the plastic leaded chip carrier are discarded.
The semi-permanent attachment techniques used for testing integrated circuit devices such as solder ball attachment to a ceramic or plastic pin grid array package are typically used for devices that have high number of interconnections and the pin grid array package is relatively expensive. The device is tested through the solder balls and the internal fan out wiring and pins of the pin grid array package that is plugged into a test socket. If the integrated circuit device is defective, the device can be removed from the pin grid array package by heating the solder balls to their melting point. The processing cost of heating and removing the chip is offset by the cost saving of reusing the pin grid array package.
The most cost effective techniques for testing and burn-in of integrated circuit devices provide a direct interconnection between the pads on the device to a probe sockets that is directly connected to the test equipment. Contemporary probes for testing integrated circuits are expensive to fabricate and are easily damaged. The individual probes are typically attached to a ring shaped printed circuit board and support cantilevered metal wires extending towards the center of the opening in the circuit board. Each probe wire must be aligned to a contact location on the integrated circuit device to be tested. The probe wires are generally fragile and easily deformed or damaged. This type of probe fixture is typically used for testing integrated circuit devices that have contacts along the perimeter of the device. This type of probe is also much larger than the IC device that is being tested and the use of this type of probe for high temperature testing is limited by the probe structure and material set.
Another technique used for testing IC devices comprises a thin flex circuit with metal bumps and fan out wiring. The bumps are typically formed by photo lithographic processes and provide a raised contact for the probe assembly. The bumps are used to contact the flat or recessed aluminum bond pads on the IC device. An elastomer pad is typically used between the back of the flex circuit and a pressure plate or rigid circuit board to provide compliance for the probe interface. This type of probe is limited to flexible film substrate materials that typically have one or two wiring layers.
High density probes used for wafer probing are typically very expensive due to the complexity of the substrate or space transformer and the process used for attaching and aligning the probes to the substrate. During the useful life of a probe fixture, it is likely to be damaged due to handling or worn from normal use. In order to avoid the expense of replacing the entire test fixture (substrate and probe contacts), it is desirable to be able to repair, rework, or replace the damaged or worn probes without replacing the entire substrate.
PRIOR ART
The prior art described below includes a several different probe fixtures for testing bare IC chips.
Rework and repair techniques exist for cantilever probes that are used to test low density I/O circuit devices. The rework and repair techniques include manual reforming and repositioning the cantilever probes as well as removing and replacing individual cantilever probes attached to the test card. The rework and repair techniques are the same manual processes used to fabricate the original cantilever probe card.
Flex circuit test probe structures are also limited to testing low density I/O circuit devices and are relatively inexpensive. The flex probe interposer is usually discarded and replaced when they are worn out or become damaged.
Cobra probes are a type of compliant interposer probe that have been used to test IC devices in IBM for many years. Cobra probes have primarily been used to test IC devices with C4 solder ball connection but can be modified to test IC devices with wire bond pads. The Cobra probes are made from a Paleney 7 alloy and are housed in a machined Vespal housing. Cobra probes can be reworked and repaired as a separate operation since the probes are not attached to a test card or fanout substrate. The rework operations that are typical for a cobra probe assembly include refinishing the contact surface of the probes to remove contamination along with disassembling and replacing damaged probes.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a means of repairing, reworking, or replacing damaged probes that are formed using a “flying lead” wire bonding process and used for testing integrated circuit devices and other electronic components.
Another object of the present invention is to provide a means of repairing, reworking, or replacing damaged probes with the same column and row spacing as the original probes.
A further object of the present invention is to provide a means of repairing, reworking, or replacing damaged probes with the same wire geometry as the original probes.
An additional object of the present invention is to provide a means of repairing, reworking, or replacing damaged probes with the same probe height as the original probes.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features, and advantages of the present invention will become apparent upon further consideration of the following detailed description of the invention when read in conjunction with the drawing figures, in which:
FIG. 1 shows a cross-section of an array of probes mounted on a substrate with a damaged tip on one of the probes.
FIG. 2 shows a cross-section of the array of probes mounted on a substrate with the surface layer alignment mask and spacer removed.
FIG. 3 shows a cross-section of an array of probes mounted on a substrate with the wires removed from two ball bonds.
FIG. 4 shows a cross-section of an array of probes mounted on a substrate with two new wires bonded on top of the reworked ball bonds.
FIG. 5 shows a cross-section of an array of probes mounted on a substrate with the surface layer alignment mask and spacer replaced over the ends of the probes.
FIG. 6 shows a cross-section of an alternate embodiment of an array of probes mounted on a substrate with a damaged probe.
FIG. 7 shows a cross-section of an alternate embodiment of an array of probes mounted on a substrate with the wires removed from two ball bonds.
FIG. 8 shows a cross-section of an alternate embodiment of an array of probes mounted on a substrate with two new wires bonded on top of the reworked ball bonds.
FIG. 9 shows a cross-section of an alternate embodiment of an array of probes mounted on a substrate with new tips attached to the ends of the new probe wires.
FIG. 10 shows a cross-section of an array of probes that have all been reworked.
FIG. 11 shows a cross-section of an array of plated probes with a section of probes that have been reworked and replated.
DETAILED DESCRIPTION OF THE INVENTION
Preferred Embodiment
FIG. 1 shows a cross section of an array of probes ( 10 ) mounted on a substrate ( 11 ) with a damaged tip ( 19 ) on one of the probes. The array of probes ( 10 ) is comprised of a plurality of curved wires ( 15 ), a surface layer alignment mask ( 21 ), and a rigid spacer ( 20 ). The plurality of curved wires ( 15 ) are attached to circuit traces ( 13 ) on a first surface ( 12 ) of the substrate ( 11 ) with ball bonds ( 14 ) formed with a modified thermosonic wire bonding process. The surface layer alignment mask ( 21 ) has a plurality of holes ( 22 ) corresponding with the plurality of curved wires ( 15 ). The ends ( 16 ) of the plurality of curved wires ( 15 ) protrude through the holes ( 22 ) in the surface layer alignment mask ( 21 ). The rigid spacer ( 20 ) surrounds the plurality of curved wires ( 15 ) and supports the surface layer alignment mask ( 21 ). The substrate ( 11 ) provides a means of fanning out the wiring from the contacts ( 13 ) on the first surface ( 12 ) to the equipment used to electrically test the integrated circuit device. The fan out substrate can be made from various materials and constructions including single and multi-layer ceramic with thick or thin film wiring, silicon wafer with thin film wiring, or epoxy glass laminate construction with high density copper wiring. The contacts ( 13 ) are usually flush with or slightly raised above the first surface ( 12 ) of the substrate ( 11 ). A damaged probe is shown in FIG. 1 with the tip of the probe ( 19 ) bent over. The damaged tip ( 19 ) prevents the probe from making contact the circuit pad on an integrated circuit device when the probe array ( 10 ) is used for testing.
FIG. 2 shows a cross section of the array of probes ( 10 ) mounted on a substrate ( 11 ) with the surface layer alignment mask ( 21 ) and rigid spacer ( 20 ) removed. In order to remove the surface layer alignment mask ( 21 ), the damaged tip ( 19 ) on the probe must be straightened or removed ( 18 ) with a pair of tweezers. The surface layer alignment mask ( 21 ) provides a means of controlling the true position of the ends ( 16 ) of the plurality of curved wires ( 15 ).
FIG. 3 shows a cross section of an array of probes ( 10 ) mounted on a substrate ( 11 ) with the curved wires ( 15 ) removed from two ball bonds ( 30 ). Since the geometry of the curved wires ( 15 ) has the tip of the probe offset from the ball bond at the base of the wire, it is necessary to remove the adjacent probe or probes that overlap with the damaged probe. If the damaged probe is in the center of a large array of probes, all of the adjacent wires in the same row as the damaged probe will need to be removed in order to repair the damaged probe. The probe wires are typically removed by pulling on the wire until it fractures at the base of the wire, above the ball bond ( 30 ).
FIG. 4 shows a cross section of an array of probes mounted on a substrate ( 11 ) with two new wires ( 33 ) bonded on top of the reworked ball bonds ( 31 ). The new wire ( 33 ) is attached to the reworked ball bond ( 31 ) by the same “flying lead” ball bonding process used to attach the original set of curved wires ( 15 ) to the substrate ( 11 ). The ball bond ( 32 ) of the new wire ( 33 ) is attached to the top of the reworked ball bond ( 31 ) and the curved wire geometry is formed identical to the original set of curved wires ( 15 ). The height of the tip ( 35 ) is the same as the height of the tip ( 17 ) of the original curved wires ( 15 ) and the spacing from wire to wire is the same for all of the curved wires ( 15 , 33 ).
FIG. 5 shows a cross section of an array of probes mounted on a substrate ( 11 ) with the surface layer alignment mask ( 21 ) and spacer ( 20 ) replaced over the ends ( 17 , 35 ) of the probes. The surface layer alignment mask ( 21 ) and spacer ( 20 ) are placed over the reworked array of curved wires ( 15 , 31 ) using the same technique used on the original set of probes. The plurality of holes ( 22 ) in the surface layer alignment mask ( 21 ) are aligned with the plurality of curved wires ( 15 , 31 ) and gently lowered to rest on the spacer ( 20 ). Once the surface layer alignment mask ( 21 ) is in place an aligned, it is securely attached to the spacer ( 20 ) and the substrate ( 11 ) and the rework process is completed.
An Alternate Preferred Embodiment
FIG. 6 shows a cross section of an alternate embodiment of an array of probes ( 50 ) mounted on a substrate ( 51 ) with a damaged probe wire ( 59 ). The array of probes ( 50 ) is comprised of a plurality of curved wires ( 55 ) with hardened tips ( 57 ) attached to the ends of the curved wires ( 55 ). The plurality of curved wires ( 55 ) are attached to circuit traces ( 53 ) on a first surface ( 52 ) of the substrate ( 51 ) with ball bonds ( 54 ) formed with a modified thermosonic wire bonding process. The plurality of probe wires ( 55 ) are formed with a curved section in between the ball bond ( 54 ) and the straight end ( 56 ) to provide a compliant, elastic structure. The substrate ( 51 ) provides a means of fanning out the wiring from the contacts ( 53 ) on the first surface ( 52 ) to the equipment used to electrically test the integrated circuit device. The damaged to the probe ( 59 ) shown in FIG. 6 prevents the probe from making contact the circuit pad on an integrated circuit device when the probe array ( 50 ) is used for testing.
FIG. 7 shows a cross section of an alternate embodiment of an array of probes ( 50 ) mounted on a substrate ( 51 ) with the curved wires ( 55 ) removed from two ball bonds ( 60 ). Due to the close spacing of the curved wires ( 55 ), it is necessary to remove the adjacent probe or probes in order to provide room for the wire bonding tool to bond new probe wires. The damaged probe wire ( 59 ) is typically removed by pulling on the wire until it fractures at the base of the wire, above the ball bond ( 60 ).
FIG. 8 shows a cross section of an alternate embodiment of an array of probes ( 50 ) mounted on a substrate ( 51 ) with two new wires ( 63 ) bonded on top of the reworked ball bonds ( 61 ). The new wire ( 63 ) is attached to the reworked ball bond ( 61 ) by the same “flying lead” ball bonding process used to attach the original set of curved wires ( 55 ) to the substrate ( 51 ). The ball bond ( 62 ) of the new wire ( 63 ) is attached to the top of the reworked ball bond ( 61 ) and the curved wire geometry is formed identical to the original set of curved wires ( 55 ).
FIG. 9 shows a cross section of an alternate embodiment of an array of probes ( 70 ) mounted on a substrate ( 51 ) with new tips ( 65 ) attached to the ends ( 64 ) of the new probe wires ( 63 ). The new tips ( 65 ) are attached to the ends ( 64 ) of the new probe wires ( 63 ) with a process that ensures the height of the new tips ( 65 ) are the same as the height of the tips ( 57 ) of the original probes ( 50 ) and the spacing from wire to wire is the same for all of the curved wires ( 55 , 63 ).
FIG. 10 shows a cross section of an array of probes ( 80 ) that have all been reworked. While it is desireable to repair, relace, or rework only the probes that have been damaged on a test fixture, it is somtimes easier to repair all of the probes on a test susbtrate if multiple probes have been damaged. The process used to repair all of the probes on a substrate is the same as the process used to selectively replace only the damaged probes as described in the previous figures. After the wires have been removed the remaining ball bonds can be flattened by a mechanical means or polished to uniform height to prepair for the next wirebonding process.
FIG. 11 shows a cross section of an array of plated probes ( 90 ) with a section of probes that have been reworked and replated. FIG. 11 is similar to FIG. 5 with the addition of plating ( 36 ) on the probe wires ( 33 ). The probe wires ( 33 ) are plated ( 36 ) after removal of the damaged probe wires and new probe wires ( 33 ) are bonded to the flattened ball bonds ( 31 ). After the repaired probe wires ( 33 ) are plated ( 36 ), the surface layer alignment mask ( 21 ) and spacer ( 20 ) replaced over the ends ( 17 , 35 ) of the probes.
While we have described our preferred embodiments of our invention, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first disclosed.
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Method for repairing, reworking or replacing damaged probes that are formed using a flying lead wire bonding process used for testing integrated circuit devices and other electronic devices, with the same column and row spacing as the original probes and using the same height as the original probes.
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FIELD OF THE INVENTION
This invention relates generally to lightwave communication systems and, more particularly, to techniques for controlling the power level of an optical signal so that harm from the optical signal emanating at a downstream fault in an optical fiber path is substantially reduced.
BACKGROUND OF THE INVENTION
Retinal and other types of eye injury can occur from inadvertent direct exposure to the optical signals used in present communication systems. Danger is presented by the power and the wavelength of such signals. Generally, these systems operate with signals having relatively high power concentrated in a tiny beam located outside the visible region.
Recent developments in optical networking have only heightened existing safety concerns. For example, optical amplifiers and other optical components are now being developed to drive optical signals to even higher output power levels. Multi-wavelength systems are also a concern because the total optical power in the optical fiber is the sum of the powers of the individual wavelength components. Consequently, optical systems having total output power of 20 dBm or more are now being realized as a result of advances in optical amplifier and multi-wavelength optical networking technologies.
Because the extent of injury is most likely proportional to the total output power and the time of exposure, it is necessary to quickly shut off or reduce the output power of a network element in the event of a fiber cut, removed connector, or any other discontinuity in the optical path. In prior arrangements, control of upstream elements relies entirely upon downstream elements nearer to the fault. For example, downstream network elements perform fault detection and localization by monitoring the degradation or interruption of the forward propagating signal, i.e., the signal propagating downstream. If such a degradation or interruption is detected, the network control and management system then communicates the necessary supervisory signals to switch off the upstream network element. This scheme is limited in several ways. First, the scheme will only work for faults that occur between the upstream and downstream elements. Secondly, this scheme will fail if, by virtue of the system failure, the downstream element cannot communicate with the upstream element, e.g., if the supervisory channel is lost as a result of the discontinuity in the optical path. Even if this scheme works, there are other issues of added cost and complexity for such control and the possibility of delay in effecting control.
SUMMARY OF THE INVENTION
Automatic reduction of optical signal power supplied by an upstream network element by a prescribed amount is achieved without the use of downstream control elements by using reflected optical signal power that is generated within the optical fiber path as a result of a downstream fiber cut, open connector, or other potentially hazardous discontinuity. Upon capturing and processing the reflected optical signal power at an upstream position in the optical fiber path, the optical signal power supplied by the upstream network element is automatically reduced. The optical signal power may either be reduced by an amount that is a function of the measured reflected optical signal power or may be completely shut off until the faulty condition is resolved. By using reflected optical signal power within the optical transmission path, the present invention does not require any additional signaling from downstream network elements or from the network control and management system and avoids delay.
In one illustrative embodiment, control circuitry is located at an upstream position to capture and process the reflected optical signal that is generated as a result of the downstream fault. The control circuitry may be coupled to a network element, such as a fiber optical amplifier, to control the output power level of the network element in response to the downstream fault. More specifically, the control circuitry generates a control signal and supplies this control signal to the network element to reduce the output power level of the network element accordingly. Alternatively, upon processing the reflected optical signal, the control circuitry may be used to introduce a predetermined amount of loss into the optical fiber to reduce the optical signal power below harmful levels. The control circuitry may be analog, digital, or may be implemented using a microprocessor under software or firmware program control.
BRIEF DESCRIPTION OF THE DRAWING
A more complete understanding of the present invention may be obtained from consideration of the following detailed description of the invention in conjunction with the drawing, with like elements referenced with like references, in which:
FIG. 1 shows a simplified block diagram of one illustrative lightwave communication system embodying the principles of the present invention;
FIG. 2 shows a simplified block diagram of an illustrative fiber optical amplifier arrangement embodying the principles of the present invention;
FIG. 3 shows a variation of the embodiment depicted in FIG. 2 useful for achieving complete power reduction;
FIG. 4 shows a simplified block diagram of another illustrative fiber optical amplifier arrangement embodying the principles of the present invention; and
FIG. 5 shows a variation of the embodiment shown in FIG. 4 useful for achieving complete power reduction.
DETAILED DESCRIPTION OF THE INVENTION
Although the principles of the invention are particularly applicable to controlling the optical signal power supplied by a fiber optical amplifier, and shall be described in this context, those skilled in the art will understand from the teachings herein that the principles of the invention are also applicable to many other optical components including, but not limited to, semiconductor optical amplifiers, optical transmitters (e.g., laser sources), add/drop multiplexers, cross-connects, or any element that supplies or propagates optical signals along an optical fiber.
FIG. 1 shows a typical lightwave communication system that includes an optical transmitter 101 , a network element 105 , and an optical receiver 104 . In this example, network element 105 includes several optical components, such as multiple stages of optical amplifiers 102 and an add/drop multiplexer 103 . In general, network element 105 could be any type of simple or complex arrangement of components. Network element 105 supplies an optical signal having a certain output power level onto optical fiber 115 . The optical signal could either be a multi-wavelength optical signal or a single wavelength optical signal. As shown, downstream cut 110 in optical fiber 115 results in a reflection of an optical signal back towards network element 105 , wherein the reflected optical signal has a power level P R .
According to one embodiment of the invention, control element 120 , which is located at an upstream position, captures and processes the reflected optical signal generated within optical fiber 115 as a result of downstream fault 110 . Upon processing the reflected optical signal, control element 120 generates and supplies the appropriate control signal to control the output power of final stage optical amplifier 102 B. In particular, control element 120 may be used to control the pump power being supplied to optical amplifier 102 B which, in effect, shuts off or reduces to a safe level the output power of optical amplifier 102 B. In effect, the optical signal power supplied by optical amplifier 102 B is automatically controlled at an upstream position relative to downstream fault 110 .
According to another embodiment illustrated in FIG. 1, the optical signal power may be controlled independent of the particular network element supplying the optical signal. More specifically, upon processing the reflected optical signal, control element 120 introduces a predetermined amount of loss in the fiber path at the upstream position in order to reduce the power level of the optical signal emanating from the fiber cut 110 . This may be accomplished by switching in a lossy element based on the power level P R of the reflected optical signal. For example, a fiber optic switch could switch the optical signal through a lossy medium, such as an unpumped erbium-doped fiber segment, once the reflected optical signal power exceeds a prescribed threshold. Those skilled in the art will recognize that other techniques may be employed according to the principles of the invention to reduce optical signal power by, for example, introducing the appropriate amount of loss into optical fiber 115 .
FIG. 2 shows an illustrative embodiment of the present invention used for controlling the output power level of optical signals from an optical amplifier. More specifically, amplifying element 201 disposed along optical fiber path 202 receives an optical signal and supplies an amplified optical signal downstream along optical fiber path 202 . For uniformity and ease of understanding in the following description, amplifying element 201 is contemplated to be a rare earth-doped optical fiber, such as an erbium-doped fiber (EDF segment). However, it is also contemplated that other suitable rare earth elements may be used, such as praseodymium, neodymium, and the like.
In order to provide an amplifying effect, EDF segment 201 is “pumped” with luminous energy using conventional techniques known in the art. As shown in FIG. 2, EDF segment 201 is optically pumped by pump sources 210 , which can be semiconductor laser pump assemblies, such as laser diode pumps or any other suitable pump sources well known in the art. The luminous energy generated by pump sources 210 , also referred to as pump light, has a shorter wavelength than any of the wavelengths in the optical signal (i.e., signal light). Optical couplers 212 are used to couple the pump light emitted by pump sources 210 to optical fiber path 202 . The use of optical couplers 212 for this purpose is also well-known to those skilled in the art.
It should also be noted that although pump sources 210 are shown in a hybrid bi-directional pump arrangement, other known pump arrangements can also be used without departing from the spirit and scope of the present invention. For example, EDF segment 201 may be pumped using a co-propagating pump configuration (forward pumping) or, alternatively, using a counter-propagating pump configuration (backward pumping), both of which are well-known in the art. For additional background on these pumping arrangements, see U.S. Pat. No. 5,218,608, Optical Fiber Amplifier, issued to Aoki and herein incorporated by reference.
As shown, an optical isolator 215 can also be included, if desired, prior to EDF segment 201 . This optional optical isolator 215 can be advantageously used to protect against the undesirable backscattering or back reflection of optical signals which may cause damage to upstream components (e.g., lasers) or which may adversely affect the operation of the upstream components.
Importantly, a directional optical transfer device 220 is disposed along optical fiber path 202 and coupled on the output side of EDF segment 201 . Directional optical transfer device 220 can be any suitable device for capturing and transferring optical energy in a directional manner, such as a multi-port optical circulator, a passive optical coupler, and the like. For the embodiments shown in FIGS. 2 and 3, directional optical transfer device 220 will be referred to as optical circulator 220 . As shown, optical circulator 220 includes an input port 221 for receiving the amplified optical signal from EDF segment 201 , an output port 222 for supplying the amplified optical signal along downstream optical fiber path 202 , and a monitor port 223 .
In operation, pump sources 210 optically pump EDF segment 201 , which in turn supplies the amplified optical signal as an output. The amplified signal exits EDF segment 201 and enters input port 221 of optical circulator 220 . Using a clockwise directional transfer implementation as an example configuration, optical circulator 220 circulates the amplified optical signal or signals via output port 222 onto downstream optical fiber path 202 . In a typical scenario, a fiber cut, open connector, or other discontinuity problem (referred hereinafter as downstream fault 210 ) occurs along optical fiber path 202 at a point downstream from EDF segment 201 . Downstream fault 210 would cause a reflection of the optical signal having a power level P R back towards output port 222 of optical circulator 220 .
Upon entering output port 222 , the reflected optical signal would exit from optical circulator 220 via monitor port 223 . Photodetector 230 is coupled to monitor port 223 to receive the reflected signal. Photodetector 230 could be any suitable means known to those skilled in the art (e.g., photodiode) for detecting optical energy and converting the optical signal to an electrical signal. The electrical signal from photodetector 230 is processed through a reflected power monitor 231 which relates the photocurrent of photodetector 230 to the power level of the reflected optical signal in its electrical form. Suitable circuitry for reflected power monitor 231 is also well-known.
Control circuitry is coupled between reflected power monitor 231 and pump sources 210 to provide the necessary control of the optical signal power supplied by EDF segment 201 . Control circuitry may comprise analog electrical circuitry, such as inverting amplifier 235 , which is used to generate an output signal having a voltage level that is inversely related to that of the reflected optical signal. The output signal from inverting amplifier 235 is then provided to pump controller/driver 211 which adjusts the bias circuitry of pump sources 210 in order to achieve a desired output level of EDF segment 201 . More specifically, in the presence of downstream fault 210 occurring in optical fiber path 202 , inverting amplifier 235 generates the inverted voltage signal of the reflected optical signal and pump controller/driver 211 , in response to the output from inverting amplifier 235 , effects the necessary reduction in pump power supplied by pump sources 210 to EDF segment 201 .
By using the analog control circuitry described above, the present invention can be used to control the pump power of EDF segment 201 in a continuous and revertive mode without the need for a manual or controller-based reset capability. It should be noted that the analog circuitry shown and described herein is intended to represent just one possible implementation. As such, other known components may be used without departing from the spirit and scope of the present invention.
An additional monitoring tap 240 can be coupled to optical fiber path 202 to support a forward signal monitoring function, typically referred to as performance monitoring. The use of passive optical couplers as monitoring taps is well-known. In general, optical amplifiers sometimes include an optical tap on the output side for tapping off a fraction of the amplified signal in order to monitor the performance of the optical amplifier (e.g., performance monitoring based on output power) as well as the integrity of the outgoing signal (e.g., power level, signal to noise ratio, wavelength, etc.). By way of example, the optical tap can be a passive optical coupler which taps off a fraction, e.g., 1%-10%, of the output signal. Monitoring tap 240 includes a first port for receiving the amplified signal, a second port for coupling a portion of the amplified signal to downstream optical fiber path 202 , and a third port coupled to pump controller/driver 211 via photodetector 241 for tapping a fraction of the incoming amplified signal from the first port for performance monitoring as described above.
A network control and management system is normally used in lightwave communication systems to carry out specified control and management functions. As previously described, prior art systems utilize the network control and management system as an integral part of the scheme for controlling the output power of fiber optical amplifiers. In particular, prior art systems utilize supervisory and/or maintenance signals generated through the network control and management system to control the pump power of upstream elements in response to downstream faults. By contrast, the present invention uses the reflected optical power of the optical signal within the transmission path itself to effect the necessary control of output power from EDF segment 201 . Accordingly, the embodiments of the present invention do not rely on supervisory signals from network control and management system 250 as do the prior systems. More specifically, optical signal power supplied by EDF segment 201 is adjusted automatically in accordance with the principles of the present invention without signaling from downstream elements via network control and management system 250 . Network control and management system 250 is shown in FIG. 2 (dotted lines) only to illustrate the coupling that may exist for carrying out the other normal control and management functions of the system.
According to the principles of the invention, a variable power reduction capability can be provided that corresponds to the amount of reflected optical signal power generated as a result of a discontinuity in the downstream fiber path. As is well-known, the power level of the reflected optical signal will vary as a function of the proximity of the discontinuity in optical fiber path 202 to EDF segment 201 . For example, a fiber cut in close proximity to EDF segment 201 will result in a higher reflected power level and thus would require a proportionally higher reduction of pump power from pump sources 202 . Accordingly, the present invention can be used to maintain safe output power levels in order to comply with applicable technical and safety standards and, most importantly, to protect maintenance personnel from injury.
As compared with prior art arrangements, another apparent and significant advantage of the previously described embodiments is the absence of an optical isolator coupled on the output side of EDF segment 201 . For example, an optical isolator is not required at the output side of EDF segment 201 in the embodiment shown in FIG. 2 because optical circulator 220 itself protects against any backscattering effects from the reflected optical signal. In particular, the reflected power entering output port 222 is circulated to monitor port 223 and not to original input port 221 . Consequently, optical circulator 220 provides an inherent isolator function without the need for additional components.
FIG. 3 shows another embodiment of the present invention which may be advantageously used when it is desirable to implement a complete shutdown of optical signal power supplied by EDF segment 201 . Because the embodiment shown in FIG. 3 is a variation of the embodiment depicted in FIG. 2, the description of the relationships and functions for like elements having like reference numerals in FIG. 2 apply equally to those in FIG. 3 and will not be re-stated here for reasons of brevity. In particular, the variation depicted in FIG. 3 relates to the control circuitry coupled between reflected power monitor 231 and pump controller/driver 211 that provides the necessary control of the optical signal power supplied by EDF segment 201 . Here, the control circuitry comprises discrete logic elements, namely comparator 335 and flip-flop device 336 .
In operation, the power level of the reflected optical signal is measured in reflected power monitor 231 , as previously described, and provided as a first input to comparator 335 . Comparator 335 compares the power level of the reflected optical signal with a predetermined reference value supplied as a second input to comparator 335 . When the reflected optical signal power exceeds the reference level, comparator 335 generates an appropriate output to flip-flop 336 . In response, flip-flop 336 generates an appropriate output signal to disable pump sources 210 via pump controller/driver 211 , effectively shutting down EDF segment 201 . This arrangement is not automatically revertive in that the system would have to be reset manually or by a controller after the discontinuity in the fiber path is repaired or otherwise removed.
It should be noted that the digital circuitry shown and described herein is intended to represent just one possible implementation for the digital control circuitry. As such, other suitable digital circuitry can be used without departing from the spirit and scope of the present invention. For example, a set-reset (S-R) flip-flop is shown, but other conventional logic elements may be equally effective in carrying out the desired function. Additionally, those skilled in the art will understand from the teachings herein that other alternatives are available to provide the pump power control functions performed by the revertive analog circuitry depicted in FIG. 2 or the discrete shutoff logic in FIG. 3 . By way of example, the analog functions of inverting amplifier 235 or the discrete functions of comparator 335 and flip-flop 336 may be carried out by microprocessors and associated software or firmware control.
FIGS. 4 and 5 illustrate other embodiments of the present invention in which optical circulator 220 from FIGS. 2 and 3 has been replaced with passive optical coupler 420 . Because the embodiments shown in FIGS. 4 and 5 are variations of the embodiments depicted in FIGS. 2 and 3, respectively, the description of the relationships and functions for like elements in FIGS. 2 and 3 apply equally to those in FIGS. 4 and 5 and will not be re-stated here for reasons of brevity.
As shown in FIG. 4, four-port passive optical coupler 420 is disposed along optical fiber path 202 at a point downstream from EDF segment 201 . It should be noted that passive optical coupler 420 may be implemented using any of a number of conventional fiber coupler devices known to those skilled in the art. As an example, passive optical coupler 420 can be the same type of optical coupler device used for monitoring tap 240 (FIGS. 2, 3 ). The basic principles of operation of optical coupler 420 are the same as those previously described for monitoring tap 240 (FIGS. 2, 3 ), except that optical coupler 420 uses four ports instead of three ports. Using conventional optical coupler devices, it is well-known that the modification to use four ports instead of three has minimal impact with regard to cost or optical loss.
As shown, the first three ports of optical coupler 420 are coupled in a similar manner as that previously described for monitoring tap 240 in FIGS. 2 and 3. Namely, a first port 421 is used for receiving the amplified optical signal from EDF segment 201 , a second port 422 is used for coupling a major portion of the amplified signal to downstream optical fiber path 202 , and a third port 423 is coupled to pump controller/driver 211 via photodetector 241 to tap a fraction of the incoming amplified signal from the first port for performance monitoring in the same way as that previously described for the embodiments shown in FIGS. 2 and 3. Additionally, a fourth port 424 of optical coupler 420 is coupled to photodetector 230 which is further coupled to reflected power monitor 231 as in the FIGS. 2 and 3.
In contrast to optical circulator 220 (FIGS. 2 and 3 ), optical coupler 420 is a passive device and, as a result, optical isolator 425 may be needed to prevent any undesirable backscattering or back reflection of optical energy. The remaining elements shown in FIGS. 4 and 5 are the same as those described for the previous embodiments. Because only a fraction of the reflected optical signal power is tapped off at port 424 , the amount of reflected optical signal power measured by reflected power monitor 231 will typically be less in this embodiment than that reflected through optical circulator 220 (FIGS. 2 and 3) since optical circulator 220 circulates substantially all the reflected optical energy to reflected power monitor 231 . Additionally, if the fiber cut is located at a greater distance downstream from EDF segment 201 , the reflected optical energy could be even less. As such, more sensitive monitoring may be required in this embodiment.
FIG. 5 represents a combination of the embodiments shown in FIGS. 3 and 4, wherein passive optical coupler 420 is used in place of optical circulator 220 as previously described in FIG. 4, and comparator 335 and flip-flop 336 are used in place of inverting amplifier 235 as previously described in FIG. 3 .
It will be understood that particular embodiments described above are only illustrative of the principles of the present invention, and that various modifications could be made by those skilled in the art without departing from the spirit and scope of the present invention. For example, although optical circulators and passive optical couplers were described in the above embodiments, those skilled in the art will recognize that other suitable components or circuitry may be used for capturing and transferring the reflected optical energy generated from a downstream fiber fault. Similarly, the particular implementation of the control circuitry for processing the reflected optical energy can be modified without departing from the principles of the present invention.
As previously described, the principles of the present invention may also be advantageously used to control optical signal power supplied by other optical components even though the above embodiments were described only in the context of fiber optical amplifiers. For example, the present invention can be used to control the output power levels of semiconductor optical amplifiers by controlling the electrical current that is supplied to “pump” the semiconductor device. The present invention can also be used to reduce or shut off power from sources and transmitters (e.g., in a transmit terminal) in response to downstream faults in a fiber path. Accordingly, the scope of the present invention is limited only by the claims that follow.
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Automatic reduction of optical signal power supplied by an upstream network element by a prescribed amount is achieved by capturing and processing reflected optical energy that is generated within the optical fiber path as a result of a downstream fiber cut, open connector, or other potentially hazardous discontinuity. Generally, the power level of the reflected optical signal is detected and measured in the optical fiber path and the optical signal power supplied by the upstream network element is automatically reduced. The optical signal power may either be reduced by an amount corresponding to the measured reflected optical signal power or may be completely shut off until the faulty condition is resolved. In one illustrative embodiment, an apparatus for automatically reducing or shutting off the optical signal power supplied by an upstream network element includes a directional optical transfer device disposed along the optical fiber path and coupled to the output of a network element, an optical power monitor for measuring the reflected optical energy received via the directional optical coupler as a result of a downstream fiber discontinuity, and control circuitry coupled between the power monitor and the network element to control the optical signal power being supplied by the network element based on the monitored power level of the reflected optical signal. The control circuitry may be analog, digital, or may be implemented using a microprocessor operating under software or firmware program control.
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BACKGROUND
[0001] (1) Field of the Invention
[0002] Relating to improvements in knives and lights, and more particularly relates to the combination of lights and knives that improve the visual perception for the user.
[0003] (2) Description of the Related Art
[0004] US Patent Citations: U.S. Pat. No. 4,751,621 granted to Jenkins teaches a light knife that helps a user to see at night. More particularly Jenkins has a knife provided with a light in its handle portion, with the light being actuated by a compression or threaded movement of a cap attached to an end of the handle. In a separate embodiment, the light may be actuated by a threaded movement of the handle end itself, while a protective cap may be positioned over the handle end and its associated light lens.
[0005] What Jenkins fails to teach, however, is how to use the knife part of his invention to cut an item and simultaneously using the light. Because the light is attached to the handle portion of his light knife it is impossible to view what you are using the knife on. Rather, the light is treated as a separate accessory to be used separately from the knife itself. Thus, an outdoorsman using the knife in the wilderness at night is forced to cut a piece of wood, prepare an animal or otherwise employ the knife in total darkness. This has the unfortunate side effects of precipitating injuries, badly cut meat from captured game or badly cut wood that would not serve for any specific use beyond firewood. There needs to be a solution to overcome the deficiency found in Jenkins.
BRIEF SUMMARY OF THE INVENTION
[0006] A lighted knife device has a knife blade connected to a handle and a lighting device forwardly directed to a cutting end of the knife blade, situated in a side of the handle, and proximate to the portion of the knife blade as it exits the handle. The lighting device is further situated to a side of the knife blade and there is a second lighting device forwardly directed to a cutting end of the knife blade, situated in an opposite side of the handle and proximate to the portion of the knife blade as it exits the handle. This second lighting device is further situated to an opposite side of the knife blade such that a second lighting device is forwardly directed to a cutting end of the knife blade, situated in an opposite side of the handle and proximate to the portion of the knife blade as it exits the handle. This second lighting device is further situated to an opposite side of the knife blade. The lighting device is made of a first plurality of lighting devices arranged in the handle following the height of the blade from its lengthwise cutting edge to its opposite face on top of the blade. There is also a second plurality of lighting devices arranged in the handle following the height of the blade from its lengthwise cutting edge to its opposite face on top of the blade such that the second plurality of lighting devices are arranged on the opposite side of the handle. In one embodiment, the first plurality of lighting devices are arranged at differing angles when measured from an axis extending longitudinally down a length of the blade and following a blade height such that the lighting devices light up an area underneath a blade cutting edge from a forward portion of the blade to the back of the blade near the handle thereby preventing shadows under the blade. The second plurality of lighting devices are arranged at differing angles when measured from an axis extending longitudinally down a length of the blade and following a blade height such that the second bank of lighting devices light up an area underneath a blade cutting edge from a forward portion of the blade to the back of the blade near the handle thereby preventing shadows under the blade. In another embodiment, the first plurality of lighting devices are arranged at a same angle when measured from an axis extending longitudinally down a length of the blade and following a blade height but also each lighting device of the first plurality of lighting device also arranged at a different angle when measured from an axis extending longitudinally down the length of the blade and following a blade thickness such that the lighting devices light up an area perpendicular to the blade wide flat surface on one side of the blade such that the surface underneath a blade cutting edge is lit up in a perpendicular fashion from one side of the blade. This other embodiment also has the second plurality of lighting devices are arranged at a same angle when measured from an axis extending longitudinally down a length of the blade and following a blade height but also each lighting device of the second bank of lighting devices also arranged at a different angle when measured from an axis extending longitudinally down the length of the blade and following a blade thickness such that the lighting devices light up an area perpendicular to the blade wide flat surface on another side of the blade such that the surface underneath a blade cutting edge is lit up in a perpendicular fashion from another side of the blade. Other features that should be appreciated that there is an energy storage device situated inside of a cavity within the handle and in physical contact with a tang portion of the knife blade. There is also a toggle switch in direct physical contact with the energy storage device and connected to each of the lighting devices of the banks of lighting devices through an internal switch. Finally, the device is arranged such that the tang portion of the blade is connected to each of the lighting devices of the banks of lighting devices.
[0007] A lighted knife device has a handle defining a cavity a knife blade including an extending portion having a sharpened edge, and an integral tang portion received within the cavity of the knife handle an energy storage device situated in the cavity of the knife handle and in physical contact with a tang portion of the knife blade a lighting device forwardly directed to a cutting end of the knife blade, situated in a side of the handle, and proximate to the portion of the knife blade as it exits the handle such that the tang portion of the knife blade is connected to the lighting device. Also, there is a switch that is connected to the lighting device and to the opposite pole of the energy storage device. It should be understood that the lighting device in an embodiment comprises a bank of lighting devices. Finally, the device has another bank of lighting devices forwardly directed to a cutting end of the knife blade, situated in another side of the handle, and proximate to the portion of the knife blade as it exits the handle such that the tang portion of the knife blade is connected to the lighting device.
[0008] A lighted knife device has a knife blade connected to a handle and a lighting device forwardly directed to a cutting end of the knife blade, situated in a side of the handle, and proximate to the portion of the knife blade as it exits the handle and a second lighting device forwardly directed to a cutting end of the knife blade, situated in an opposite side of the handle, and proximate to the portion of the knife blade as it exits the handle such that shadowing is prevented underneath the blade.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] FIG. 1 illustrates a side view and cross-sectional side view of an embodiment of an improved lighted knife device.
[0010] FIG. 2 illustrates a cross-sectional close-up of the effect of various light emitting diode (LED) dispositions according to embodiments of an improved lighted knife device.
[0011] FIG. 3 illustrates a head-on view of an embodiment of a lighted knife device device showing the effect of a spread or splaying pattern for the LEDs.
[0012] FIG. 4 illustrates a top cross-sectional view of an embodiment of the lighted knife device showing the internal components and how they interrelate to effect the lighting effect.
DETAILED DESCRIPTION OF THE INVENTION
[0013] FIG. 1 illustrates a side view and cross-sectional side view of an embodiment of a lighted knife device. FIG. 1 a shows a side view of the main components of the knife flashlight of the instant embodiment having a blade 100 , a handle 110 made from two complementary handle portions, a push button toggle switch 120 and external fins 130 having light emitting diodes (LEDs) situated therein. The blade 100 is made from any suitable man made material such as stainless steel, titanium, laminates and more; the handle 110 is made from suitable manmade materials such as wood, plastics, stainless steel, aluminum, polyphthalamide that is optionally reinforced with kevlar or fiberglass or more. The toggle switch is screw in ON-OFF type switch that opens or closes a circuit and is custom made directly with external markings fitting the environment and style where the knife is to be used. Finally, there are three external fins on each side of the handle to make a total of six fins; these are located just behind the external portion of the blade closest to the handle on either handle piece. These fins 130 are molded or cut as part of the handle and are hollowed out to permit the insertion and securing of light emitting diodes LEDs therein.
[0014] FIG. 1 b illustrates a cross-sectional side view of an embodiment of a knife flashlight device; more particularly, it shows one of the complementary portions of the handle 110 from FIG. 1 a that are held along with its complement by screws, pins, adhesives or similar connecting mechanisms as well as the contents therein. The handle 110 that is formed by two complementary portions has a longitudinal hollow 190 for the insertion of various components to be described herein. The blade 100 described previously extends inwards through a hollow portion 190 of the handle 110 so that this portion or ‘tang’ 180 if you prefer extends inwards and is in direct physical contact with the positive terminal of battery 170 that is similarly situated in hollow portion 190 but on the other side of inwardly directed protrusions. It should be noted that these inward protrusions separate the battery 170 and tang 180 so that the tang 180 and the rest of the blade 100 do not slide backwards into the handle further than it should. Of course there is sufficient clearance in between the protrusions to permit the entry of the positive terminal of the battery 170 and thereby facilitate contact with tang 180 . Battery 170 is a typical ‘AA’ battery that and any different DC source is substituted based upon the needs of the implementation; i.e., ‘AAA’, a set of disk batteries connected appropriately etcetera.
[0015] To make the current flow in the circuit using battery 170 , toggle switch 120 has male terminals 160 representing the output terminals of the switch that are in physical contact with the negative terminals of the battery 170 . When the button 120 is switched between OFF to ON then the electrical connection internal to the Toggle switch 120 is activated permitting current to flow out of the two terminals 160 as will be described with reference to FIG. 4 . The toggle switch 120 also has threads 150 that correspond with grooves so as to permit the screwing of the switch 120 into the handle 110 once the two complementary portions of the handle 110 have been permanently connected. In this fashion, the toggle switch 120 can be unscrewed and a fresh battery replace an old one once the old one has been de-energized.
[0016] FIG. 2 illustrates a cross-sectional close-up of the effect of various light emitting diode (LED) dispositions according to embodiments of a lighted knife device. More particularly FIG. 2 a shows a portion of the handle 200 is shown have a triple bank of LEDs at the forward section of the handle 200 . Once light is switched on in the circuit, the current flows and the LEDs light up. A set of three LEDs 210 , 220 , 230 are shown in FIG. 2 a and have a corresponding set of LEDs attached similarly on the other complementary side of the handle 200 . In FIG. 2 a each of the LEDs are disposed at a slightly different angle such that the top LED 210 is at a smaller angle to the horizontal then the next LED 220 and then the LED 220 is at a smaller angle to the horizontal than the next LED 230 . The effect of this configuration is to permit the spreading of the light directly underneath the blade 240 as shown in the figure having a coverage from the front of the blade to the back of the blade or at least a portion of this region.
[0017] FIG. 2 b shows a configuration of LEDs that spreads the light underneath the blade 240 but in a straight line. This is made possible by using the same angle to the horizontal on each LED but using a different angle on each LED to the surface of the LED plane. The light spreads out maximally at approximately a point that would be the most important cutting point and falls off further away from that zone forwards or backwards of that zone as seen from the top view in the FIG. 2 b . Each of the LEDs is situated within fins that spread outside of the complementary handle portions and have two inwardly directed circular protrusions 250 for each individual set of LEDs. These two circular protrusions (one is part of the internal structure of the fin and prevents the LED from falling out forwards) help anchor the LED in place since one is of such a size that it does not permit the LED to move backwards and the other prevents forwards motion as it is too small to permit the head or neck ledge to slide outwards under ordinary usage. Of course, in the event that sufficient pressure or force is applied the LED can be forced out since the protrusions are pliable enough to permit a user to replace the LED but not so that they can disengage the LED during ordinary usage. Alternatively, instead of the dual circular protrusions the LEDs are held in place by the forward protrusion that is integral with the internal structure of the fins and the grasping of the legs of each side with finely leg-threaded protrusions that extend from each inner side, adhesive or similar types of attachments.
[0018] FIG. 3 illustrates a head-on view of an embodiment of a lighted knife device showing the effect of a spread or splaying pattern for the LEDs. Two triple banks of LEDs are situated in the fins described previously in the forward section of two handle portions 300 that have been assembled with the intervening blade as shown. A splayed coverage area is shown directly underneath the blade such that a line of coverage extends perpendicularly to the blade from one side under the blade and perpendicularly onto the other side of the blade. The bottom LED on each side is angled slightly more than the one above it away from the blade and the next one up is slightly more angled than the topmost LED. In this fashion a perpendicular zone of light coverage spreads out directly underneath the blade. The coverage of the lights from the topmost LEDs has been illustrated combined at the most useful cutting point under the blade other spreads are possible whereby the two light rays combine edge to edge directly underneath the blade rather than being totally in unison or even a partial unison of two light coverage rays or zones.
[0019] FIG. 4 illustrates a top cross-sectional view 400 of an embodiment of lighted knife device showing the internal components and how they interrelate to effect the lighting effect. A metal wire or insulated lead 410 is welded to a leg of the LED on each side of the complementary handles. This lead or wire is held in place by protrusions 440 and 450 on either side of the complementary handle portions. These protrusions are tiny cylinders through which a lead may be threaded. Alternatively, a large protrusion covers the wire or lead longitudinally down the entire necessary length to effect the physical contact with the energizing components. The connector, wire, or lead 410 is connected on its opposite end to terminals 470 of the toggle switch such that when the switch is turned ON then electricity will flow through the male prongs of the switch and if turned OFF then no electricity will flow through the male prongs of the switch.
[0020] The other end of the LEDS are connected to the tang 430 of the blade at weld points 480 . Thus, electricity flows from the battery through an ON switch male prongs through the switch terminals 470 , through one LED, through the tang and back down the other terminal of the battery. The same happens on the other LED situated in the complementary handle portion. Additionally, it should be appreciated that the wiring scheme applies to the other four LEDs of the two complementary banks of LEDs. Finally, there is a set if protrusions 460 that extend from the inner surface of the complementary handles that help hold the blade stationary and do not permit it to dance inside the handle complements. It should be understood that the blade is held in place by notches therein. These notches have a holding mechanism with tongues or protrusions that extend from within the internal structure of the complementary handle portions.
[0021] Finally, while there has been shown and described the preferred embodiment of the instant invention it is to be appreciated that the invention may be embodied otherwise than is herein specifically shown and described and that, within said embodiment, certain changes may be made in the form without departing from the underlying ideas or principles of this invention as set forth in the Claims appended herewith.
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A lighted knife device has a knife blade, handle and a lighting device in a side of the handle and also there is a second lighting device arranged in mirror fashion. The first and second plurality of lighting devices are arranged at differing angles to light up an area underneath a blade edge. Alternatively, the first and second plurality of lighting devices are arranged at a same angle but also at a different angle such that the surface underneath a blade edge is lit up in a perpendicular fashion from sides of the blade. An energy storage device situated inside of a cavity within the handle contacting a tang blade portion. There is also a toggle switch contacting the energy device and the lighting devices of the banks of lighting devices through an internal switch of the toggle switch. The blade tang connected to each of the lighting devices.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefits of the Disclosure Ser.#536671 filed Aug. 18, 2003. This application is entitled to the benefits of Provisional Patent Application Ser.#60/500301 filed Sept. 5, 2003. This invention uses the transmission of my co-pending application, Disclosure Ser.#541450 filed Nov. 6, 2003.
[0002] Compound Post Union Frame for the purpose of having a means to securely fasten elongated objects together to form a single post.
STATEMENT REGARDING FEDERALLY SPONSORED RESEACH OR DEVELOPMENT
[0003] NOT APPLICABLE
SEQUENCE LISTING
[0004] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0005] The present invention relates to construction of a frame 28 to join two or more post, pipe, rods or similar items 46 C into a super strong durable post 80 . The Frame 28 makes it easy to attach items to the Frame and exposes individual post 46 C for easy attachment of items to them. This Compound Post 80 can be used in the place of any post of any material for enclosure fences, building support post, power poles, light support, observation towers, barricades, and antenna.
[0006] Compound Post 80 will have many possible uses and variants to describe even the ones already mention would be extensive. Descriptions, design, use and installation describe here will be for enclosure, exclusion fences. Fence T-post 46 C will represent all of the elongated items possible for use in horizontal or vertical positions.
[0007] The present invention relates to fence post construction 80 , and more particularly to a T-post 46 C fencing unit. Another aspect of the present invention is a lateral bracing arrangement or assemblage that may be used for a comer fence assembly utilizing at least two T-post 46 C fencing units described herein. The present invention further relates to a method for forming a braced fencing arrangement, a rail fence assembly, a puzzle method, and a post extender method.
[0008] Fencing patents have been numerous for over a 100 years proving that a need for improved fencing is important. The T-post 46 C and barbwire have became the predominate choice. The T-post 46 C alone is lacking in strength and stability for building a long life fence. The compound post 80 presented here has strength in all directions and is easily braced in all directions if so desired. The Compound Post 80 is very serviceable when made of readily available T-post 46 C. I have personal experience of T-post 46 C still in use after 50 years. Wooden post and even steel pipe rarely last this long, and both may contain hazards material.
[0009] U.S. Pat. No. 6,536,745 issued to Roark, Harold Dean on Mar. 25, 2003 relates the fencing problems very well. It has a post and brace design that does brace in the line of the fence. This Compound Post 80 does not retain the weak points of a single T-post the way his patent does. The Compound Post 80 has a untied strength in all directions and has fewer and less expensive parts, it is more securely lock together for long term use and abuse.
[0010] U.S. Pat. No. 0,066,995A1 issued to Collins,Charles R. on Apr. 10, 2003 is like all previous designs, braced in the line of fences, weak to ninety degree pressure, complicated to build and assemble. The Compound Post 80 has the strength of multiple T-post 46 C and with compound frame of choice can be assembled with readily available materials.
[0011] U.S. Pat. No. 6,443,433B1 issued to Auldridge, Douglas on Sep. 3, 2002 has a capable way of making a light duty rail fences that retains the weakness of the single T-post except in the direction the fence runs. The Compound Post 80 has the lateral strength and can be assembled with any of several styles of Compound Frame 28 .
[0012] U.S. Pat. No. 5,395,093 issued to Chrisman, Lawrence C. on Mar. 7, 1995 has a patent for a T-post height extender but is limited to a single T-post and the weakness inherit. The Presented Compound Frames 28 can be made into a extender by adding more T-post 46 C positions with unlimited horizontal length and height limited by stability only.
[0013] U.S. Pat. No. 3,119,471 issued to Turner B. R. on Jan. 28, 1964 has a tower design that has to be pre-welded post to braces. The presented Compound Frame 28 can be assembled in the field making shipping of materials more compact. T-post and cement reinforcements bar 46 C are being produced in recycle steel foundries wide spread in the US.
[0014] U.S. Pat. No. 826,996 issued to Cooke, C. C. on Jul. 24, 1906 has a telegraph pole design, but is more complicated, requires more parts and is more difficult to assemble than the Compound Frame 28 assemble being presented.
[0015] U.S. Pat. No. 6,000,682 issued to Lechtenbohmer, Hans Norbert on Dec. 14, 1999 has a patent with mulitiple rods for a compound fence post but appears to be designed for wood plank fence only and is extremly complicated and costly.
[0016] U.S. Pat. No. 6,585,234 issued to Berto; Joseph J. Jul. 1, 2003 has a device attaching too a T-post 46 C. Berto's patent holds pvc 46 C and wire. The Post Frame 28 - 80 though different will do all that Berto's does. The Compound Post Union Frame 28 - 80 will also have bracing capabilities and strength in all directions not provided with his. The Compound Post Union Frame 28 - 80 will also be a height extender 44 E if needed.
BRIEF SUMMARY OF THE INVENTION
[0017] The Compound Post 80 makes possible an all metal fence of uniform appearance. Said fence can be made that will have minimal damage by fire. Compound Posts 80 are strong for force pull points and where fence line changes direction. The Compound Post 80 is strong in all directions, creating a more lean proof fence. Gates, barbwire and other items attach easily. Digging post-holes is not required and firming time for stress post is eliminated. The material to build is readily available. Arsenic treated wooden post have been found to be dangerous. Wooden post often rot or burn. Pipe is expensive and used pipe often have contaminates. Rail fences with Compound Post Union Frame 28 can have a rail at each Frame 28 level made of T-post, Pvc Pipe, cement reinforcement rod or other items 46 C. The Compound Post 80 with top Compound Post Union Frame 28 having additional post positions 44 E can be extended. The round Frame 62 - 80 can form hunting or observation towers 80 , and other revolving items, such as lights. Compound Post Union Frame 62 - 80 can be fitted with one or several 360 degree gates for livestock work. The Compound Post Union Frame 62 - 80 is a good design for use with antennas. Materials, size, and shape of both Frame 28 and connected items 46 C may be varied for any reason.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 . A through F are connectors 50 . 1 i is a connector for Track 66 A FIG. 7B to Compound Post 80 . 1 G-H and J are prior art, as samples of items used.
[0019] FIG. 2 . A diagonal view of square Frame 28 - 54 with an engaging means on three sides. Connectors are plate 50 B.
[0020] FIG. 3 . A diagonal view of square Frame 28 - 56 with engaging means on three sides. Connectors are rods 50 A 2
[0021] FIG. 4 . A diagonal view of square Frame 28 - 58 with engaging means on three sides. Connectors are 34 - 50 E cut from plate 48 .
[0022] FIG. 5 . A diagonal view of a square one plate 48 Frame 28 - 52 with engaging means on three sides. Connectors are channel 50 C.
[0023] FIG. 6A . Side view of one channel bar Frame 28 - 72 with engaging means 44 on channel sides and both ends.
[0024] FIG. 6B . Side view of two Compound Post Union Frame 28 - 72 joined to form a T with engaging means 44 on channel sides and exposed ends.
[0025] FIG. 6C . Side view of three channel bar Frame 28 - 72 joined to form a capital I with engaging means 44 on three channel sides and four exposed ends.
[0026] FIG. 6D . Side view of four equal length channel bar Frame 28 - 72 joined at the ends to form a rectangle with engaging means on four channel sides. Four engaging means 44 E add extension capabilities as an example of extender 44 E.
[0027] FIG. 7A . View of round Frame 28 - 62 with engaging means for brace, six support post 46 C, and optional a three hundred and sixty degree turn attachment.
[0028] FIG. 7B . View of round track 66 A used for revolving attachments on lower Compound Post 80 - 62 assemblies.
[0029] FIG. 7C . View of upper arm 70 with top engaging means from Compound Post Union Frame 80 - 62 to attachments.
[0030] FIG. 7D . View of yoke 68 with low engaging means from track 66 A to attachments.
[0031] FIG. 8 . Side view of trapezoid Frame 28 - 60 with engaging means on two sides.
[0032] FIG. 9 . Corner view of assembled two rail fence corner or barbwire fence braced corner of Compound Post 80 .
DETAILED DESCRIPTION OF THE INVENTION
[heading-0033] 28 . Frame FIGS. 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9
[0034] Compound Post Union Frame 28 can be round 62 , trapezoid 60 square 52 - 54 - 56 - 58 - 78 , bar 72 - 74 - 76 - 78 or rectangle (not shown in flat material) but is made by extending a square between, the side with two cutouts 44 and the opposite side without cutouts 44 . A compound post frame 28 will hold small post 46 C together to form a larger stronger post 80 .
[heading-0035] 30 . Holes Frame 28 FIGS. 2 - 3 - 4 - 5 - 7 - 9
[0036] Holes in all frames 28 (except channel bar 72 - 74 - 76 - 78 on these models holes are optional the U-bolt and bracket 46 A-B surrounds bar 72 ) to accept insertion of U-bolts 46 A, for attaching braces of T-post, Pipe or Cement reinforcement bar 46 C, from one compound post 80 , to another compound post 80 , or to attach a gate or other items to the compound post 80 . The holes 30 can be arranged so that two clamps 46 A can hold brace post 46 C in all directions.
[heading-0037] 32 . Holes in clamp connectors FIGS. 1 - 2 - 4 - 5 - 6 - 7 - 8 - 9
[heading-0038] Holes in clamp connectors FIG. 1F 34 - 50 E, 50 -B-C-D for U-bolt clamps 46 A. To attach individual post 46 C to post frame ( 28 ).
[heading-0039] 34 . Bottle shaped connector FIGS. 1-4
[heading-0040] Bottle shaped 50 E connector 34 - 50 E formed by cut and bend 42 out, 36 leaving one side attached to be bent (at point 42 ) out to connect two identical cutout 34 - 50 E plates 48 to form a frame 28 for connecting post 46 C to form a compound post 80 .
[heading-0041] 36 . Holes FIG. 4
[heading-0042] Holes 36 not used where a connector 34 - 50 E has been cut and bent 42 out.
[heading-0043] 38 . Rectangle cutouts FIG. 4
[heading-0044] rectangle cutouts to accept the protruded top 40 of bottle shaped cutout 34 - 50 E.
[heading-0045] 40 . Protruded top of bottle shaped connector 34 - 50 E FIG. 1F-4
[heading-0046] Protruded top of bottle shaped cut 34 and bend 42 out 34 - 50 E made to insert into cutout 38 to attach and separate plates 28 .
[heading-0047] 42 . Bend out point of connector FIG. 1F-4 Bend out point of connector 50 E, cutout 34 .
[heading-0048] 44 . Rectangle cutouts FIGS. 1D and E- 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9
[0049] Rectangle cutouts on the edge of all frames 28 and connectors 5 OC-D to accept individual post 46 C to form a compound post 80 . Present drawings and descriptions or for a cutout 44 to accept the unnoduled side of a enclosure fence type T-post 46 C, but represent all items that can be used as a post and may vary even on a frame.
[0050] E. Additional cutout positions for extender Compound Post Union Frame 28 FIG. 6D model 78
[heading-0051] 46 .
[0052] A. U-bolts and nuts used on all frames 28 , they are used to attach T-post 46 C to Frame 28 FIGS. 1G-9
[0053] B. Bracket for open end of U-bolt 46 A FIG. 1H
[0054] C. Enclosure fence type T-post 46 C is used to represent any post, pipe, rod or tubing 46 C FIGS. 1J-9
[heading-0055] 48 . Plate FIGS. 2 - 3 - 4 - 5 - 7 - 8 - 9
[0056] Steel square, rectangle, circle or a trapezoid plate used as a frame 28 or as half of a frame 28 ; 54 - 56 - 58 - 60 - 62 . All of these plates 48 have rectangle cutouts 44 in a pattern for attaching items (in examples and drawings, T-post 46 C) will be used to form a compound post 80 .
[heading-0057] 50 . Steel clamp connector and/or spacer FIG. 1
[0058] A. 1 Bolts and Nuts
[0059] A. 2 Two rods FIG. 3
[0060] B. Flat Plate FIGS. 2 - 7 - 8 - 9
[0061] C. Channel Bar FIGS. 1D-5
[0062] D. Angle Plate FIG. 1E
[0063] E. Cutouts 34 - 50 E FIGS. 4-1F
[0064] Steel clamp connectors 50 B-C-D are about one fourth the size of Frame 28 , plate 48 for Connecting and separating two plates 48 of a Frame 28 and or for attaching U-bolt 46 A to hold small post 46 C. The clamp connector 50 can be flat 50 B, angle 50 D or channel bar 50 C, steel rod 50 A 2 welded to Frame 28 , plate 48 bolts and nuts 50 A 1 are bolted to Frame 28 , plate 48 , or cutouts 34 - 50 E. Connectors can be 50 A 1 - 2 or 34 - 50 E can be bracketed with T-post 46 C, by clamp 46 A and drawn tight and secure, connector 34 - 50 E is made by cutting three sides of a rectangle with a small square on the top- 40 and bending out- 42 .
[heading-0065] 52 . Single flat plate frame 28 FIG. 5
[0066] Is a single flat plate 48 , frame 28 with four cutouts 44 near each comer for attaching T-post 46 C. Angle 50 D or channel bar 50 C connector is welded and centered on each cutout 44 to clamp 46 A T-post 46 C to the frame 28 , plate 48 forming a single plate 48 , frame 28 compound post 80 .
[heading-0067] 54 . Frame 28 FIG. 2
[0068] A frame 28 of two identically cut and drilled plates 48 rectangle or square connected by four connectors 50 A 1 and 2 -B-C-D-E to form a frame 28 for a multiple post 46 C compound post 80 . FIG. 2 is with connector 50 B, FIG. 3 is with 50 A 2 rod to form Frame 56 .
[heading-0069] 56 . Frame FIG. 3
[0070] A frame of two (square shown in FIG. 3 ), rectangle, trapezoid or circle plates 48 with cutouts 44 and brace holes 30 . The plates 48 are held in place by pairs of welded rods 50 A- 2 centered on cutouts 44 . A clamp 46 A surrounds the bolts 50 A 1 , rods 50 A 2 or 34 - 50 E and the T-post 46 C in cutout 44 to form the compound post 80 .
[heading-0071] 58 . Frame 28 FIG. 4
[0072] A frame 28 (square shown in FIG. 4 ) is made with this press and cut and bend 42 method. The rectangle would be the square extended between the end of plate 48 with two cutouts 44 and the end with none. This press cut and bend 42 method can be applied to all frames. The cutouts 44 in the near comer pattern (two on one side near each comer, none on the opposite side, one each on the other two sides near the comers farthest from the side with cutouts 44 ). There are four for the square 54 , three for the trapezoid 60 and six evenly spaced around the round 62 . The side with two cutouts 44 has centered on the left cutout 44 and position so that the uncut base is 13 mm-one half inch farther from the edge than the depth of the cutout 44 two rectangular bottle shaped partial cutouts 34 - 50 E. The partial cutouts 34 - 50 E are approximately 25 mm-one inch wide and 75 mm-three inches long. The cut end of the cutout 34 - 50 E is made to have a protrusion in the middle that is 25 mm-one half inch by 25 mm-one half inch. The diagonal comer has the same cutouts 34 - 50 E. The right comer on the side with two cutouts 44 have centered on them and 25 mm-one half inch farther from the edge two, 25 mm-one half inch by 3 mm-one eight inch cutouts 38 that are parallel to the side. The left diagonal comer has the same. The bottle shaped cut and bend out 50 E- 34 are bent 42 upward on two identical plates. Then connectors 50 E- 34 are turned to one another and plate 48 is turned to align bottle 50 E- 34 top 40 with hole 38 for insertion and bending of top 40 to form compound post 80 frame 28 . This method of construction with lighter material also forms a puzzle for entertainment.
[heading-0073] 60 . Frame 28 Trapezoid FIG. 8
[heading-0074] A frame 28 ( FIG. 8 ) of two identically cut and drilled trapezoid plates 28 connected by any connector 50 A 1 and 2 -B-C-D-E to form a triangular three post 46 C compound post 80 , frame 28 . FIG. 8 is shown with flat connector 50 B.
[heading-0075] 62 . Frame 28 Round FIG. 7A
[0076] Is a round frame 28 constructed of two identically cut and drilled plates 48 of weld (shown in FIG. 7A ) or press cut methods (square shown in FIG. 4 ) is connected by any of the connectors 50 A 1 and 2 -B-C-D-E. This frame 28 has a larger bolt hole 64 A in the center for mounting a 360 degree turning gate, observation stand, antenna and other items.
[heading-0077] 64 . A. FIG. 7A a large hole in the center of frame 62 for mounting items for use.
[heading-0078] 66 . Track FIG. 7B
[0079] A. A round flat metal open wheel like track of a size to encircle Compound Post 62 - 80 with inside centered connection straps 66 B for bracketing and locking wheel 66 A too frame 62 assembled with post 46 C to carry gates attached at bottom hinge in 360 degree turn around compound post 80 .
[0080] B. Strap of steel flat metal with bolt hole 32 in one end and the other end is welded to track 66 A. It is even spaced and centered on the inside of the track 66 A. Hole 32 is connected by double nut to clamp 46 A on assembled Compound Post Union Frame 62 - 80 .
[heading-0081] 68 . Yoke FIG. 7D
[heading-0082] Yoke with center wheel 68 A and wheel shaft 68 B for holding bottom of gate on to the 360 degree track 66 A of compound post 80 , frame 62 when used to hold a gate or revolving items.
[0083] A. Wheel to carry weight of gate and move around compound post 80 of frame 62 . One of 68 is needed for each gate and possible more for other items..
[0084] B. Bolt shaft to hold wheel 68 A on yoke 68 as the wheel 68 A moves on track ( 66 A) around compound post 80 . Shaft 68 B also pulls together the yoke 68 to catch track 66 A in the hooked notched end of yoke 68 .
[heading-0085] 70 . Gate arm FIG. 7C
[heading-0086] Top gate arm of flat steel or round bar with a bolt hole 64 A in one end for the gate to turn freely on and attach with bolt assembly 70 A in hole 64 A, to compound post 62 frame. The other end attaches to the top hinge end of a gate.
[0087] A. large bolt and nut assembly for mounting items on frame 62 Compound Post 80 FIG. 7C
[heading-0088] 72 . Channel bar Frame FIG. 6A
[0089] Frame 28 constructed from a single length of channel bar steel or pressed steel in shape of channel bar with cutouts 44 and holes 32 for mounting T-post 46 C. When mounting post 46 C on ends of 72 - 74 - 76 U-bolt clamp 46 A will be used and connect into a hole 32 made for it or the holes 32 for near comer connect 44 already there. This frame 28 can be used to hold two to four post for a compound post 80 and can be used as steps of a ladder on other compound post 80 .
[heading-0090] 74 . T shaped Frame 28 FIG. 6B
[heading-0091] Frame constructed by attaching one channel frame 72 to the middle back (flat side) of another channel frame 72 to form a T shaped frame 28 .
[heading-0092] 76 . I shaped Frame 28 FIG. 6C
[heading-0093] Frame 28 constructed by attaching one channel frame 72 by its flat middle back to a frame 28 - 74 to form a capital I shaped frame 28 .
[0094] 78 . Box channel Frame 28 FIG. 6D a frame 28 constructed by joining four frame 72 end to end with concave side out to form a box channel frame 28 . All channel frames 72 may not have bolt holes 30 for brace post 46 C but instead be embraced by connector clamp 46 A with cross clamp brackets 46 B. All channel frames do have bolt holes 32 centered on cutouts 44 .
[heading-0095] 80 . Is an assembled Compound Post 80 . FIG. 9 is of three Compound Post 80
[heading-0096] 82 . FIG. 9 is three assembled compound post 80 connected by four T-post 46 C as braces.
[0097] The object of this invention (Compound Post Union Frame 28 ) is to have a means to securely fasten items (post, pipe, rods or tubing) together to add or multiply their strength in a single Post 80 .
[0098] The Compound Post Union Frame 28 FIGS. 2 through 9 can be made in several shapes and sizes for a variety of uses, price and strength requirements. The Post Union Frame 28 can be made with different production methods. The single channel bar 72 , two channel bars 74 - 72 joined to form a capital T, three channel bars 76 - 72 joined to form a capital I, and four channel bars 78 - 72 joined concave side out and end to end to form a square or rectangle 78 - 72 , may be the most versatile and least expensive. Square Post Union Frame 54 - 28 of flat steel plate 48 trapezoid 60 - 28 of flat steel plate 48 and round 62 - 28 of flat steel plate 48 , have been made and tested. The rectangle not shown would be the same as the square 52 , 54 , 56 and 58 with added length between the sides with two cutouts 44 near the comers for small post and the side with none. The other two sides each have one cutout 44 near the comer next too the side with none. This square pattern and the round pattern of evenly spaced cutouts 44 when increased in number forms the extension Post Union Frame 28 - 44 E FIG. 6D . All Post Frames 28 have cutouts 44 and holes 30 in a pattern for attaching items such as T-Post 46 C. The pattern depends on the items to be attached and the clamp 32 used.
[0099] The 72 through 78 frames 28 may not have holes 30 for U bolt clamps 46 A to attach cross braces 46 C, gates or other items all of the others may need them. The U-bolt, bracket and nuts 46 A embrace the T-post 46 C, gate connector or other items to the channel bar 72 itself. The single flat plate 48 frame 52 is not as strong as the double plate 54 , 56 , 58 , 60 , 62 or the channel bar 72 models.
[0100] The first descriptions used and the construction methods described for Compound Post Union Frame 28 will be a general description for double plate 48 cut and weld frames made for four T post— 46 C of the enclosure fence. Rigid strong material is required to make the Compound Post Union Frame 28 and recycled steel will be used in the description.
[0101] MAKING THE SQUARE CUT AND WELD COMPOUND POST UNION FRAME 54 - 28 FIG. 2 This is a description for making one version of the square variation of the Compound Post Frame 28 use approximately 3 mm-one eight inch steel plates approximately 21 cm-eight inches square, have four cutouts 44 approximately 20 mm-three fourth inches deep, approximately 7 mm-one fourth inch wide to accept the unnodule side of T-post 46 C two of these cutouts 44 are on one side approximately 38 mm-one and one half inches from the comers. The opposite side does not have cutouts 44 . The adjoining sides each have a cutout 44 approximately 38 mm-one and one half inch from the far comer of the side with two, four holes 30 are drilled near the center of the plate 48 the holes 30 are in a pattern to match the U-bolt 46 A to be used. The size and spacing of the holes 30 will accept the U-bolt 46 A and be arranged for use of two U-bolts 46 A in any direction.
[0102] Four approximately 3 mm-one eight inch steel plates 50 B,C,D approximately 63 mm-two and one half inches one way and the other the width of the U-bolt 46 A to be used plus 25 mm-one inch. The U-bolt 46 A width side has holes 32 drilled for the U-bolt 46 A centered on the 63 mm-two and one half one way and centered for the U-bolt 46 A to align with T-post 46 C cutouts 44 on the larger plate 48 when small plate 50 B,C,D is welded at a ninety degree angle connecting both plates 48 .
[0103] ASSEMBLE: Place two frames 28 , two cutouts 44 sides up on flat surface spaced about 60 cm-two feet apart. Lay two T-post 46 C unnodules side in cutouts 44 position, to leave length of T-post 46 C above top of frame 28 to operate single post, T-post 46 C hammer. Insert U-bolts 46 A around T-post 46 C and into frame connectors 50 B,C,D attach nut fasteners 46 A to firm but light torque, rotate assembly and repeat post 46 C assembly for remaining two post 46
[0104] INSTALLING: Compound Post 80 in fence, place Compound post assembly 80 square with fence line and two post 46 C side nearest line of fence. Relieve torque tension on two clamps 46 A of one post 46 C and drive into ground with T-post 46 C hammer. Torque clamps 46 A to secure if frames 28 are at desired level or light if frame 28 will be adjusted when all four post 46 C have had this procedure accomplished. The farm implement for pounding large post in the ground, that is on the market should also work, Disclosure 541480 Nov. 6, 2003 UNITED T-POST HAMMER may have to be used when installing Compound Post 80 of a height above average reach.
[0105] MAKING THE PRESS CUT FORM OF COMPOUND POST UNION FRAME 58 - 28 FIG. 4 Press cut two 3 mm-one eight inch steel plates 48 approximately 21 cm-eight inches square, have four cutouts 44 approximately 20 mm-three fourth inch deep approximately 5 mm-three sixteen inch wide to accept the unnodules side of T-post 46 C. Two of these cut outs 44 are on one side approximately 38 mm-one and one half inch from the comers. The opposite side does not have cutouts 44 . The adjoining sides each have a cutout 44 approximately 38 mm-one and one half inch from the far comer of the side with two. The side with two cutouts 44 has centered on the left cutout 44 and position so that the uncut base is 13 mm-one half inch farther from the edge than the depth of the cutout 44 are two rectangular bottle shaped partial cutouts 34 - 50 E. The partial cutouts 34 - 50 E are approximately 25 mm-one inch wide and 75 mm-three inches long. The cut end of the cutout 34 - 50 E is made to have a protrusion in the middle that is 13 mm-one half inch by 13 mm-one half inch. The diagonal comer has the same cutouts 34 - 50 E. The right comer on the side with two cutouts 44 have centered on them and 13 mm-one half inch farther from the edge, two 13 mm-one half inch by 3 mm-one eight inch cutouts 38 that are parallel to the side. The left diagonal comer has the same. The Post Frame 28 to be made for brace post 46 C will have four holes 30 drilled in right comer farther from the edge than the cutouts 38 . The cutouts 38 and 34 will serve as connectors 50 E for the two plates 48 and have in the center of the rectangle part a hole 32 to receive one side of the U-bolt clamp 46 A with nuts only.
[0106] Holding the two plates 48 - 58 in a side by side position so that they are identical with bottle shaped connector 50 E bent up, turn as closing a book. The top 40 of bottle shaped connectors 34 - 50 E go into cutouts 38 and are bent to lock the two plates 48 - 58 to together. This press and cut design can be used on all Post Frames. The rectangle Post Frame 28 not shown is identical though extended to all square models and same construction apply.
[0107] MAKING THE COMPOUND POST UNION FRAME 56 - 28 FIG. 3 . The Post Frame 56 is made with double plates 48 of any shape. The cutout 44 pattern is the same as those used on other Post Frames 28 of the same shape. The connect rod 50 A is welded to the plate 48 to establish desired distance between plates 48 centered on the cutout 44 . The bolt 50 A or connector 50 E can be used in the same method. Assembly requires a U-bolt, nuts 46 A, and bracket 46 B to embrace connector rod 50 A or E and T-post 46 C in cutouts 44 .
[0108] MAKING THE ROUND COMPOUND POST UNION FRAME 62 - 28 FIG. 7 The Post Frame 62 is made of two round plates 48 size and number of post 46 can vary for use. Description will be for a 30 cm-one foot diameter circle plate 28 with six evenly spaced cutouts 44 around outer edge. The Post Frame 62 may have drilled U-bolt holes 30 if braces are to be attached. The Post Frame 62 will have a bolt hole 64 A drilled in the center in both plates 28 to accept a bolt 64 B. Post Frame 62 can be made using 50 A 1 and 2 B,C or E as connectors centered on cutouts 44 . Post Frame 62 - 80 when used as a hunting or observation stand would have frames 62 at spaced points chosen and one at the top of the tower for a revolving seat. Near the top of the tower 80 or attached to the revolving seat would be a standing platform with camouflage cover. Post Frame 62 - 80 when used as a 360 degree gate post can mount several gates to be used in a livestock circular pen for livestock to be loaded, medicated or separated. The Post Frame 62 - 80 can be used for entrances where the gate needs to open in either direction and swing back until something other than the post 80 itself stops the gate.
[0109] ASSEMBLY: Post Frame 62 is similar to all other Post Frames 28 . The frame forms a channel with a U-bolt 46 A exerting pressure in the middle area of the channel to lock items to Post Frame 28 . Post Frames 62 for 360 degree revolving gate requires the addition of a track 66 A to encircle Post Frame 62 on a lower level frame 62 and is attached by straps 66 B welded on the track 66 A, to the U-bolts 46 A holding T-post 46 C as part of Post Frame 62 - 80 . The gate on the bottom will have one end of a yoke 68 shaped attachment in the place of the normal hinge assembly. The yoke 68 may have to be a double yoke 68 for gates used in heavy stress. The yoke 68 may have a channel configuration at the ends of the forks of yoke 68 to prevent the gate being lifted on the non hinge end and a revolving roller, wheel 68 A device to carry the weight of the gate. The wheel would be mounted on a bolt or shaft 68 B that also adjust forks of yoke 68 to track 66 A. The gate will have one end of a arm 70 attached to the hinge end ,top of the gate. The other end with a hole in it will curve to align with a large bolt 64 B in the hole 64 A in the center of Post Frame 62 - 80 at the top of post 80 . The bolt 64 B end of 70 may need to vary in shape on each when used with additional gates to allow for short overlapping moves during operation. The yoke 68 on low attachments does not have this circumstance.
[0110] MAKING THE TRAPEZOID 60 COMPOUND POST UNION FRAME FIG. 8 This is a description of the three post 46 C trapezoid 60 Post Frame. The narrow side of the trapezoid has a connector cutout 44 and is wide enough to accept a connector 50 . The opposite side has the two cutout 44 connectors approximately 38 mm-one and one half inch from the comer. The other two sides have none. When using connectors 50 A,B,C or D, two identical plates are attached. When using connector 50 E one plate 48 has cutouts 34 and the other has cutouts 38 . Placement of connectors are centered on cutout 44 .
[0111] MAKING THE FLAT PLATE 28 ANY SHAPE 52 COMPOUND POST UNION FRAME 28 (square in FIG. 5 ): The Post Frame 52 is made with a single plate 48 of any shape. The Post Frame 52 can use only connectors 50 C or D. The connectors are welded so that the angle of 50 C or D can have cutout 44 and be positioned the same as in Post Frames 54 , 56 , 58 , 60 or 62 .
[0112] MAKING THE CHANNEL BAR COMPOUND POST UNION FRAME 72 - 28 AND THE JOINED FORM COMPOUND POST UNION FRAMES 74 , 76 AND 78 FIG. 6 This is a description of four of the unlimited number of models that can be created from the channel bar 72 . The not described models will be created when additional channel bar 72 are connected.
[0113] A basic two rod or post 46 C model would only require 15 cm-six inches of bar or less when using only ends and would have cutout 44 38 mm-one and one half inch from each end, and centered on each end. The holes 32 for T-post 46 C clamps 46 A attachment will be in the third side centered on the cutouts 44 . This pattern has unlimited possible designs for post 46 C and channel bar additions in other direction. Channel bar Post Frame 72 - 28 can be joined to a Post Frame 72 by positioning end to end, along the flat side or the narrow channel end. The connection can be made by welding or by cutouts 38 and protrusion 40 of the channel bar.
[0114] The Post Frame 72 - 28 FIG. 6A is a length of channel bar with cutouts on both channel sides in matching pairs. An optional pair of cutouts 44 can be made in the ends. The end post 46 C connection can be connected by reversing the U-bolt 46 A connection from other Post Frame 28 . A single hole 32 in the middle of channel bottom with a U-bolt 46 A inserted through and out to embrace a T-post 46 C and using a bracket 46 B and nuts to complete and secure the embrace.
[0115] Post Frame 74 FIG. 6B is made by connecting the end of one Post Frame 72 to the middle of the flat side of another to form a T.
[0116] Post Frame 76 FIG. 6C is made by connecting one Post Frame 72 by its flat side in the middle to a Post Frame 74 to form a I.
[0117] Compound Post Union Frame 78 FIG. 6D is made by connecting four Post Frames 72 with channel side out end to end to form a square or rectangle. FIG. 6D has Post Frame 78 with extender cutouts 44 E. The Post Frame 78 requires less additional change to become a Post Frame extender model due to brace connection without holes 30 and extra cutout 44 on Fames 72 .
[0118] In conclusion, having described the invention in detail, those skilled in the art will appreciate that modifications may be made to the various aspects of the invention without departing from the scope and spirit of the invention disclosed and described herein. It is, therefore, not intended that the scope of the invention be limited to the specific embodiments illustrated and described but rather it is intended that the scope of the present invention be determined by the appended claims and their equivalents. Moreover, all patents, patent applications, publications, and literature references presented herein are incorporated by reference in their entirety for and disclosure pertinent to the practice of this invention. Numerous variations are still possible, while adhering to the inventive concept. Such variations are contemplated as being a part of the present.
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A Compound Post Frame ( 28 - 80 ) with securing devices ( 46 A). It provides a means to united small post, pipe, rods or tubing ( 46 C) in marriage to form a strong single Compound Post ( 80 ). Other items can be attach easily and the post replaces any post of any material.
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FIELD OF THE INVENTION
The present invention relates generally to the field of tissue ligation, and more particularly to an improved device and method for electrosurgically severing lesions.
BACKGROUND OF THE INVENTION
A wide variety of lesions, including internal hemorrhoids, polyps, and mucositis, may be treated by ligation. Ligating bands and severing snares are two types of devices commonly used to sever targeted lesions from surrounding tissue.
When performing ligating band ligation, a ligating band is initially placed over the targeted lesion or blood vessel section. As a ligating band is typically elastic in nature, the band must be stretched beyond its undeformed diameter before it can be placed over any tissue. After the tissue to be ligated has been drawn within the inner diameter of the ligating band, the band is allowed to return to its undeformed size and therefore apply inward pressure on the section of tissue caught within the band. The effect of the inward pressure applied by the band is to stop all circulation through the targeted tissue, thereby causing the tissue to die. In due course, the body sloughs off the dead tissue and allows it to pass through the body naturally.
Ligating band dispensing means are used to facilitate the placement of a single ligating band or a set of ligating bands over the targeted tissue. Two examples of ligating band dispensers are U.S. Pat. No. 5,356,416 to Chu et al. and U.S. Pat. No. 5,398,844 to Zaslavsky et al., both of which are incorporated herein by reference.
Alternately, a lesion may be removed through the use of an electrosurgical severing snare. Electrosurgery can be defined as the use of a radio frequency electric current to sever tissue or achieve hemostasis. A high radio frequency is used because a low frequency (i.e., below 100,000 Hz.) will stimulate muscles and nerves and could injure the patient. Electrosurgery is typically performed at frequencies of approximately 500,000 Hz., although frequencies as high as 4,000,000 Hz. may be used.
Medical diathermy is similar to electrosurgery in that radio frequency current is passed through the patient's body. The major difference between these two techniques is the density of the radio frequency electric current; the current density used in medical diathermy is kept low so as to reduce tissue heating and prevent necrosis.
There are three surgical effects that can be achieved with electrosurgery. These include electrosurgical desiccation, which is a low power coagulation caused without sparking to the tissue; electrosurgical cutting, where electricity sparks to the targeted tissue and produces a cutting effect; and electrosurgical fulguration, where electricity sparks to the targeted tissue without causing significant cutting.
The above-described surgical effects can be accomplished by using either a monopolar or bipolar output. For many applications, however, bipolar output is preferable because the patient return electrode (necessary in monopolar procedures and a common source of accidents) is eliminated, and any desiccation performed is extremely localized because, in a true bipolar operation, only the tissue that is grasped between the two electrodes is desiccated. Bipolar output, however, is poor for cutting or fulgurating, and thus monopolar tools remain commonplace. Severing snares, for example, are almost all monopolar instruments.
Three types of electrical current waveforms are typically used in electrosurgery. These include a "cutting" waveform, which cuts tissue very cleanly but may cause the incised tissue to bleed excessively; a "coagulating" waveform, which desiccates and fulgurates tissue without significant cutting; and a "blended" waveform, which is a cutting waveform that has a moderate hemostatic effect. A waveform's "Crest Factor" describes the degree of hemostasis that waveform can produce if properly applied.
To remove a lesion (or polyp) with an electrosurgical severing snare, a wire snare is looped around the targeted lesion. Next, the lesion is desiccated and is cut through electrosurgically. It is also possible to sever the lesion in a single step. By cutting with a "blended" current, it is possible to cut through a lesion in one pass without having to worry about bleeding. Alternately, a lesion may be cut through mechanically with a thin snare wire after the blood supply to the targeted tissue has been coagulated and the tissue softened by a desiccation current.
After the targeted lesion has been severed from the surrounding tissue, the severed tissue may be aspirated into an endoscope or similar device. In this manner, a sample may be retrieved for further study. Alternately, the severed tissue can be allowed to pass through the body naturally.
While bands are more effective in removing tissue while controlling bleeding, snares allow severed tissue to be retrieved and allow a user to cut deeper into the tissue, when increased suction is applied, to ensure, for example, that all diseased tissue is removed at once.
Electrosurgical cutting, however, is a difficult technique to master, especially when cutting large or sessile polyps. When using the "two step" cutting method (i.e., desiccation before cutting) whether the actual cut is to be made mechanically or electrosurgically, a precise amount of desiccation is required. If there is too little desiccation, the stalk may bleed when cut. If there is too much, the stalk may become too hard and dry to cut either mechanically or electrically. It is also exceedingly difficult to master "one step" cutting, which uses a blended current to ensure sufficient hemostasis. This is especially true when thick snare wires are used or a current with a high Crest Factor is applied. Often it will be very difficult to start cutting a given polyp. Thus, at times it may be desirable to use a pure cutting waveform to get the cut started. However, this may result in serious bleeding because the polyp has not previously been properly desiccated.
Currently, if it is desired to alternate between ligating band ligation and the use of electrosurgical snare, one or the other of these two types of instruments must be inserted through the working channel of an endoscope. Finishing with the first device, the user would have to withdraw this device from the endoscope before replacing it with the second device. In treatment of multiple lesions, for example, this process may need to be repeated several times, wasting the user's time, exposing the instruments to possible contamination during removal, and increasing the time and discomfort associated with the procedure.
SUMMARY OF THE INVENTION
The present invention is directed to a system for severing lesions within a living body which includes a housing defining an interior tissue receiving chamber coupled to the distal end of an endoscope. At least one snare extends around the ligating band supporting surface so that drawing the snare off the ligating band supporting surface releases a corresponding ligating band from the ligating band supporting surface.
In addition, the present invention is directed to a method for severing tissue comprising the steps of introducing into the body an endoscope to which a housing defining an interior tissue receiving chamber is coupled, wherein at least one snare and a corresponding ligating band extend around the ligating band supporting surface. The distal end of the endoscope is advanced into the body until the housing is located adjacent to a first portion of tissue to be severed. The first portion of tissue is then drawn into the interior chamber and a snare is drawn off the distal end of the housing to release the corresponding ligating band from the ligating band supporting surface so that the ligating band and the snare encircle the first portion of tissue. The user may then use the snare to sever an outer portion of tissue while the ligating band remains in place on an inner portion thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood through the following detailed description, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a first embodiment of the present invention;
FIG. 2 is a sectional view of the first embodiment as taken along line 2--2 of FIG. 1;
FIG. 3 is an enlarged detailed view of the distal end of the first embodiment;
FIG. 4 is a plan view of the distal end of the first embodiment, and only showing one snare engaging a ligating band;
FIG. 5a is a side view of a pull wire/snare assembly used in the first embodiment of the invention;
FIG. 5b is a side view of the pull wire/snare assembly of FIG. 5a with the loop 65a electrically coupled to the pull wire 100;
FIG. 5c is a side view of the pull wire/snare assembly of FIG. 5a with the loop 65b electrically coupled to the pull wire 100;
FIG. 6 is a cross-sectional view of the first embodiment of the invention showing the invention being used to sever a lesion;
FIG. 7 is a side view of a second embodiment of the invention;
FIG. 8 is a cross-sectional view of the second embodiment being used to sever a lesion;
FIG. 9 is a cross-sectional view of a third embodiment of the present invention in which the pull wire 100 extends through the housing 1 from a proximal end to a distal end thereof;
FIG. 10a is a side view of a connection between a pull wire, a pull wire crank and an r/f energy generator;
FIG. 10b is a cross-sectional view of the connection of FIG. 10a taken along line 10b--10b of FIG. 10a;
FIG. 11 shows a side view of a distal end of a fourth embodiment of the present invention in which each of the snares and pull wires is formed as a single wire;
FIG. 12 shows a cross-sectional view of the distal end of FIG. 11 taken along line 12--12 of FIG. 11; and
FIG. 13 shows a side view of a pull wire for use with the apparatus of FIG. 11.
DETAILED DESCRIPTION
As shown in FIGS. 1 through 6, the present invention comprises a housing 1, which has a proximal end 5 and a distal end 10. A lumen 15 extends between the proximal and distal ends 5 and 10, and may preferably have a generally circular cross-section. A distal aperture 20 is defined at the point where the lumen 15 exits the distal end 10 of the housing 1.
In operation, the housing 1 is attached to the working end 30 of an endoscope 25 by means, for example, of an elastic ring 26 coupled to a proximal end of the housing 1 as is known in the art. The endoscope 25 contains a working channel 35, which is defined within the endoscope 25 between a proximal end 40 and the working end 30. The working channel 35 is sized to allow the free passage of instruments from the proximal end 40, through the working channel 35 to the working end 30. In this manner, a user using the endoscope 25 can perform procedures on the patient in which the endoscope 25 and the housing 1 have been inserted.
The endoscope 25 may be any standard endoscope which is sufficiently long to reach the targeted lesions within the patient's body. In addition, the elastic ring 26 allows the housing 1 to be attached to endoscopes 25 of various sizes.
It may also be preferable to have an external channel 45 located outside the endoscope 25. As will be discussed later, a first embodiment of the invention includes a pull wire 100 that extends through an entrance port 55 of the external channel 45 to a position proximate an exit port 50 of the external channel 45. A portion of the pull wire 100 extends beyond the entrance port 55, so that a user may manipulate the pull wire 100 by applying a force on the exposed portion of the pull wire 100. By having the pull wire 100 pass through the external channel 45 rather than through the working channel 35 of the endoscope 25, a user may pass additional instruments, such as a needle 200 (seen in FIG. 6), through the working channel 35 of the endoscope 25 and the lumen 15 of the housing 1 without interfering or becoming entangled with the pull wire 100.
Alternatively, as shown in FIG. 9 in the third embodiment, the pull wire 100 may extend through the working channel 35 of the endoscope 25 to directly enter the housing 1.
As seen in FIGS. 1 and 3, one or more ligating bands 60 are disposed about the housing 1 proximate the distal end 10 of the housing 1. For sake of illustration, the housing 1 is shown in FIG. 1 as holding three ligating bands 60a-c, although any number of ligating bands 60 may be used. In the first embodiment of the invention, for example, a total of 3-8 or more ligating bands 60 and a corresponding number of severing snares 70 may preferably be used. The numbering of ligating bands 60a-c corresponds to the order in which the ligating bands 60a-c will be dispensed from the housing 1. Ligating band 60a, for example, is located closest to the distal end 10 of the housing 1 and will therefore be the first ligating band 60 to be dispensed from the device.
Each ligating band 60a-c, is partially engaged by a portion of a distal loop 65a-c of a respective severing snare 70a-c. Each distal loop 65a-c of the severing snares 70a-c extends underneath each ligating band 60a-c that is more distal than the corresponding ligating band 60a-c which the respective severing snare 70a-c is designed to engage, the respective loop 65a-c then wraps over the respective band 60a-c and passes back under the more distal of the bands 60a-c to a snare catch 90. Distal loop 65c, therefore, passes underneath ligating bands 60a and 60b, before wrapping around the ligating band 60c and passing back underneath ligating bands 60a and 60b to the snare catch 90. Each severing snare 70a-c also includes a proximal end 75a-c, which is connected to the pull wire 100 at attachment points 80a-c.
The method by which a distal loop 65a-c engages a ligating band 60a-c will now be described with reference to distal loop 65c and the corresponding ligating band 60c. The distal loop 65c passes from the lumen 15 of the housing 1 through a snare port 85c. Alternately, a portion of the snare 70c exclusive of the distal loop 65c may pass through the snare port 85c, such that the entire distal loop 65c is initially outside the housing 1. First, the loop 65c of the proximal-most snare 70c is drawn out of the snare port 85c so that each of side sections 65c' and 65c" of the loop 65c passes through snare notches 68c and 68c' to extend along the sides of the housing 1. The ligating band 60c is then installed over the housing 1 and the side sections 65c' and 65c" are drawn over the ligating band 60c to extend around a snare catch 90. Thereafter, the loop 65b of the snare 70b is drawn out of the snare port 85b, so that side portions 65b' and 65b" of the loop 65b pass through corresponding snare notches 68b' and 68b" to extend along the sides of the housing 1. The ligating band 60b is then installed over the housing 1, with the loop 65c and the side sections 65b' and 65b" on the distal side of the ligating band 65c. The loop 65b is then drawn over the ligating band 60b to extend around the snare catch 90 and the process is repeated with each successive ligating band 60 moving distally along the housing 1. Although FIG. 1 shows three snares 70 and three ligating bands 60, those skilled in the art will understand that any number of snares and ligating bands may be employed using this installation procedure.
All three distal loops 65a-c engage the snare catch 90. As seen in FIG. 3, distal loop 65c has been loaded onto snare catch 90 first, so that distal loops 65a and 65b can be disengaged from snare catch 90 without becoming entangled with distal loop 65c. The same goes for distal loop 65b with respect to distal loop 65a. Snare catch 90 is designed so that when a severing snare (e.g., 70a) is engaged, the ligating band 60a will be dispensed from the housing 1 over snare catch 90, without becoming entangled with any of the other distal loops 65b or 65c.
As seen in FIG. 4, each of the distal loops 65a-c (only distal loop 65a is shown) has a corresponding snare port 85a-c and a respective pair of snare notches 68a-c and 68a'-c'. In this manner, each distal loop 65a-c can be dispensed from the housing 1 without becoming entangled with any other distal loop 65a-c, provided the distal loops 65 are dispensed in the proper sequence (i.e., a, then b, then c). Also, snare ports 85a-c are preferably slightly recessed proximally from the distal aperture 20, to increase the angle at which the distal loops 65a-c engage snare notches 68a-c and 68a'-c'.
As mentioned earlier, the proximal ends 65a-c of the severing snares 70a-c are attached to the pull wire 100 at attachment points 80a-c at which electrically conducting portions of the distal loops 65a-c are exposed, while remaining portions of the distal loops 65a-c are electrically insulated except for distal end portions 82a-c. The severing snare 70a-c is attached to a pull wire 100 in such a manner so as to leave an amount of slack 105b and 105c in proximal ends 75b and 75c. This slack 105b-c is useful because when the pull wire 100 is initially engaged, tension is applied to the proximal end 75a of severing snare 70a first, without being applied to the proximal ends 75b-c of severing snares 70b-c. Instead, as the pull wire 100 moves proximally (to the left in FIG. 2), portions of the slack 105b-c are taken up before tension is applied to the proximal ends 75b-c. In this manner, the pull wire 100 may be used to manipulate each of the severing snares 70a-c independently of one another. The amount of slack 105b-c is preferably selected so that a respective ligating band 60 may be dispensed first by, e.g., one half turn of the crank 112 while a targeted lesion 110 may be severed by the corresponding snare 70 (e.g, snare 70a) by a further one half turn of the crank 112, after which the snare 70a is drawn completely through the snare port 85a into the housing 1, before the slack 105b associated with the next severing snare 70b has been taken up. Thus, the next snare 70b and the corresponding ligating band 60 will not be dispensed accidentally immediately after snare 70a has been deployed, (i.e., before the housing 1 is positioned adjacent to a second portion of tissue to be resected). Specifically, an amount of slack 105b will be selected so that the length of snare 70b is substantially equal to the length of the snare 70a plus a length equal to a full turn of the crank 112 and the amount of slack 105c will be selected so that the length of the snare 70c is equal to the length of the snare 70a plus two full turns of the crank 112.
As is known in the art, a device such as a pull wire crank 112 as shown in FIGS. 10a and 10b, may be used to apply the necessary force to the pull wire 100 preferably via a stiffened, hooked pull wire 100a to dispense the ligating bands 60a-c and to manipulate the severing snares 70a-c. For example, the length of slack 105 may preferably be chosen so that a half turn of the pull wire crank 112 would release a ligating band 60 while a further one half turn of the crank 112 would draw the corresponding snare 70 into the housing 1 to sever the desired portion of tissue. The use of a slightly more rigid pull wire 100a also makes the threading of the pull wire 100 through the endoscope easier.
A detailed view of the attachment points 80a-c of the pull wire 100 is shown in FIG. 5a-5c. As described above, in order to transfer r/f energy from the proximal end of the endoscope 25 to the snares 70, the pull wire 100 is formed of electrically conducting material which may be selectively electrically coupled to each of the snares 70a-c. This is accomplished through the action of slack 105b-c. Specifically, in an initial configuration, the pull wire 100 is electrically coupled to the loop 65a through contact between the contact portion 80a of the distal loop 65a and a distal contact portion 100' of the pull wire 100 in which the electrical insulation covering the remainder of a distal portion of the pull wire 100 is not present. Of course, an area on the proximal portion of the pull wire 100 also includes a proximal contact portion 100" at which the electrically conducting wire is exposed for coupling to the hooked pull wire 100a which is, in turn, coupled to a source of r/f energy. Of course, this source of r/f energy may be activated and deactivated by a user of the device through, for example, a foot switch (not shown). As shown in FIGS. 5a-c, the distal loop 65b is longer than the distal loop 65a while the distal loop 65c is longer than the distal loop 65b, etc. Thus, the length of each of the distal loops 65 is increased in a regular progression from the loop 65a through the loop corresponding to the ligating band 60 installed proximal-most on the housing 1. As described above, this increase in length which forms the slack 105b-c ensures that only one of the snares 70 and the corresponding ligating band 60 will be activated at a time as the pull wire 100 is drawn proximally.
In addition, this slack allows the source of r/f energy (preferably coupled to the proximal contact area 100" of the pull wire 100 via a plug 114 formed on the pull wire crank 112) to be coupled to the one snare 70 currently being manipulated by the user. As shown in FIGS. 5b and 5c, the pull wire 100 is formed as a loop of conducting material which extends through each of the loops 65a-c so that, as the pull wire 100 is drawn proximally the first loop 65a is drawn into the housing 1 and the distal contact portion 100' of the pull wire 100 advances relative to the contact portion 80b until the two contacting portions 80b and 100' come into contact with each other electrically coupling the loop 65b with the source of r/f energy. Similarly, after the user has finished with the snare 70b, drawing the pull wire 100 further into the housing 1 draws the contacting portion 80c further proximally until electrical contact with the distal contacting portion 100' is established. Thus, each of the loops 65 is first electrically linked to the source of r/f energy only as it is deployed from the housing 1, while the inactive loops 65 which remain in position around the housing 1 are decoupled from the source to prevent injury to surrounding tissue. Of course, the previously deployed snares 70 remain active, but these snares 70 are safely encased within the housing 1.
In use, as shown in FIG. 6 the endoscope is advanced until the distal end is adjacent to a lesion 110 to be ligated. The device may be positioned visually via an optical device (not shown) mounted in the endoscope. After visualizing the lesion 110, the user then decides whether to perform ligating band ligation, severing snare ligation, or a combination of the two on the targeted lesion 110. The user may also decide whether to engage the lesion 110 or the vessel wall 115 with a sclerotherapy needle 200, or other instrument, such as a forceps, basket, or cautery device, which may be passed through the working channel 35 of the endoscope 25 to the lumen 15 of the housing 1. Because the pull wire 100 preferably passes through the external channel 45, the working channel 35 is clear for the user to pass such additional instruments therethrough. The user may draw the lesion 110 into the distal aperture 20 under suction or with an instrument such as a forceps and may employ the forceps or suction after engaging the lesion 110 with a ligating band 60a, so that a tissue sample may be retrieved.
After the lesion 110 has been drawn within the housing 1, the user dispenses a ligating band 60a from the housing 1 by applying a force to the pull wire 100 (to the left in FIG. 6). The now-dispensed ligating band 60a engages lesion 110 and applies an inward force on the lesion 110, thereby restricting the flow of blood from the vessel wall 115 to lesion 110. In this manner, the desired level of hemostasis may be achieved and, eventually, the tissue dies and is sloughed off.
After the user has drawn the lesion 110 within the housing 1 and has dispensed the ligating band 60a from the housing 1, the distal loop 65a, which had engaged ligating band 60a about housing 1, is positioned about the stalk 120 of the lesion 110. Therefore, by drawing the pull wire 100 further proximally, the user pulls the distal loop 65a about the stalk 120, and may sever the lesion 110 either mechanically or electrosurgically. This severing step is preferably accomplished with one continual pull on pull wire 100, which, if the user elects to sever the lesion 110 electrosurgically, is done while simultaneously applying r/f energy to the snare 70a to facilitate cutting and cauterizing the targeted stalk 120.
If the user elects to use only ligating band ligation (i.e., not to use a severing snare), the user simply dispenses the ligating band 60a from the housing 1 after drawing the lesion 110 within the distal aperture 20 of the housing 1 by, for example, turning the crank 112 one half turn. Then, the user releases the tissue from the housing 1 and draws the snare 70 into the housing by a further one half turn of the crank 112.
After the lesion 110 has been severed from the vessel wall 115, the user may continue to apply suction through the working channel 35 to aspirate the lesion 110 through the lumen 15 into the working channel 35 of the endoscope 25. Alternately, the user may use suction to retain the lesion 110 within the lumen 15 of the housing 1 and then withdrawn the endoscope 25 and housing 1 from the patient. By proceeding in either of these manners, the user may obtain a sample of the lesion that has been severed for pathology evaluation. Alternately, the user may pass an instrument, such as a forceps, through the working channel 35 of the endoscope 25 and retrieve a sample of the lesion 110 for further study, either before or after the lesion 110 has been severed from the vessel wall 115.
Alternately, the user may disengage the suction means to allow the severed lesion 110 to pass through the body naturally. Whether the lesion is completely aspirated through the working channel of the endoscope 25, or allowed to pass through the body naturally, the user may proceed to treat additional lesions without removing the endoscope 25 from the patient. Of course, if the user desires to treat multiple lesions, the present device must be preloaded with a corresponding plurality of severing snares 70a-c and ligating bands 60a-c, rather than a single snare 70a and one ligating band 60a, as shown in FIG. 6. When the first lesion 110 has been severed, the user simply positions the housing 1 adjacent to a second lesion 110 and repeats the above described method.
A second embodiment of the present invention is illustrated in FIGS. 7 and 8, in which a distal loop 125 of a severing snare 130 is positioned around the housing 1, but is located behind the ligating band 135 (i.e., is positioned proximally with respect to the band 135). The severing snare 130 passes along the endoscope 25 through a sheath 138, located outside the endoscope 25. By containing the severing snare 130 and the pull wire (not shown) within the sheath 138, the working channel 35 remains substantially clear so as to allow a user to pass an additional instrument, such as a needle (not shown) through the working channel 35 and through the lumen 15 without becoming entangled with the severing snare 130 or the pull wire.
By applying a force to the pull wire in the distal direction (i.e., to the left in FIG. 8), the distal loop 125 is moved toward the distal end 10 of housing 1 and dispenses the ligating band 135 from the housing 1. As discussed previously, if it is desired to engage a lesion 110 with the ligating band 135, the lesion is first suctioned into the lumen 15 of the housing 1. Then, with lesion 110 within the lumen 15, the ligating band 135 is dispensed to engage the stalk 120 of the lesion 110. By moving the pull wire further in the distal direction, the user can position the distal loop 125 around the desired portion of the lesion 110 and then retract the pull wire in the proximal direction to tighten the distal loop 125 about the lesion 110 and sever the lesion 110 mechanically or electrosurgically. Movement of the pull wire is preferably controlled by a handle 140 or similar means.
In the second embodiment of the invention, it is preferable to use a fairly sturdy distal loop 125 so that a ligating band 135 may be dispensed from the housing 1 when the pull wire is moved in the distal direction. That is, the pull wire must be stiff enough to carry a compressive load from the user to the distal loop 125 sufficient to overcome the friction forces maintaining the ligating band 135 on the housing 1.
An apparatus according to a fourth embodiment of the invention, as shown in FIGS. 11-13, is similar in construction to the previously described embodiments except that a single pull wire 100 is threaded through the device 1 to create a plurality of snares 70 which extend around the housing 1 abutting snares 70a-c which are located proximally of an optional proximal end wall 118.
As seen in FIG. 12, an instrument 116, e.g. a sclerotherapy needle, is present in the working channel 35 as well as the single pull wire 100 which extends through the working channel 35 in the space surrounding the instrument 116 to a first snare port 85a. The use of a single pull wire 100 allows the working channel 35 to comfortably accommodate an instrument 116 while providing the required control of the snares 70a-c. In addition, as no channels external to the endoscope are required with this apparatus, the cross-section of the device remains circular and the maneuverability of the device is enhanced.
Specifically as shown in FIG. 13, the pull wire 100 of this embodiment includes a first knot 102, a second knot 104, a third knot 106, a fourth knot 105, a fifth knot 107 and a loop 108. The pull wire 100 extends through the snare port 85a and underneath the ligating band 60a so that the knot 102 is located adjacent to a proximal edge of ligating band 60a. The pull wire 100 then wraps around the housing 1 to form snare 70a and passes back under the ligating band 60a and through the snare port 85a so that the knot 104 is located proximally of the snare port 85a. The knot 104 and the snare ports 85a and 85b are sized relative to one another so that the knot 104 may not pass through either of the snare ports 85a and 85b. The pull wire 100 extends from the knot 104 through the snare port 85b, passes underneath the ligating band 60a, under the snare 70a and under the ligating band 60b so that the knot 106 abuts a proximal edge of the ligating band 60b and wraps around the housing 1 to form snare 70b. The pull wire 100 wraps around the housing 1 and passes back under the ligating band 60b, under the snare 70a, under the ligating band 60a and reenters the snare port 85b so that the knot 105 is located on the proximal side of the snare port 85b. The knot 105 and the snare ports 85b and 85c are sized relative to one another so that the knot 105 may not pass through either of the snare ports 85b and 85c. Of course, those skilled in the art will understand that, although this embodiment is shown with 3 ligating bands 60a-c and 70a-c, this wrapping pattern may be repeated to create as many snares 70 as are desired until, after the pull wire 100 has passed under the proximal-most ligating band, 60c in FIG. 11, the pull wire 100 extends from the knot 107 abutting the proximal edge of the band 60c, around the housing 1 where, after encircling the housing 1, the snare 70c is formed by tieing a loop 108 around the preceding portion of the pull wire 100.
Those skilled in the art will understand, although FIG. 11 shows the ligating bands 60a-c spaced apart, that this is for illustration only. As the single pull wire 100 of this apparatus will transmit energy to all of the snares 70a-c when the source of r/f energy is engaged, the snares 70a-c should preferably be prevented from damaging adjacent tissue by abutting the ligating bands 60a-c against one another. Thus, the snares 70a-c will not contact the surrounding tissue.
In operation, when a portion of lesion tissue 110 is drawn into the housing 1 and it is desired to deploy the band 60a, the user turns the crank 112 one half turn as described above and the pull wire and the knot 102 are drawn distally across the housing 1, pulling the band 601 off of the distal end of the housing 1. Further rotation of the crank 112 will tighten the snare 70a around the lesion 110, eventually severing the tissue. Once the snare 70a has been fully retracted into the snare port 85a (knot 102 is sized so that it may pass through the snare port 85a), the pull wire 100 straightens out and portion of the pull wire 100 which formed the snare 70a no longer forms a loop. The amount of the pull wire 100 that needs to be taken up to fully retract the snare 70a also serves the purpose of preventing the premature release of the more proximal bands 60b-60c, etc. When a second portion of lesion tissue 110 has been located and drawn into the housing 1, the second ligating band 60b is released by a further one half turn of the crank 112. The knot 104 is drawn into the working channel 35 of the endoscope and knot 106 draws the band 60b off of the distal end of the housing 1. Thereafter, the operation of the snare 70b and any number of more proximally located snares 70 would be the same as that described for 70a and except that the proximal-most snare 70 will tighten like a noose as the pull wire 100 is drawn proximally, sliding through the loop 108.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the above-recited detailed description, wherein only preferred embodiments of the invention has been shown and described.
The description of the preferred embodiments is simply by way of illustration of the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modification in various respects, all without departing from the invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and the scope of the invention is intended to be limited only by the claims appended hereto.
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A system for severing lesions within a living body includes a housing defining an interior tissue receiving chamber is coupled to the distal end of an endoscope. At least one snare extends around the ligating band supporting surface so that, when at least one ligating band is received around the ligating band supporting surface, drawing the at least one snare off the ligating band supporting surface releases a corresponding ligating band from the ligating band supporting surface. In addition, a method for severing tissue comprises the steps of introducing into the body an endoscope to which a housing defining an interior tissue receiving chamber is coupled, wherein at least one snare and at least one ligating band extend around the ligating band supporting surface and advancing the distal end of the endoscope into the body until the housing is located adjacent to a first portion of tissue to be severed. The first portion of tissue is then drawn into the interior chamber and a snare is drawn off the distal end of the housing to release a corresponding ligating band from the ligating band supporting surface so that the ligating band and the snare encircle the first portion of tissue.
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FIELD OF THE INVENTION
[0001] This invention is related to the field of aquaculture fish farming, and in particular, to an improved open ocean fish cage that can be readily moved from contaminated waters for use in aquaculture fish farming.
BACKGROUND OF THE INVENTION
[0002] On Apr. 20, 2010, a semi-submersible exploratory offshore drilling rig in the Gulf of Mexico exploded resulting in an oil spill described as the largest environmental disaster in U.S. history. Due to the location of the oil leak, nearly one mile beneath the surface of the water, accurate predictions of the volume of oil released is not possible. While the owners of the drilling rig estimate that an oil leak between 1,000 and 5,000 barrels a day is occurring, scientists have estimated oil flow rates up to 84,000 barrels per day (13,400 m3/d). A second, smaller leak has been estimated to be releasing 25 , 000 barrels per day (4,000 m3/d) by itself suggesting that the total size of the leak may well be in excess of 100,000 barrels per day.
[0003] No matter what the actual amount of oil has leaked, or will continue to leak, the oil spill is contaminating the coast lines of Texas, Louisiana, Mississippi, Alabama and Florida. The oil spill threatens wildlife refuges, ecologically sensitive areas, fisheries, densely populated waterfronts. Efforts to address the oil spill include controlled burns which have limited or no success. Inflatable booms have been deployed wherein floating oil is contained and skimmers are then used to draw oil from the surface. However, the oil disperses very quickly making containment difficult, even when the seas are calm.
[0004] To combat the oil spill huge quantities of chemical dispersant are being deployed in an effort to stop as much of the slick as possible from reaching land. Oil dispersants are detergent-like chemicals that break up oil slicks on the surface of the water into smaller droplets, which can then be broken down by bacteria in the water and by other natural processes. Dispersants can help prevent the oil droplets from coalescing to form other slicks. However, oil spill dispersants do not reduce the total amount of oil entering the environment. Rather, they change the chemical and physical properties of the oil, making it more likely to mix into the water column than to contaminate the surrounding waters. Dispersants alter the destination of the toxic compounds in the oil, redirecting its impact from feathered and fur-bearing animals on shore to organisms in the water column itself and on the seafloor. Most critically, a large quantity of the dispersant is being injected into the oil leak at the ocean bottom, some 5000 feet deep. The result is the suppressing of a large amount of oil from every reaching the surface of the water.
[0005] The current deployment of dispersants will likely result in the single largest deployment of dispersants against an oil spill in U.S. history. Reports indicate that nearly 140,000 gallons (529,928 liters) of dispersants have been used within the first 50 days of the oil spill.
[0006] Corexit® and other dispersants, made up of classified chemicals may result in a devastating effect in the Gulf. Aside from the fact that dispersants never before have been used on such a vast scale, the current chemicals are being injection at the well head over 5000 deep which has never occurred before. In addition, many of the dispersants are made up of classified chemical so it is not possible to access the danger they pose when the ingredients are kept confidential.
[0007] Thus, the oil spill threatens a major food supply. The clean-up of the oil is estimated to take years. The damage to certain fisheries may take a life time to repair. Certain species of fish may be extinguished.
[0008] In addition, the U.S. imports over $9.6 billion dollars worth of seafood each year with 60% aquaculture grown. This represents approximately 40,000 jobs that can be brought to the Gulf of Mexico if a system was employed that can “fish around” the damaged areas. In view of the massive loss of jobs caused by the spill, including the livelihood of conventional fisherman, what is needed is a system for offshore aquaculture fishing that can be adapted to fish in safe waters, be capable of withstanding hurricane force winds, and be readily moveable to avoid man made disasters. Offshore aquaculture in the Gulf of Mexico can directly replace some of the longest lasting impacts of the current oil spill by replacing wild fishing with farming planned in safe unaffected clean sites.
[0009] Aquaculture is the rearing of marine organisms under controlled conditions and has been practiced for thousands of years. For instance, it is known that Talapia was farmed during early Egypt times.
[0010] Aquaculture facilities may be used to house many different types of fish such as halibut, haddock, cod, flounder, bass, snapper, cobia, tuna, mahi mahi, and so forth. In the Gulf of Mexico, the species of immediate threat are the red drum, spotted trout, grouper, snook, cobia, triple tail, pompano, and mullet snappers to name a few.
[0011] Historically ocean water fish farming has been done in protected near shore areas where access to the cages has been very good and cleaning and maintaining cage screens has been affordable and not prohibitive due to open sea conditions, distance and increasing labor rates. Current offshore aquaculture containment structures are typically sheltered from harsh weather and ocean waves in bays, fjords and by islands. However, sheltered areas for aquaculture are quickly becoming saturated and bays are becoming polluted from over farming densities.
[0012] Today many countries have used and over used the acceptable protected aquaculture sites and are now forced to go offshore to expand. The United States is committed to develop an offshore aquaculture plan for federal waters. Most of the U.S acceptable sites are 10 to 70 miles offshore and in areas that are susceptible to severe weather. The solution for severe weather areas is underwater cages that are not affected by surface waves.
[0013] The Gulf of Mexico is in a hurricane zone and known European and Asia technology is not adaptable to the area. Offshore aquaculture is one of the few options available to create jobs and provide seafood security.
[0014] Offshore aquaculture is a more modern development because of the obstacles of maintaining large structures in offshore conditions. Open ocean offshore aquaculture imposes the highest demands on equipment exposed in high energy ocean environments. The purpose of the open ocean aquaculture is to raise a species of fish in a controlled environment. The open ocean environment allows for the natural cleansing of the holding pen without the concentration of waste found in near shore aquaculture. Open ocean aquaculture facilities consist of cages, holding pens, or the like that may be free floating, secured to a structure, or lowered to the ocean bottom. Open ocean aquaculture also makes use of the vast area of the ocean wherein cage size is not limited, as compared to the placement of cages within bays or the like tightly boarded area. The fish farming industry has enjoyed a steady strong growth for many years and can produce sustainable high quality fish products.
[0015] Extensive offshore floating facilities are currently found in most costal countries such as Australia, Chile, China, France, Ireland, Italy, Japan and Norway. The United States has only a few open ocean facilities while other countries are experimenting with such facilities such as Panama, Korea, Spain, Mexico, Brazil and other Central and South America countries. Labor offshore has many difficulties including poor working conditions, health risk and transportation costs. This is especially true for underwater cages where divers are required for almost all of the work.
[0016] Offshore aquaculture is among the fastest growing industries today. Fish consumption is rising and wild stocks are unable to meet demand. Many ocean species contain valuable omega oils that are recommended by doctors for good health. These 3 oils are not abundantly found in fresh water species. The health benefits of ocean fish will continue to drive demand for ocean grown fish for decades to come. Offshore aquaculture has not developed in the United States despite the fact that the United States has the largest exclusive economic zone in the world at 3.4 million square miles.
[0017] Environmental concerns and labor rates of the developed countries are the new barriers for continued growth of the industry. While many new aquaculture operations are looking to go offshore despite higher costs, the problems for offshore cages are very different and require advanced infrastructures to be reliable and competitive. The new requirements include automation, communication, monitoring and more concern for environment and personal safety. Damaged cages will result in huge financial losses, and fish escapes may effect the environment.
[0018] Most fish cage designs consist of a floating arrangement in a rectangular dock arrangement or in one or more large polyethylene pipes placed in a circle with netting underneath. Improvements have been in lower cost and better durability as the fish farms have been forced further offshore because of a lack of sheltered sites. Floating offshore cages are unsightly and are exposed to threats from high seas, hurricanes, above and below water predators including humans, and are navigation hazards.
[0019] Open ocean cages are generally a gravity style cage or a floating style cage, or hybrids thereof. Gravity cages depend on gravity to sink the net and form the shape of the cage. Floating cages usually use inexpensive common trawl netting with antifouling chemicals to retard marine growth. Large floating cages usually have a walkway around the perimeter making work from the surface easy, however some disadvantages exist. High currents can sweep up the net reducing the volume of the cage and stressing the fish wherein substantial mortalities can occur. Also, surface cages take a beating as rough weather can breach a cage and result in the total loss of the fish by escape or predator entrance.
[0020] Because floating cages cost less then other cages, currently they are the most popular. Farmers can save costs by finding reasonably sheltered areas for location sites. Often these sites are near populations having less ocean currents and are not environmentally sound. Surface cages are more vulnerable to rough sea failures and with common netting, the fish are more vulnerable for attack by birds, mammals and sharks.
[0021] Currents also cause problems for cages as the currents can change the shape of the netting and lower effective volume of the cages, as well as the high maintenance of floating hardware and current cleaning expenses due to the present day net design.
[0022] A common problem with such facilities is the exposure to the elements wherein damage to the containment facility can quickly result in a loss of contained fish. For instance, should a facility consist of a cage with netting, a breach in the cage structure can result in the release of the fish into the open water or the introduction of predators into the cage. Exposure to the elements is not limited to wave action but includes predators such as sharks that work tirelessly to find or create a breech in the netting for access to the fish.
[0023] Currently there are several types of cages that address individual issues.
[0024] Bourdon U.S. Pat. No. 4,716,854 discloses an open sea aquaculture fish cage installation that comprises a central structure similar to an offshore drilling platform and several floating modules anchored to the seabed.
[0025] Bones U.S. Pat. No. 5,628,279 discloses an hexagonally framed aquaculture fish cage that is raised and lowered along the submerged support columns of an offshore oil platform. The pens rely on injection-molded, fiberglass-reinforced grating panels painted with antifouling paint. The grating panels are supported in a rigid, generally hexagonal structure. An optional net may be installed if the fish are too small to be contained by the grating panels.
[0026] Koma U.S. Pat. No. 4,957,064 discloses an aquaculture fish cage having a polygonal frame composed of a multiplicity of frame elements. An upper net is hung down from the polygonal frame and is slackened enough so that it has a length of slack sufficient to cover up and down movement of the polygonal frame caused by waves. A lower net composed of a side net fixed to the upper net and a bottom portion fixed to a bottom end of the side net is provided. The lower net has an opening at its top end. Underwater floats are fitted to the side net, and mooring wires are provided to moor the bottom end of the lower net to the bottom of the sea.
[0027] Willinsky U.S. Pat. No. 5,251,571 discloses an offshore containment pen in the shape of a geodesic sphere formed of hubs and interconnecting struts. The hemispheric nets are attached to the interior of the sphere, by attaching the net at many points. The sphere can be lowered below the ocean surface, and it can rotate at the surface using an axle and buoyant elements incorporated into the sphere.
[0028] Zemach U.S. Pat. No. 5,412,903 discloses a metal skeleton with a superimposed netting covering the skeleton.
[0029] McRobert U.S. Pat. No. 6,216,635 discloses a aquaculture pen having a frame for suspending of a net. The frame is sufficiently buoyant to suspend a net without sinking below the water level.
[0030] Knott U.S. Pat. No. 6,386,146 discloses an aquaculture cage having a buoyant upper support for positioning at the water surface, a side wall projecting below the surface of the water formed from a contractible non buoyant panels.
[0031] Zemach U.S. Pat. No. 6,481,378 discloses an aquaculture cage having controllable buoyancy having multiple chambers that can be submerged and refloated.
[0032] Page U.S. Publication 2006/0102087A1 & 2008/0000429A1 disclose various geodesic cage designs for use with aquaculture.
[0033] Niezrecki U.S Publication 2005/0235921 discloses a self deployable open ocean aquaculture cage and underwater structure.
[0034] While previous geodesic cages exist, known cages are designed from many different triangles to form a sphere like cage. The angles between each section become closer and closer to 180 degrees as the shape gets larger. The ability to pull hard perpendicularly at any point gets lower as the sphere gets larger. As the spheres get larger they quickly become more fragile.
[0035] Disclosed is an improved offshore aquaculture fish cage that addresses the needs of future fish farmers and the immediate need of placing fish in an area that is not contaminated.
SUMMARY OF THE INVENTION
[0036] Disclosed is a geodesic aquaculture fish cage formed from an injection molded composite structure having adjustable buoyancy formed from hollow tube members that interconnect with a series of junction nodes. The junction nodes also provide through holes that can be use as access ports, harvester ports, feeder ports, tower supports, or used as tie-down brackets. In one embodiment where the cage is placed just below the water line, a tower with a self contained power supply can be attached for use in navigation identification, communication, and automation. Navigation aides can include lighting and transponders for identification. Video and data transmission and be used for monitoring of all conditions.
[0037] Thus an objective of the invention is to disclose an offshore fish cage that is durable and able to withstand movement to areas not affected by oil or in the event of severe weather conditions.
[0038] Another objective of the invention is to disclose an offshore fish cage having a self-contained infrastructure for support of navigational lighting and identification. Such an infrastructure will allow frequent movement as an oil spill moves due to current or weather patterns.
[0039] Still another objective of the invention is to disclose an offshore fish cage having an infrastructure to support communications including data and video, and mounts for cameras, oxygen sensors, current sensors and the like instruments.
[0040] Another objective of the invention is to disclose an offshore fish cage capable of generating storing power by solar, wind generator, wave generator, or a generator powered by fuel.
[0041] Another objective of the invention is to disclose an offshore fish cage that improves safety to operators by use of multiple node entrances.
[0042] Still another objective of the invention is to disclose an offshore fish cage that can be attached at several points for towing and anchoring, including single point mooring, and has fastening points for wires, cables and conduits.
[0043] Still another objective of the invention is to disclose an offshore fish cage that is low in cost, can be upgraded, and employs standard replacement parts.
[0044] Another objective of the invention is to disclose an offshore fish cage that has precision buoyancy control, can float high and rotate, and the high flotation allows for towing and the use of heavy or dense screens.
[0045] Another objective of the invention is to disclose an offshore fish cage that has precision buoyancy control that allows for stable anchoring dynamics and optimizes flotation characteristics to meet any off shore static or dynamic condition.
[0046] Still another objective of the invention is to disclose an offshore fish cage that can accommodate and integrate automated feeding systems and harvesting systems, and has no internal obstructions to inhibit automated cleaning equipment.
[0047] Another objective of the invention is to disclose an offshore fish cage that can accommodate any type of screen and is self supporting for dry dock construction.
[0048] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objectives and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] FIG. 1 is a pictorial view of an aquaculture cage of the instant invention;
[0050] FIG. 2 is a pictorial vies of an aquaculture cage secured to a mooring;
[0051] FIG. 3 is a perspective view of two frame members;
[0052] FIG. 4 is an exploded view of FIG. 3 ;
[0053] FIG. 5 is a perspective view of a junction fitting for the frame members;
[0054] FIG. 6 is a top view of FIG. 5 ;
[0055] FIG. 7 is a section view A-A of FIG. 6 ;
[0056] FIG. 8 is a detail view B of FIG. 7 ;
[0057] FIG. 9 is an exploded view of FIG. 5 ;
[0058] FIG. 10 is a pictorial view of a junction fitting with a feeder;
[0059] FIG. 11 is a pictorial view of a junction fitting with a harvester;
[0060] FIG. 12 is a pictorial view of a junction fitting with an access hatch;
[0061] FIG. 13 is a pictorial view of a communications tower secured to the aquaculture cage;
[0062] FIG. 14 is a pictorial view of the base of a communications tower secured to the aquaculture cage;
[0063] FIG. 15 is a pictorial view of a communications tower; and
[0064] FIG. 16 is a pictorial view of a smaller incubator cage attached to the aquaculture cage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0065] The fish cage of the instant invention is formed from a geodesic structure that is capable of having a capacity greater than 2000 cubic meters while maintaining the strength necessary to resist most any wave action, including turbulence created by hurricane force winds.
[0066] Referring now to the figures in general, and in particular to FIG. 1 , disclosed is the geodesic aquaculture fish cage ( 10 ) of the preferred embodiment. The structure consists of a plurality of outer edge junction nodes ( 12 ) and insertion junction nodes ( 16 ) that are conically shaped with angled attachment flanges and used to secure cylindrical shaped hollow tube frame members ( 14 ) into a geodesic shaped structure. The outer edge junction nodes are positioned along an outer edge of the structure and each use four attachment flanges which are not connected directly to an adjoining outer edge junction node. The outer edge junction nodes are connected to the insertion junction nodes ( 16 ) which have six attachment flanges to create a plurality of triangular segments. The nodes preferably include an anti-fouling or antimicrobial agent.
[0067] A screen is placed within each of the formed triangular segments and fastened to the tube members. The preferred screen is formed from a molecularly oriented single strand filament that is crossed and welded at predetermined intersections to make the screen or net configuration. The filament is molecularly oriented by stretching to a ratio of between 2:1 and 6:1. The filament has a cross section of at least 2.0 mm in any direction and is an extruded thermoplastic material made from nylon, polyester, polyethylene, polyurethane or polypropylene having a preferred cross section in a “D” or oval shape to better facilitate welding the intersections. An antimicrobial or biocide may be added to the filament. The screen or net is preferably of a bright color such as yellow, green, white or a translucent white. The preferred material is further described in co-pending patent application Ser. No. 12/779,066, the contents of which are incorporated herein by reference.
[0068] The outer edge junction nodes ( 12 ) and the junction node ( 16 ) allow for modification of the structure in accordance with the intended use. For instance, in diver dependant cages a diver can enter the screened cage by use of a hinged access hatch ( 20 ) that is shown as secured to a junction node and is sized to allow the passage of a diver carrying tanks ( 200 ) into the cage. The insertion junction node illustrated includes a cone shaped pick-up apparatus ( 22 ) for harvesting fish. The fish are drawn by use of a vacuum pump such as that disclosed in U.S. Pat. No. 7,462,016 the contents of which are incorporated herein by reference. Additionally an apparatus ( 24 ) is provided for feeding for inserting of fish food through a junction node into the chamber of the fish cage. Tie down bracket ( 26 ) is illustrated through a number of the nodes for use in securing the structure to anchors, a mooring, or for use in towing the structure to a location. The use of the junction nodes provide a stable attachment point for such items thereby eliminating the risk of fish loss due to a screen or frame modification. The use of standardized frame and junction node members lowers the manufacturing, assembly and maintenance costs.
[0069] A tower structure ( 28 ) is shown securable to at least one of the junction nodes ( 30 ). The tower structure projects outwardly a predetermined distance allowing extension above the water level ( 210 ) to provide an indication that the cage is submerged. The tower preferably includes navigation lights ( 32 ) which are powered by batteries and recharged by solar panels ( 34 ). The tower structure ( 28 ) can include support guidelines ( 36 ) for coupling to various junction nodes thereby adding stability to the tower.
[0070] FIG. 2 is a tower-less embodiment of the geodesic aquaculture fish cage ( 10 ) illustrating a tie down bracket ( 26 ) secured to a mooring structure ( 212 ) by length of chain ( 214 ). In this embodiment anchors are placed at offset angles, as depicted by the anchor lines ( 216 ) positioned about the structure thereby providing stability in areas prone to changing currents or wave actions caused by high winds such as hurricanes. In this embodiment the structure ( 10 ) does not have a communications tower but includes the use of a harvesting apparatus ( 22 ) for drawing of the live fish as well as the feeding apparatus ( 24 ) for providing nutrients to the fish. Unique to the apparatus is the ability to place the hinged access hatches ( 20 ) through any of the junction nodes so as to provide multiple locations for ingress and egress for the safety of divers.
[0071] FIG. 3 depicts a cylindrical hollow tube frame member ( 40 ) formed by a plurality of molded tube segments ( 42 and 44 ). The molded tube segments include a continuous side wall ( 46 ) having an access port ( 48 and 50 ) placed into the side wall and shown with reinforced gussets ( 52 ) and ( 54 ). The access ports can be used for the introduction of air into the cavity ( 56 ) of the molded tube segment ( 42 ) to provide buoyancy to the structure. Use of a second access port ( 50 ) can be also be used for buoyancy control, for instance, the port can be used in the controlled escape of the air or in the alternative can be used for flooding of the chamber so as to place buoyancy at a predetermined level. Adjoining molded tube segments as illustrated by ( 42 ) and ( 44 ) are coupled together by the use of first flange member ( 60 ) for securement against first flange member ( 62 ). Flange members include a plurality of bolt holes for receipt of securement bolts ( 64 ) and attachment fasteners ( 66 ). A blocking seal member ( 68 ) is insertable between the flange members and for enhanced sealability the use of O-rings ( 70 ) and ( 72 ) conform to a lip within each flange and conforming to a lip in the seal ( 68 ) providing a fluid seal between the adjoining tube segments ( 42 and 44 ). Molded tube segment ( 42 ) shown with a screen attachment rail ( 76 ) having a plurality of slots ( 78 ) for attachment of a screen by use of a fastener. As noted, the rail ( 76 ) extends from the first end ( 60 ) to the second end ( 62 ). For structural strength the side walls ( 46 ) can be conical shaped along a first end ( 80 ) extending from flange ( 60 ) to a central location ( 82 ). Similarly a conical shaped wall ( 84 ) can be formed from the second flange ( 62 ) to the center point ( 82 ). Attachment rail ( 76 ) further provides structural reinforcement to the molded tube segment by extending between the flanges forming a structural rib along the side surface. The attachment rail allows securement of a flat screen to the molded tube.
[0072] In the preferred embodiment, the molded tube segments are formed from injection molded plastics. Preferably plastic is reinforcement molded plastic of nylon, PET, or the like having between 30-60 percent glass providing a tensile strength of 20,000 psi and higher and flex modules of 1,000,000 psi and higher. It should be noted that cast and fabricated parts may also be used because it is believed that the injection molded plastic having uniform parts is the most economical for the segment construction. In addition, it should be noted that the molded tube segments are standardized as they are all equal in length and may be reversed wherein the first flange can operate as the second flange and vice versa.
[0073] The basic physical value of an engineering material can be expressed by taking (cost/lb×density) divided by the tensile strength.
[0074] Materials
[0000]
Description
Strength
Cost
Sp. Gr.
Cost adj
Steel low carbon pipe
35
yield
.75
7.8
.16
Stainless Steel ⅛ hard 304L
75
yield
2.50
7.8
.26
Aluminum
40
yield
2.20
2.7
.148
Plastics composites
Dow questra
19.1
Yield
2.00
1.32
.138
EMS grivory PVS 5H
24.7
3.50
1.58
.224
GV - 5H
30.5
ultimate
3.00
1.56
.153
GV_6H
37.5
ultimate
4.00
1.69
.180
Plastic lumber
5
ultimate
2.00
.95
.38
Fiber thermostes 50%
Glass epoxy
47
6.00
2.0
.24
Basalt epoxy
100
8.00
2.0
.16
Kevlar epoxy
110
16.00
1.8
.23
Carbon epoxy
200
45.00
1.9
.43
[0075] While plastic is the preferred construction material, the nodes and frame members can be made from any rigid material. Plastics can be coated with an anti-growth material similar to steel frames. Plastic composites having imbedded antimicrobials provide the best weight for strength advantage. For instance, testing of underwater salt water growth in various plastics revealed that a basalt composite part grew only tube worms. The use of basalt in the test demonstrated physical properties that made it cost effective and that basalt did not absorb water like glass fiber. Resins with imbedded antimicrobials are also possible with composites. The actual material chosen is dependant upon the location and expected marine growth.
[0076] Now referring to FIGS. 5-9 , disclosed is an outer edge junction node ( 12 ) depicted by a conical shaped housing ( 90 ) having spaced apart attachment flanges ( 92 , 94 , 96 and 98 ). A centrally located through hole ( 100 ) is available for attachment of the aforementioned access hatch, harvesting fish apparatus, feeding fish apparatus, tie down bracket, or the tower structure. The junction node can be cast as a single piece, or as shown in the illustration, the use of multiple pieces allows the node to be constructed to a four or six flange junction. It should be noted that three, five or even seven flange junction could also be used in the geodesic structure and deemed to be within the scope of this invention. FIG. 6 illustrates the junction node ( 12 ) from a top view with tie down bracket ( 26 ) secured thereto. The tie down bracket is bolted to the node through fastener holes ( 102 ) located along the perimeter of the junction node. It should be noted that the adjustability of the junction node is made possible by use of larger segments ( 110 ) or by the slidable expansion allowed wherein each segment has a flange section ( 112 ) and an attachment section ( 114 ) which is shown as an undercut to allow securement to an adjoining segment. FIGS. 7 and 8 depict a section of the cap capture which allows the tie down bracket to be easily aligned with the fastener holes of the junction node.
[0077] Referring now to FIG. 10 set forth is an outer edge junction node ( 12 ) illustrating a means for harvesting fish consisting of an apparatus having a base plate ( 120 ) securely to the passage way of the node ( 12 ). A discharge pipe ( 122 ) includes a plurality of a discharge orifices ( 124 ) wherein food and nutrients delivered through a delivery tube ( 126 ) and distributed within the cage by orifices ( 124 ) providing even distribution therein.
[0078] FIG. 11 depicts an outer edge junction node ( 12 ) having a means for harvesting fish consisting of a mounting plate ( 130 ) secured to the through hole of a node with a conical shaped inlet ( 132 ) attached to a suction hose ( 134 ). The harvesting tube is coupled to a specialty design fish pump such as disclosed in U.S. Pat. No. 7,462,016. The harvesting apparatus allows for the gentle movement of the fish from one location to another or during the subsequent harvest of the fish farm. Fish are drawn through the harvesting apparatus with little or no stress so as to maintain longevity of the fish.
[0079] FIG. 12 depicts an outer edge junction node ( 12 ) having an access hatch ( 20 ) which is secured to the through hole of the node and hinged having a handle ( 140 ) to provide ease of control by the diver ( 200 ) during ingress and egress. A latch mechanism ( 142 ) maintains the hatch in a closed and locked position when not in use. The ability to place access hatches throughout the structure aids in the safety to the divers who service the structure. Ideally the access hatches are placed in every node that does not need a tie down or feeding/harvesting apparatus.
[0080] Now referring to FIGS. 13 and 14 , set forth is the tower structure ( 28 ) shown attached to an outer edge junction node ( 30 ) with securement tie downs ( 36 ) further coupled to adjoining junction nodes. The tower structure is designed to project out of the water a distance to provide a navigation aid for those vessels around the structure during day and night. The tower employs navigation lights ( 32 ) for use at night and solar panels ( 34 ) provide recharging of the batteries during the day as well as providing a reflective surface. The structure having sufficient material and reflectivity from the panels to allow convenient ship radar to pick up the structure thereby addressing navigational hazards during the day. The tower structure has triangular placement of cross connects ( 29 ) to provide enhanced stability. The heavy duty standardized nodes make attachment of most any device, including sensors and accessories, a simple task.
[0081] FIG. 15 illustrates a communications tower structure ( 28 ) having the navigation lights ( 32 ) with solar panels ( 34 ) providing power through a battery ( 160 ). The communications tower may include the use of a camera ( 162 ) including electronics ( 164 ) that allow for spooling of the data for transfer through a transmitter receiver ( 166 ) for purposes of communicating by satellite, RF transmitter, or in storage drive for later review. A fuel power generator ( 180 ) may also be used to provide power to the batteries as well as for use in providing power as necessary for servicing the fish cage. The generator having an air intake ( 182 ) with an exhaust ( 184 ) and a fuel cell ( 186 ). This generator may also be used to provide portable power to divers for use with air compressors, to avoid the need of carrying tanks, or any other type of power accessory needed to maintain the fish cage.
[0082] FIG. 16 depicts the use of an aquaculture cage ( 10 ) adjoined by a smaller, but similarly formed, incubator cage ( 150 ). The illustration exemplifies an embodiment that allows juvenile fish to be grown in a controlled area and, upon reaching a mature stage, released into the larger cage ( 12 ) by opening of the through hole ( 192 ). Additional cages can be further attached, not shown, which can provide a staging area for growing fish in independent age/size groups.
[0083] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings/figures.
[0084] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should by understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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Disclosed is a geodesic aquaculture fish cage formed from an injection molded composite structure having adjustable buoyancy. The composition structure is component based made and constructed from standardized structural tube members that are coupled together to form independently sealable chambers. Junction nodes interconnect with the structural tube members and are constructed and arranged to provide a standardized support platform through hole that can be capped with an access port, harvester port, feeder port, tower support, or with individual tie-down brackets. A tower with a self contained power supply can be attached for use in navigation identification, communication, and automation.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a Section 371 filing of international application No. PCT/FR2005/050173 filed on Mar. 18, 2005, and published, in French, as International Publication No. WO 2005/105639 A1 on Nov. 10, 2005, and claims priority of French Application No. 0450776 filed on Apr. 23, 2004, which applications are hereby incorporated by reference, in their entirety.
BACKGROUND ART
The invention relates to the technical field of textile yarn processing machines.
In particular, the invention relates to machines like those comprising a plurality of working positions, particularly arranged in juxtaposition. Each of them has various means suitable for transforming the yarn in one or a plurality of steps, followed by its rewinding or spooling.
As examples, mention can be made of yarn processing machines which combine, on the one hand, means for advancing the yarns and, on the other, means for treating the yarns. The yarn advance means may consist of cylinders cooperating with press rollers, capstans, thread guides or other. The yarn treatment means may be based on a rotation, conferring on the yarns, for example, a twist on themselves or a winding of the yarns on one another.
The principle of this transformation is known, based on the one hand, on a rotation and conferring a torsion of the yarns on themselves or a winding of the yarns around one another, governed by the ratio of the speed of rotation of the spindle to the speed of travel of the yarn and, on the other, on the control of the yarn tension. A method called “single twisting” can be recalled here, which confers on the yarn a torsion on itself per turn of the spindle, while a “two-for-one twisting” method confers on the yarn two-torsions on itself per turn of the spindle.
In many cases, the transformation method also calls for treating several yarns in parallel, and assembling these yarns for subsequent transformation or spooling. Hence this implies an assembly of several transformed yarns on neighboring positions before sending them together to other transformation means and/or before rewinding them together.
According to the invention, it has appeared important to be able to control this assembly.
In known treatment machines, like those defined previously, they may comprise several members designed to advance the yarns, some of them being provided with non-slip driving means, and others, equipped with means optionally allowing slippage. The relative speeds of these members serve to control the tensions in the yarns, to create stretchings, to obtain stress relief or tension slackening. Only the drive speed, without slippage, of the members, serves to guarantee the speed of travel of the yarn and consequently the uniformity of the twisting.
During the assembly of a plurality of yarns, this means that for the assembled yarns to be of perfectly controlled length (for example, identical lengths), it is necessary:
to have at least one common non-slip yarn advance member or perfectly synchronized members; for the yarns to reach this member with a perfectly controlled tension (for example, equal tensions) from one yarn to the next.
In yarn cabling or twisting machines, it is perfectly known to a person skilled in the art to provide a drive device designed to lower the yarn tension, for example, in the form of a capstan or a grid type delivery unit, generally known by the name of pre-delivery unit or pre-feeding unit. In the rest of the specification, the member is referred to as the “first feeding means”. In general, this member permits slippage of the yarn and rotates in overspeed with respect to the yarn travel.
The yarn is then fed to a second “feeding” member, generally without slippage, ensuring control of the yarn travel speed. Very often, this second feed is provided by the rewinding system itself.
This ensures that the tensile force resulting from the yarn tension in the upstream processes is essentially absorbed by the first feeding means.
Reference can be made to FIG. 1 , which shows, as an indicative and nonlimiting example, a yarn treatment machine having members suitable for producing an assembly of a plurality of yarns, according to the prior art.
This figure shows that the first feeding and yarn travel means ( 2 a , 2 b , 2 c , 2 d ) are aligned together and rotated by a common shaft, by means of a drive member ( 8 ). The same applies to the feeding and spooling means ( 3 a , 3 b , 3 c , 3 d ), which are aligned together and rotated by a common shaft by means of a drive member ( 5 ).
These arrangements serve to obtain a perfect synchronism between the positions. However, this configuration leads to tension variations at the outlet of the first feeding means, low in absolute value, but significant in relative value. These tension variations result from the upstream tension dispersions between the positions, added to which are the variations in friction coefficient, geometric tolerances of the components of the feeding system itself. For example, for an upstream tension of between 10 and 12 N, the outlet conditions may vary from one position to another from 0.3 N to 0.6 N.
While such variations do not have any significant impact on the spooling quality when the yarn is spooled individually, the same cannot be said for an assembly of yarns required to meet an equi-length requirement.
In fact, during an assembly, such relative tension variations at the outlet of the first feeding means are incompatible with the requirements to control the length of the assembled yarns, if the assembly is made at this location.
To attempt to solve this problem, according to the prior art, the assembly is prepared upstream of the first feeding member, with the understanding that at this location, even if the absolute dispersion is wider, the relative dispersion is much narrower. As shown in FIG. 1 , as a result, the yarn guide means ( 7 a , 7 b , 7 c , 7 d ) from their working position to the assembly point (A), are arranged before the first feeding means ( 2 b ), which has the following drawbacks:
the various means ( 7 a , 7 b , 7 c , 7 d ), and drive member ( 5 ) are installed in the immediate vicinity of the upstream yarn treatment unit; the guide members are subjected to high tensions, generating severe requirements as regards reliability; the yarn tension, after assembly, is equal to the sum of the tensions of each yarn, so that the feeding and spooling means on the assembled yarns must be dimensioned to withstand this total tension; the yarns follow a long route with several corners under high tension which, by internal friction on the guide members, causes deterioration and affects the quality of the yarns; the difficulty, indeed impossibility, of assembling individual yarns having different characteristics (count, yarn type, number or direction of plies, etc.), due to the differences in tension resulting from these differences in characteristics.
SUMMARY OF THE INVENTION
It is the object of the invention to remedy these drawbacks, in a simple, safe, effective and efficient manner, and to solve the problem posed of obtaining perfect control of the yarn assembly process.
To solve such a problem, a device has been designed and developed for managing the assemblies of yarns in textile machines for processing said yarns comprising yarn upstream treatment or transformation units, first yarn feeding and advance means, and feeding and/or spooling means via a thread guide.
According to the invention, to solve the problem posed, the device comprises members suitable for producing an assembly of a plurality of yarns mounted in combination with a plurality of first feeding and advance means which are each controlled by an individual motor, said assembly members being placed between said first feeding means and one of the feeding and/or spooling means suitable for controlling the speed of travel of the joined yarns.
Regardless of the drive means of the feeding and spooling means of the thread guides, separately or synchronized, each individual motor of the first feeding and advance means is subjected to a speed variator.
Based on this underlying concept:
either the feeding and spooling means and the thread guides are each driven by a collective motor; or the feeding and spooling means and the thread guides are each driven by an individual motor.
According to another embodiment, the thread guides are driven by an individual motor, the feeding and spooling means and the first feeding and advance means being driven in synchronism by the same motor. In this embodiment, the speed ratio between the two means is determined by a system of pulleys.
An improvement to the invention consists in measuring the tension of each yarn by placing a sensor between the first yarn feeding and advance means and the assembly point, and by transmitting these tensions to a computer which controls the variators.
In the case in which the first yarn feeding and advance means have no synchronization link with the feeding and/or spooling members, the computer orders speed adjustments of the first feeding means to adjust the yarn tension measured, to a preprogrammed setpoint.
In the case in which the thread guides are driven by an individual motor, while the first feeding and advance means and the feeding and spooling means are driven in synchronism by the same motor, the computer takes as reference the yarn tension corresponding to the position to which the yarns are pulled, and orders speed adjustments of the first feeding members of the other positions, for example, to equalize the tensions.
Considering the basic features of the invention, it has appeared that the means and arrangements claimed have an advantageous application for producing a yarn, resulting from the assembly by twisting, cabling or covering of several basic yarns composed of a plurality of elementary yarns, some of which undergo a prior transformation operation before being assembled and receiving a new transformation step, at least one of the elementary yarns being different or undergoing a different transformation from the others.
It appears that the development of new textile materials, gives rise to the increasing consideration of novel fabrication methods for obtaining yarns resulting from the combination by assembly of increasingly diversified yarns. This is the case in particular of yarns for technical use, as in the following nonlimiting examples:
for the production of cords, straps, technical fabrics for special uses and having specific mechanical or physical properties of toughness, tensile strength, elasticity, and elongation under load, etc.; for the production of fabrics, belts, carpeting, textile coatings, having particular aesthetic, mechanical or physical properties; for the production of textile reinforcements for composites such as elastomers, such as for reinforcing tires, corrugated belts, etc., said yarns intended to be individually inserted, in layers, or employed in the form, for example, of fabrics, and requiring specific mechanical or physical properties of toughness, tensile strength, elasticity, elongation under load, etc.
The invention relates in particular to methods in which the prior transformation operations on the elementary yarn or yarns are methods of single twisting, two-for-one twisting, cabling or covering, etc.
Certain technical features of the yarns such as tensile strength, elasticity, elongation curve under load, fatigue strength, etc., are obtained by combining a plurality of yarns, each subjected to individual treatment, then assembled by perfectly controlled methods. The elementary yarns may be identical or different, and/or undergo identical or different transformations. Depending on the actual application, the methods may be designed to obtain an equi-length and/or equi-tension assembly. In other cases, the assembly method may consist, on the contrary, in assembling yarns having different elongation or tension levels.
In the following discussion, the term “hybrid yarn” is used to denote such yarns resulting from the assembly by twisting or cabling of yarns of different types, having undergone a different treatment or fed under different tensions.
Mention can be made, as a nonlimiting example, of U.S. Pat. No. 6,799,618, which relates to hybrid yarns resulting from the assembly of a plurality of elementary yarns which differ in their type and their prior treatment.
According to the prior art, hybrid yarns, composed of a plurality of elementary yarns which differ in their type and in their prior treatment, like those discussed as examples in the abovementioned patent, are usually produced in two steps. Each elementary yarn is transformed separately in a first step, for example on two-for-one twisting machines, and is individually received on an intermediate bobbin. The intermediate bobbins are then picked up on a creel feeding a machine which combines the assembly phase and the final treatment, such as a method by twisting the assembled yarns. This final treatment is usually carried out by a single twisting method.
This sequencing mode has the following drawbacks:
it imposes the need for at least two types of machines (for example, a two-for-one twisting machine for the first step, an assembly and single twisting machine for the second step); it requires the management, storage and handling of several batches of intermediate bobbins; the second assembly step is usually carried out in single twisting, which is a method producing at low speed, for example, on a ring frame, which uses rotating bobbins, with limited weight, and hence requiring frequent clearings. This second step has a relatively low productivity.
It therefore appeared important to propose means for increasing the possibilities of combining different individual yarns and controlling the assembly process, while offering great simplicity of application and better productivity.
The problem that the invention proposes to solve is to obtain a means for producing a hybrid yarn, resulting from the assembly by twisting, cabling or covering of a plurality of basic yarns, these basic yarns being identical or different, and being themselves treated by identical or different twisting or cabling methods. One object of the invention is to perfectly control the speed and/or tension of the yarns at the assembly point (said speeds and/or tensions being equal or different).
This results in a method according to which
at least one of the basic yarns is different from the others and/or undergoes a different first transformation from the others; the prior transformation is carried out in parallel in the same machine consisting of a juxtaposition of independent transformation means equipped with control means and being individually adjustable; an adjustment of the tension of each yarn, in particular a slackening from the tension resulting from the first transformation to the tension at an assembly point, is carried out on feeding devices equipped with adjusting means and control systems which can be adjusted individually so that the tension at the assembly point is adjusted individually; the yarns are routed by guide means to the assembly point where they are joined and arranged in parallel; a bobbin receives the yarns thereby assembled in a device itself constituting, or being associated with, positive feeding means, that is, operating without slippage with respect to the yarn, and able to control the speed of movement of the joined yarns;
The yarn bobbin thus formed is placed on a spindle of a twisting machine according to a second two-for-one twisting, cabling or covering treatment, in which the yarns are joined together by twisting the assembled yarns on themselves, by winding the assembled yarns around another yarn, or by winding another yarn around the assembled yarns.
Depending on the type of hybrid yarn to be produced, the treatment of the receiving bobbin takes place with different means.
The sequencing of these steps may, optionally, be supplemented by adding other supplementary operations, which may be carried out in parallel or be inserted between the abovementioned operations, without altering the sequencing thereof.
According to one embodiment, at least one of the basic yarns has a low elongation capacity under load, preferably combined with a high toughness, and of which at least one other elementary yarn has a higher elasticity and/or elongation capacity under load, the basic yarns being twisted separately to the different plies, then assembled under equal or different tensions, and twisted together.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The invention is described in greater detail below with reference to the figures in the drawings appended hereto in which:
FIG. 1 is a schematic view of a transformation machine equipped with yarn assembly members according to the prior art;
FIG. 2 shows a machine according to the one shown in FIG. 1 , equipped with the yarn management and assembly device according to the invention and in an embodiment in which the feeding and spooling means and the thread guides are each driven by a collective motor;
FIG. 3 is a view similar to FIG. 2 in which the feeding and spooling means and the thread guides are each driven by an individual motor;
FIG. 4 is a view corresponding to FIG. 3 in which the thread guides are driven by an individual motor, while the feeding and spooling means, and the first feeding and advanced means are driven in synchronism by the same motor;
FIG. 5 shows the application and use of a computer and a yarn tension sensor, applied to the embodiment shown in FIG. 3 , with the observation that this application may obviously relate to the embodiments shown in FIGS. 2 , 3 and 4 ;
FIG. 6 is a schematic view of a method for producing a hybrid yarn, shown here as an example of three-end twisting, by the inventive method, in which the prior twisting of the elementary yarns and the assembly is carried out with independent two-for-one twisting positions, and the final twisting of the assembled yarn is carried out by the two-for-one twisting method;
FIG. 7 is a schematic view of the assembly tension control means;
FIG. 8 is a very schematic view showing the two-step method of the invention, as shown in greater detail in FIG. 6 ;
FIG. 9 is a very schematic view of a complete two-step method in which the second step is carried out by two-for-one twisting of three assembled yarns, each of these assembled yarns consisting of pairs assembled by a direct cabling method;
FIG. 10 is a very schematic view of a complete two-for-one method in which the second step is carried out by direct cabling of two assembled yarns, each of these assembled yarns consisting of three yarns twisted by two-for-one twisting;
FIG. 11 is a very schematic view of a complete two-step method in which the second step is carried out by direct twisting of two assembled yarns, each of these two assembled yarns consisting of two yarns assembled by a direct cabling method;
FIG. 12 is a schematic view of an alternative of the inventive method in which an auxiliary yarn is added in the final two-for-one twisting step.
DETAILED DESCRIPTION
For a better understanding of the rest of the specification, the same numerals are used for the various embodiments of the invention.
In a manner perfectly known to a person skilled in the art, the transformation machine comprises a plurality of working positions. Each position comprises an upstream yarn treatment unit consisting, for example, of two-for-one twisting or cabling spindles ( 11 a , 11 b , 11 c , 11 d , . . . ), first feeding and advance means ( 2 a , 2 b , 2 c , 2 d , . . . ) of the yarn ( 1 z , 1 b , 1 c , 1 d , . . . ) and feeding and/or spooling means ( 3 a , 3 b , 3 c , 3 d , . . . ) via a thread guide ( 6 a , 6 b , 6 c , 6 d , . . . ).
According to the invention, the device comprises members ( 7 a , 7 b , 7 c , 7 d ) suitable for preparing an assembly (A) of a plurality of yarns, these members being mounted in combination with a plurality of the first feeding and advance means ( 2 a , 2 b , 2 c , . . . ).
Importantly, according to the invention, each of the first feeding and advance means ( 2 a , 2 b , 2 c , 2 d , . . . ) are controlled by an individual motor ( 8 a , 8 b , 8 c , 8 d , . . . ). The assembly members ( 7 a , 7 b , 7 c , 7 d , . . . ) are placed between the first feeding and advance means ( 2 a , 2 b , 2 c , . . . ), and one of the feeding and spooling means ( 3 b ) suitable for controlling the travel speed of the joined yarns. The assembly members ( 7 a , 7 b , 7 c , 7 d , . . . ) are therefore placed downstream of the first feeding and advance means ( 2 a , 2 b , 2 c , . . . ) and upstream of the feeding and spooling means ( 3 a , 3 b , 3 c , . . . ).
It has been observed that the feeding and/or spooling means ( 3 a , 3 c ) and their corresponding thread guides ( 6 a , 6 c ) are, in the particular case of the assembly mentioned as an example, unused, because their respective yarns are diverted toward the feeding means ( 3 b ) and its corresponding thread guide ( 6 b ).
Advantageously, regardless of the embodiment ( FIG. 2 , FIG. 3 , FIG. 4 ), each individual motor ( 8 a , 8 b , 8 c , 8 d , . . . ) of the first feeding and advance means ( 2 a , 2 b , 2 c , 2 d , . . . ), is subjected to a variator ( 15 a , 15 b , 15 c , . . . ).
In the embodiment shown in FIG. 2 , the feeding and spooling means ( 3 a , 3 b , 3 c , 3 d , . . . ) are driven by a common drive member ( 5 ). The thread guides ( 6 a , 6 b , 6 c , 6 d , . . . ) are driven by a common drive member ( 6 ).
In the embodiment shown in FIG. 3 , the feeding and spooling means ( 3 a , 3 b , 3 c , 3 d , . . . ) are each driven by an individual drive member ( 10 a , 10 b , 10 c , . . . ). The same applies to the thread guides ( 6 a , 6 b , 6 c , 6 d , . . . ) which are each driven by an individual motor ( 12 a , 12 b , 12 c , 12 d , . . . ).
In the embodiment shown in FIG. 4 , the feeding and spooling means ( 3 a , 3 b , 3 c , 3 d , . . . ) and the first feeding and advance means ( 2 a , 2 b , 2 c , 2 d , . . . ) are driven in synchronism by the same motor ( 8 a , 8 b , 8 c , 8 d , . . . ). The speed ratio between the means ( 2 a , 3 a ), ( 2 b , 3 b ), ( 2 c , 3 c ), ( 2 d , 3 d ), is fixed, for example, by a ratio of pulleys ( 9 a , 9 b , 9 c ).
The variators ( 15 a , 15 b , 15 c , . . . ) controlling the first feeding means are associated with speed adjusting means in the form, for example, of local control accessible by an operator.
Alternatively, the variators ( 15 a , 15 b , 15 c , . . . ) are controlled by a computer ( 14 ) delivering a setpoint to each variator, said setpoint being, for example, programmed by an operator.
As indicated, the device has a particularly advantageous application, for the production of a hybrid yarn resulting from the assembly by twisting, cabling or covering of a plurality of basic yarns ( 1 a , 1 b , 1 c , . . . ).
It may be recalled, in a manner perfectly known to a person skilled in the art, that the transformation process comprises three main operations:
a first transformation (Pa, Pb, Pc, . . . ) or all or part of the elementary yarns (Fa, Fb, Fc, . . . ) by a twisting, cabling, covering operation. This operation is carried out on a twisting spindle; an assembly, the yarns being joined parallel to one another at point (A); a second transformation (S) of the assembled yarns, which is a twisting, cabling or covering operation. This operation is carried out on a twisting spindle.
These operations may, optionally, be preceded upstream, or be supplemented by other steps, intermediate or associated with one or the other of these three operations, such as operations of rewinding, thermofixing, stretching, etc., without this affecting the scope of the present application insofar as the abovementioned three operations are grouped in two steps according to the sequencing mode described.
According to one important aspect of the invention, the means ( 11 a , 11 b , 11 c , . . . ) serve to carry out the first transformation (Pa, Pb, Pc, . . . ) of the basic yarns ( 1 a , 1 b , 1 c , . . . ) and are preferably placed adjacently and comprise individual drive means, each individually controlled by systems such as speed variators ( 16 a , 16 b , 16 c , . . . ). Each means ( 11 a , 11 b , 11 c , . . . ) is therefore set to carry out a transformation (Pa, Pb, Pc, . . . ) specific to each yarn, which may be different from the others, for example, a twisting of different value or direction. Optionally, some of the yarns ( 1 a , 1 b , 1 c , . . . ) may not be transformed, or their transformations may be at 0 turns, the yarn no longer receiving a twist, and only the unwinding and/or pretension means of the corresponding transformation means being employed. At the outlet of the transformation means ( 11 a , 11 b , 11 c , . . . ), each yarn has a tension which depends on its count and on the transformation (e.g. speed, drum diameter, yarn count, etc.).
Each yarn ( 1 a , 1 b , 1 c , . . . ) passes through first feeding means ( 2 a , 2 b , 2 c , . . . ) for adjusting its tension and particularly for reducing the yarn tension resulting from the transformation of the yarn (Pa, Pb, Pc . . . ), in the form, for example, of a capstan or a grid type delivery unit, generally known as a “pre-delivery unit” or “pre-feeding” unit. In the rest of the specification, this member is designated by the name of “first feeding means”. For example, to produce a slackening, this member permits a slippage of the yarn and turns in overspeed with regard to the yarn travel.
Importantly, each of the first feeding and advance means ( 2 a , 2 b , 2 c , . . . ) is provided with means for adjusting its efficiency. This means may, for example, consist in adjusting the winding arc of a delivery unit grid, or the number of turns wound around a capstan. This adjustment can be achieved manually or by actuators. This means for individually adjusting the efficiency of the first feeding means ( 2 a , 2 b , 2 c , . . . ) may also consist in adjusting the speed of the delivery member, for example, by being controlled by an individual motor ( 8 a , 8 b , 8 c . . . ), individually controlled by systems such as speed variators ( 15 a , 15 b , 15 c . . . ).
Each feeding and advance means ( 2 a , 2 b , 2 c . . . ) is hence set to adjust the specific tension of each yarn to the assembly tension which may be different from the others. At the outlet of the feeding and advance means ( 2 a , 2 b , 2 c . . . ), the yarn has a tension corresponding to the tension to be obtained at the assembly point (A).
The yarns ( 2 a , 2 b , 2 c . . . ) are routed to the assembly point (A) by guide members ( 7 a , 7 b , 7 c , . . . ). The members ( 7 a , 7 b , 7 c , . . . ) and the point (A) are placed between the first feeding and advance means ( 2 a , 2 b , 2 c . . . ) and the spooling means ( 3 ) suitable for controlling the travel speed of the joined yarns. The yarns ( 1 a , 1 b , 1 c ) joined in parallel, are then drawn by one of the spooling means which forms an intermediate bobbin ( 4 ).
The bobbin ( 4 ) of unitary yarns ( 1 a , 1 b , 1 c . . . ) having received the first treatment (Pa, Pb, Pc . . . ) is then taken up in a second machine to receive the second treatment (S). The assembled yarn is twisted in the spindle ( 17 ), passes through a feeding member ( 18 ) and is then spooled by the spooling means ( 19 ), forming the final bobbin ( 20 ).
Advantageously, regardless of the embodiment ( FIG. 6 et seq), each individual motor of the first transformation means ( 11 a , 11 b , 11 c . . . ) is subjected to a variator ( 16 a , 16 b , 16 c . . . ) and each individual feeding motor ( 8 a , 8 b , 8 c . . . ) and advance motor ( 2 a , 2 b , 2 c . . . ) is subjected to a variator ( 15 a , 15 b , 15 c . . . ). These variators ( 15 a , 15 b , 15 c . . . 16 a , 16 b , 16 c . . . ) are associated with speed adjusting means in the form, for example, of a setpoint or a local control accessible to an operator.
Alternatively, the variators ( 15 a , 15 b , 15 c . . . 16 a , 16 b , 16 c . . . ) are controlled by a computer ( 14 ) delivering a setpoint to each variator, said setpoint being, for example, programmable by an operator.
An improvement to the invention, shown in FIG. 7 , consists in placing the means for measuring the tension of each yarn, in the form, for example, of sensors ( 13 a , 13 b , 13 c , . . . ) downstream of the first feeding and advance means ( 2 a , 2 b , 2 c , . . . ) and upstream of the yarn assembly point (A). The tension indication of each yarn is sent to a computer ( 14 ) which transmits the setpoints to the variators ( 15 a , 15 b , 15 c . . . ) controlling the motors ( 8 a , 8 b , 8 c , . . . ) of the first feeding and advance means ( 2 a , 2 b , 2 c . . . ).
The computer ( 14 ), in the form for example of a central processor, permanently adjusts the speed of the first feeding means ( 2 a , 2 b , 2 c . . . ) to guarantee perfect compliance with the yarn tension demanded by the method at the assembly point (A) in order to offset any drift in the settings over time.
The tensions required by the assembly method may be equal tensions between each yarn or different tensions from one yarn to another.
According to the invention, it is therefore possible to prepare assemblies of yarns ( 1 a , 1 b , 1 c , . . . ) having different characteristics, each yarn being led to the assembly point (A) under a predefined tension controlled by the system. This result is particularly advantageous for assembling yarns having different elasticities.
It should be noted that means for measuring the tension of each yarn may be replaced and/or supplemented by means suitable for measuring the travel speed of the yarn immediately before the assembly point (A).
The inventive method, illustrated in FIGS. 8 and 9 , is particularly designed for producing a hybrid yarn for reinforcing tires or composites. This method consists in using at least two basic yarns ( 1 a , 1 b , 1 c , . . . ) of which at least one is different from the others. At least one of the basic yarns has a low elongation capacity under load, and at least one other elementary yarn has a higher elasticity and/or elongation capacity. The basic yarns are twisted separately to different plies, then assembled under equal or different tensions, and twisted together.
The production process according to the invention comprises the following steps:
all or part of the elementary yarns are twisted simultaneously and in parallel by a two-for-one twisting or direct cabling method (Pa, Pb, Pc . . . ), on spindles ( 11 a , 11 b , 11 c . . . ) preferably adjacent of a twisting machine;
each yarn is sent to a first delivery member ( 2 a , 2 b , 2 c , . . . ) of which the efficiency is adjustable independently from the others, to adjust its tension to the assembly tension; the yarns are guided by guide devices ( 7 a , 7 b , 7 c , . . . ) to the assembly point (A) where they are joined in an essentially parallel arrangement; the yarns thereby assembled are spooled to form an intermediate bobbin ( 4 ), the yarns being driven without slippage; the intermediate bobbin of assembled yarns ( 4 ) thus formed is placed on a two-for-one twisting spindle ( 17 ) and the assembled yarns are twisted by the conventional two-for-one twisting method (S), the assembled yarns being joined together by winding on themselves.
According to the invention, some of the yarns ( 1 a , 1 b , 1 c , . . . ) may not be transformed or twisted, only the unwinding and pretension means of the corresponding transformation means being used.
According to the embodiment of the invention shown in FIG. 12 , an auxiliary yarn ( 21 ) may be introduced into the assembly.
According to each case, it may be:
assembled without prior transformation at the assembly point A, its tension being optionally adjusted by a tensioner or any similar auxiliary delivery member; introduced on the two-for-one twisting spindle ( 17 ) via the hollow shaft, to join the yarns assembled in the first step at the outlet of the spindle ( 17 ), so that the auxiliary yarn is not twisted but is joined by winding around the assembled yarns which are twisted together in two-for-one twisting mode (two twist per turn of the spindle).
The auxiliary yarn ( 21 ) may be a yarn having an auxiliary function such as, for example, an antistatic or gas absorbing yarn. It may, itself, be a yarn formed by the assembly of a plurality of yarns, and/or may have undergone prior treatments.
The inventive method, illustrated by FIGS. 10 and 11 , is particularly intended for producing a complex hybrid yarn for reinforcing tires or composites. This second embodiment of the inventive method is characterized in that it uses at least two staple yarns of which at least one of the elementary yarns has a low elongation capacity, preferably combined with high toughness and of which at least one other elementary yarn has a higher elasticity and/or elongation capacity, the staple yarns being twisted separately to different levels, and then assembled under equal or different tensions, and joined together by winding with another yarn.
The method comprises the same steps as that described previously with the sole difference that the intermediate bobbin ( 4 ) is placed on a hollow spindle ( 10 ) for twisting or covering ( 17 ), the assembled yarns are joined by associating them with another yarn ( 4 ′), by a twisting or covering method.
According to this second embodiment, the other yarn ( 4 ′) which is associated with the first yarn ( 4 ) in the final step is different from the first assembled yarn ( 4 ), either in its composition of yarns ( 1 ′ a , 1 ′ b , 1 ′ c ), or in the treatment undergone (P′a, P′b, P′c, . . . ), the two yarns ( 4 ) and ( 4 ′) being joined by the process known as “direct cabling”.
According to this second embodiment, said assembled yarn ( 4 ) constitutes the core, and the yarn ( 4 ′) associated in the last step is a binding yarn surrounding the core yarn by a covering method.
The associated yarn ( 4 ′) may be a yarn having an auxiliary function such as, for example, an antistatic or gas absorbing yarn. It may itself be a yarn formed by the assembly of a plurality of yarns, and/or have undergone prior treatments.
According to the invention, in the first transformation (Pa, Pb, Pc . . . ) the speed of each spindle ( 11 a , 11 b , 11 c . . . ) twisting the basic yarns ( 1 a , 1 b , 1 c , . . . ) is set so that the yarn(s) with the lowest elongation capacity receive(s) a higher number of twists per meter than the high-elasticity yarn(s).
According to the invention, in the first transformation (Pa, Pb, Pc . . . ), the spindles ( 11 a , 11 b , 11 c . . . ), using the lower elongation capacity yarn(s) rotate:
either in the same direction as that of the spindles twisting the high-elasticity yarn(s); or in the reverse direction to that of the spindles twisting the high-elasticity yarn(s), for example, the lower elongation capacity yarn(s) are twisted in “Z” and the higher elasticity yarn(s) are twisted in “S”.
According to the invention, in the second transformation (S), the final twisting of the assembled yarns takes place in the reverse direction to the twisting of the yarn(s) having the lowest elongation capacity.
According to the invention, in the second transformation (S), the number of plies per meter during the final twisting is less than or equal to the number of plies per given meter during the first transformation of the yarn(s) having the lowest elongation capacity.
A first example of the inventive method is given below, applied to the production of a yarn for the production of belts, consisting of two elementary yarns of BCF 1240 dtex polypropylene, twisted at 180 turns per meter in Z, and a CF 600 dtex polypropylene yarn twisted at 130 turns/meter in S. The three yarns are joined and twisted together at 160 turns/meter in Z.
The two BCF polypropylene yarns ( 1 a , 1 b ) are twisted in the spindles ( 11 a , 11 b ) set to rotate at 5500 r/min in Z, and the polypropylene CF yarn ( 1 c ) is twisted in the spindle ( 11 c ) set to rotate at 3970 r/min in S.
The spooling system ( 3 ) winds the assembled yarns on a spindle ( 4 ) at a spooling speed of 61.1 m/min, without slippage.
The bobbin ( 4 ) is taken up on a two-for-one twisting spindle ( 17 ) rotating at 3500 r/min, with a feeding speed of 43.7 m/min, without slippage.
A second example of the inventive method is given below, applied to the production of a yarn for reinforcing tires, consisting of two elementary yarns of aramide 1100 dtex, twisted at 510 turns per meter in Z, and a nylon 940 dtex yarn twisted at 350 turns/meter in Z. The three yarns are assembled and twisted together at 350 turns/meter in S.
The two aramide yarns ( 1 a , 1 b ) are twisted on the spindles ( 11 a , 11 b ), set to rotate at 7000 r/min in Z, and the nylon yarn ( 1 c ) is twisted on the spindle ( 11 c ) set to rotate at 4800 r/min in Z.
The spooling system ( 3 ) winds the assembled yarns on a bobbin ( 4 ) at a spooling speed of 27.45 m/min, without slippage.
The bobbin ( 4 ) is taken up on a two-for-one twisting spindle ( 17 ) rotating at 5250 r/min, with a feeding speed of 30 m/min, without slippage.
The preceding examples are given to illustrate the implementation of the inventive method and are nonlimiting.
The advantages clearly appear from the specification, and the following are particularly emphasized and recalled:
The means for guiding the yarn toward the assembly point are installed in a zone distant from the spindle and hence more accessible to the operator. The guide members (casters, guides) are subject to low tensions since they are located after the first feeding. The pre-delivery members only have to withstand the tension of one yarn. The yarns follow a long route and have several corners under low tension, thereby preventing the deterioration of their quality (tensile strength, risk of broken strands, etc). It is possible to prepare yarn assemblies, each yarn being of a different type or count and receiving a different first treatment (in twisting direction or parameter number of plies) from the other yarns. After this first transformation, the yarns can be led to the assembly point under predefined tensions or speeds different from the others. The transfer from the first step to the second is provided by a single intermediate bobbin which contains the preassembled and preconditioned yarns in order to obtain the desired equilibrium of length and tension. The second transformation can be carried out by the two-for-one twisting or direct twisting method, which procures optimal productivity. A very wide variety of assembly configurations can be considered, with the joining of an unlimited number of yarns.
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A method and apparatus for production of a yarn, by plying, twisting or covering several basic yarns, subjected to a prior transformation, is provided. At least one of the basic yarns is different from the others and/or is subjected to a different prior transformation. The prior transformation may be carried out in parallel in the same machine, by independent transformation members able to be independently controlled. A slackening of yarn tension resulting from the prior transformation to give the desired tension at an assembly point is carried out on yarn feeding devices. Routing of the yarns is achieved by guide members towards the point of assembly, where the staple yarns are combined and arranged in parallel. A bobbin receives the assembled yarns in a device, constituting or associated with a positive feed device operating without slippage with relation to the yarn. The yarn bobbin with assembled yarns is then placed on a spindle of a twisting machine for a second double plying, twisting, or covering process.
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CROSS REFERENCE TO RELATED APPLICATIONS
This non-provisional United States (U.S.) patent application claims the benefit of U.S. Provisional Application No. 60/287,532, filed by inventors Ahmad Chini et al. on Apr. 30, 2001, titled “Wideband Symbol Synchronization In The Presence Of Multiple Strong Narrowband Interference”.
FIELD
This invention relates generally to communication devices, systems, and methods. More particularly, one embodiment of the invention relates to a method, apparatus, and system for wideband symbol synchronization in the presence of multiple strong narrowband interference.
GENERAL BACKGROUND
Receiver devices or systems in a communication system may receive signals or waveforms which are distorted by interference or noise. Some wideband communication systems are supposed to work in the presence of strong narrowband interference.
Despite such narrowband interference, a receiving device must be able to detect a signal and determine its content. A receiving device must be able to align or synchronize the received signal in order to determine the start of a signal or message and/or to determine whether such signal contains a message.
However, many time domain and frequency domain synchronization algorithms fail in the presence of such interference. Some algorithms are more complex and some do not tolerate multiple interference. Some algorithms are very sensitive to the signal gain or require specific forms of symbols or patterns for synchronization.
Time domain correlation synchronizers may be used for synchronization but require many high-resolution multiplications for each received sample. For instance, 256×256 multiplications are required for a time domain correlation synchronizer for a synchronization symbol two hundred fifty-six (256) samples long.
Some time domain synchronizers use only the received signal sign to reduce the implementation complexity. However, such sign-based synchronizers often fail in the presence of strong narrowband interference.
Some frequency domain correlation synchronizers have to calculate the fast Fourier transform (FFT) coefficient of the signal on each coming time sample. This obviously is very complex to implement in real-time applications.
There is a frequency domain symbol synchronizer, which is based on only one time FFT calculation per symbol (each symbol comprising multiple time samples). However, this approach is based on calculation of FFT output phases and requires comparison with every possible phase settings to obtain the timing reference. Phase calculations and a large number of comparisons make this approach less attractive compared to the approach of the invention.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is an exemplary embodiment of a preamble signal as may be utilized for symbol synchronization in the present invention.
FIG. 2 is an exemplary block diagram illustrating the operation of the present invention.
FIG. 3 is an exemplary code illustrating the operation at various points on the block diagram in FIG. 2 .
FIG. 4 illustrates an exemplary embodiment of two strong narrowband interferences as seen at the FFT output point X in the block diagram shown in FIG. 2 .
FIG. 5 illustrates a typical shape of an exemplary signal obtained at point C on the block diagram shown in FIG. 2 .
FIG. 6 illustrates an exemplary Synch signal obtained using the synchronizer of FIG. 2 .
FIG. 7 illustrates another exemplary Synch signal were the time-shift is in the reverse direction as that of FIG. 6 .
DETAILED DESCRIPTION
In the following detailed description of the invention, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it is contemplated that the invention may be Practiced without these specific details. In other instances well known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the invention.
To address the problem of signal alignment or synchronization in the presence of interference, the invention provides a frequency domain symbol synchronization algorithm which works in the presence of multiple strong narrowband interference signals. Wideband Code Division Multiple Access (CDMA) and Orthogonal Frequency Division Multiplexing (OFDM) are among the communication systems, which could be benefited from this algorithm.
In one aspect of the invention, frequency analysis of the received signal confines narrowband interference signals to a small portion of the signal bandwidth. The signal is then processed to find the symbol time-shift, indicating the amount of signal misalignment, which appears as a modulated signal in the frequency domain. The modulating frequency is extracted and used to estimate the symbol time-shift.
For purposes of synchronization or signal alignment, a number of wideband synchronization symbols are initially appended to a signal. The synchronization symbol(s) may be of any length sufficient to allow a receiving device to determine if the received signal or waveform contains legitimate content or data or determine where the content begins within the signal.
According to one implementation, a synchronization symbol of length N is employed (where N is the number of samples). For example, a randomly generated symbol of length two hundred fifty-six (256) samples may be used. The synchronization symbol may be repeated multiple times to allow for better time alignment.
FIG. 1 is an exemplary embodiment of a preamble signal as may be utilized for symbol synchronization in the present invention. As illustrated in FIG. 1 the same wideband synchronization symbol is repeated four times (indicated as A, B, C, and D) to form a preamble signal.
The preamble signal, along with a frame of data, is transmitted across the channel where it is corrupted by additive noise and narrowband interference signals.
FIG. 2 is a block diagram illustrating the processing and synchronization of a transmitted signal or waveform at a receiving device or system. FIG. 3 illustrates pseudo code for implementing one embodiment of the invention according to the block diagram of FIG. 2 . FIGS. 4-7 provide illustrative signals as they may appear at various points of the block diagram in FIG. 2 .
Referring to FIG. 2 , a received signal (Input Data Stream) is processed by an analog to digital converter 102 (ADC), the ADC output 104 is framed and windowed (truncated) 106 to a length equal to the length of the synchronization symbols. For example, a two hundred and fifty-six (256) Hanning window may be used in an implementation where a synchronization symbol two hundred and fifty-six (256) samples long is employed.
Windowing 106 is performed to reduce the interference spread in the frequency domain. The windowed data 108 is analyzed using a FFT processor 110 of a proper length to convert the signal from the time domain into the frequency domain.
An example of the output of the FFT X 110 is illustrated in FIG. 4 . The presence of two strong narrowband interference signals 402 and 404 is seen in this graph. This illustrative graph, as well as those of FIGS. 5-7 , assume a signal to noise ratio of about ten (10) decibels (dB), and two interference signals 402 and 404 of about twenty-five (25) dB and twenty (20) dB stronger than the signal, respectively.
The output X 112 of the FFT 110 is then correlated (multiplied in the frequency domain) with the reference synchronization symbol 138 . The reference synchronization symbol 138 is the frequency domain representation of the transmitted synchronization symbol and is known beforehand by the receiving system.
The result of the correlation (product) 114 is a signal with real 140 and imaginary 142 components containing time-shift information for the input data stream.
The sign of each signal component 116 and 118 is then obtained to provide corresponding signals A 144 and B 146 respectively. Relying on the sign of the outputs 116 and 118 of the frequency domain correlator 114 makes the invented approach less complex and more robust to signal gain or magnitude variations. Determining the sign of the outputs 116 and 118 also removes processing ambiguities associated with signal phases greater than three hundred sixty (360) degrees.
The resulting sign signals A 144 and B 146 are then convolved 120 . A convolved signal C 132 of typical shape is shown in FIG. 4 . Convolving the signals A 144 and B 146 , which carry common signal information, helps to reduce the noise in the resulting signal C 132 .
The frequency and sign of signal C 132 provide the time-shift information to align the input data signal (Input Data Stream). An exemplary embodiment of a signal (at point C 132 in FIG. 2 ) is illustrated in FIG. 5 . To extract the time-shift information from the signal C 132 , another FFT processing 122 is performed. The real 150 and imaginary 152 components of the resulting signal are then added (sum) 124 to provide a synchronization (Synch) signal 126 . The Synch signal 126 indicates how much alignment (symbol time-shift) is necessary to synchronize the input data stream.
The Synch signal 126 may then be processed by a peak detection module to provide the time-shift parameters (peak 134 and index 136 ).
FIG. 6 illustrates an example Synch 126 signal. The index 136 and the sign of the peak 134 (positive or negative) of this signal is used by a controller 130 to determine the amount and the direction of the required time-shift 148 .
For the example illustrated in FIG. 6 , a time-shift 148 of twenty (20) samples is required to align the receiver and the transmitter. The number of samples is indicated by the index 136 corresponding to the location of the peak 600 . The peak sign indicates the direction of the time-shift.
FIG. 7 shows the case where a time-shift 148 in the reverse direction 700 is required. The same structure of FIG. 2 may be used to initially detect the signal.
According to one aspect of the invention, the presence of a preamble synchronization symbol may be first asserted by comparing the peak signal 134 with a threshold magnitude level, before proceeding with symbol synchronization as described.
The algorithm of the invention works with a wide range of synchronization symbols including many randomly generated ones.
According to another aspect of the invention, the symbol synchronizer of FIG. 2 may be repeatedly invoked with various initial time-shifts (provided that preamble is long enough) to more accurately synchronize the input signal or data stream. In one implementation the resulting time-shift signal 148 may be integrated for more accurate symbol synchronization.
Various windowing functions may be employed including, but not limited to, Hanning, Hamming, Blackman, Blackman-Harris, Kaiser-Bessel, and rectangular windowing without deviating from the invention.
According to an alternative implementation, a single signal, either A 144 or B 146 , may be employed in obtaining the synchronization signal. In such embodiment, the convolution 120 is skipped.
As a person of ordinary skill in the art will recognize, a narrowband is merely narrow relative to the overall width of the communication channel employed. Thus, the width of narrowband interference need not be narrow in absolute terms but just in relative terms.
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art. Additionally, it is possible to implement the invention or some of its features in hardware, programmable devices, firmware, integrated circuits, software or a combination thereof where the software is provided in a machine-readable or processor-readable storage medium such as a magnetic, optical, or semiconductor storage medium.
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A method and apparatus for time-shift extraction in a wideband transmitted signal containing strong narrowband interference or noise. The time-shift extraction is based on the time domain and frequency domain relation of symbol misalignment. The invention uses the sign of the product of a recieved signal sample and a reference symbol in the frequency domain to determine the time-shift. It does not rely on the signal magnitude and is therefore less dependent on the signal gain. It also does not rely on the soft phase values, which have ambiguity for values more than three hundred sixty (360) degrees.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. §119 to Danish Patent DK PA 1999 01207, filed Aug. 31, 1999 and U.S. Provisional Application Serial No. 60/157,042 filed Oct. 1, 1999, the entire contents of both of which are hereby incorporated by reference in their entirety for all purposes.
FIELD OF THE INVENTION
The present invention provides a method and an apparatus for stimulating and/or modulating growth and differentiation in biological or plant tissue, seeds, plants, and microorganisms. An apparatus of this type includes a pulse generator and a plurality of coils, in which pulsed currents cause fluctuating magnetic fields in a predetermined region holding the material to be stimulated. The fluctuating magnetic fields will induce an electric field in the material.
BACKGROUND OF THE INVENTION
Pulsed electromagnetic fields (PEMF) have been used widely to treat delayed non-heating fractures, pseudoarthrosis, osteoarthritis, bone fractures and related problems (Bassett, C. A., Mitchell, S. N. & Gaston, S. R. (1981); (Trock et al., 1994). “Treatment of ununited tibial diaphyseal fractures with pulsing electromagnetic fields”, Journal of Bone and Joint Surgery [American], 63-A, 511-523 and Bassett, C. A. L., Pilla, A. A. & Pawluk, R. J. (1977) “A non-operative salvage of surgically-resistant pseudarthroses and non-unions by pulsing electromagnetic fields: a preliminary report”, Clinical Orthopaedics, 128-143) and have also been suggested for the treatment of nerve growth and wound healing (Sisken, B. F., Kanje, M., Lundborg, G., Herbst, E. & Kurtz, W. (1989), “Stimulation of rat sciatic nerve regeneration with pulsed electromagnetic fields”, Brain Research, 485, 309-316 and Patino, O., Grana, D., Bolgiani, A., Prezzavento, G., Mino, J., Merlo, A. & Benaim, F. (1996), and “Pulsed electromagnetic fields in experimental cutaneous wound healing in rats” Joural of Burn Care and Rehabilitation, 17, 528-531). It has been suggested that some of the important effects relating to an enhanced bone growth is the PEMF-induced promotion of angiogenesis, but this issue is not yet resolved (The National Institute of Environmental Health Services (NIEHS): “Assessment of Health Effects from Exposure to Power-Line Frequency Electric and Magnetic Fields”. (http://www.niehs.nih.gov/emfrapid/home.htm)).
A temporarily varying magnetic flux through an area induces an electric field, E, along the perimeter of the area according to the basic laws of electromagnetism. If the varying magnetic field, B(t), is applied to a material containing free (or mobile) charge carriers, these will be accelerated by the electric field thereby generating eddy currents in the material. The induced electric field or the generated current depends upon the rate of change, dB/dt, of the magnetic field, the electric field or current increasing with increasing rate of change.
The main point in treating biological tissue i.e. bone healing, wound healing, nerve growth, and angiogenesis is the introduction of tissue currents with an intensity and duration that can activate cellular signalling processes and extracellular signals, thus initiating cell proliferation and differentiation and other biological processes.
WO 85/00293 and WO 99/10041 describe the use of conducting coils to stimulate growth and healing in living tissue. The coils are positioned so as to generate a strong field at the region to be treated and a pulsating current signal is supplied for conduction in the coils.
PEMF has been used for activating muscle and neural cells as an alternative method to electrodes see e.g. EP 788 813 or U.S. Pat. No. 5,738,625. PEMF induced by conducting coils has the advantage that no electrodes in direct contact with the skin have to be used. The PEMF used for activating cells must be fast and/or large enough to induce electric potentials large enough to elicit the action potentials of excitable cells. In order to achieve such large electrical potentials, very large currents are used in the coil and the fields from several coils are added. In EP 788 813, the PEMF is used to activate muscle cells to flex a group of pelvic floor muscles in order to treat urinary incontinence. In U.S. Pat. No. 5,738,625, the PEMF is used to activate neural cells in order to investigate or diagnose the nervous system.
The effects of fluctuating magnetic fields in the tissue can be anticipated to be due to the effect of the induced electric field upon charged particles and entities (ions, molecules and macromolecules such as proteins, and inositol phosphates and other signalling compounds, cells and their extracellular signalling compounds such as hormones and other neurotransmitters etc.). Hence, the effects of fluctuating magnetic fields can be anticipated to be due to the extracellular as well as intracellular events caused by the electric fields and currents.
Regarding extracellular effects it can be expected that the on and off rate constants for the associations between neurotransmitters, hormones and their receptors will be affected, to the extent that net positive or negative charges are associated with the process, as well as inducing piezo-electric currents in bone tissue, thus mimicking physiological processes. The intracellular effects that might be the most affected are biochemical reactions that are involved in promoting cell division and differentiation. Amongst cellular signalling processes that have been suggested to be essential for the initiation of cell proliferation is the activation of protein kinase A. This enzyme is activated by cAMP (cyclic adenosine 5′ monophophate) that is synthesised from ATP by a receptor activated adenylyl cyclase. cAMP binds to protein kinase A and forms catalytic subunits, and this signal can be carried to the nucleus. Here it leads to activation of cAMP-inducible genes. Activation of the synthesis of cGMP, by iron containing enzymes such as nitrogen oxide synthetase that in turn activates classes of protein kinase G, are also important candidates. Several studies have implicated that the activation of ornithine decarboxylase, causing synthesis of prutescine and other related compounds, that promotes DNA transcription, also appear to be essential. The mechanism by which signalling processes are initiated appear to be due to a combined effect of proteins with a net charge, that will move in the cell interior (G-proteins, protein kinases, mRNA binding proteins etc.). Those can associate with target proteins and exert a biological effect and changes in the association constants for these processes will affect cellular function. Other ions, such as Ca 2+ , are highly affected by electrical fields, and will also exert a biological effect by associating with intracellular proteins and ion channels. The essential point is that signalling molecules with net charges or areas with net charges will be affected by the changing magnetic fields and all charged particles will rotate in magnetic fields depending on movements relative to the magnetic field.
One important aspect of promoting growth of osteoblasts, chondroblasts, chondrocytes and their derivatives (bone and cartilage), nerve cells, and other tissues is the induction of growth of small vessels (capillaries) that supply the blood cells, hormones and nutrients for sustaining cell proliferation and differentiation. The small vessels consist of endothelial cells, smooth muscle cells, and other cell types that together will protrude into new areas following the activation of nitric oxide (NO) and growth factors. These cells are also connected to each other both through signalling by chemical substances but also electrically through gap junctions. Both NO, vascular endothelial growth factor (VEGF) and other factors, appear to play an essential role in activating growth and differentiation amongst other things through activation of MAP kinase signalling pathways. However, the intracellular signalling processes play an equally important role in the cellular activation and when considering the effects of PEMF on angiogenesis both extracellular as well intracellular events should be considered.
The induced electric field from a circular coil can be calculated in a plane parallel to the coil, at a given distance from the coil. Due to the cylindrical symmetry, the induced electric field will have a circular symmetry in the plane, and have a maximum at a circle centered at the center axis of the coil with a radius, r, smaller than the radius, R, of the coil. As the distance from the coil to the plane increases, the peak of the maximum flattens out and the radius of the ring shaped maximum varies slightly. Thereby, the maximum of the induced electrical field in a direction away from the coil, form a tubular region centered on the center axis of the coil, and in a plane at a given distance from the coil, the induced electrical field will have a ring shaped maximum with a minimum in the center.
In the apparatuses of the prior art, the region to be treated is centered in the coil thereby experiencing an approximately homogeneous induced electrical field while the ring shaped maximum is positioned in regions encircling the region to be treated. Hence all-over, the field is inhomogeneous.
The biochemical features outlined in the above take place at a large range of electric fields. However, if the induced electrical field gets too high in the region to be treated, it will lead to elicitation of action potentials of excitable cells in the region. Elicitation of cellular action potentials is normally undesirable since it may lead to nuisance for the patient or give rise to undesirable physiological reactions. For example, the effects of the large induced electrical fields in EP 788 813 or U.S. Pat. No. 5,738,625 are a flexing of muscles due to activation of muscle cells or elicitation of nerve impulses due to activation of neural cells. These are undesirable side effects for a person undergoing a continuous treatment.
Therefore, under normal conditions it is not possible simply to increase the current or its rise time in the coils in order to achieve a larger induced electrical field over the region to be treated. The average field can only be increased until the field at the ring shaped maximum reaches the limit for elicitation of the action potentials of cells. Thus the average induced electrical field in the larger central part will not be increased to a very high degree. Hence by increasing the current or its rise time, the field in the region to be treated can only be brought to an average value lying considerably lower than the limit for elicitation of the action potentials of cells. In order to maintain the homogeneous field in the region to be treated, one will pay the price of a lower field and a large stimulation in the surrounding regions, which are not to be treated.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method and apparatus that stimulates biological tissues that substantially overcomes one or more of the problems due to the limitations and disadvantages of the related art.
The present invention utilizes the realization that stimulation of the biological tissue depends on the magnetic field in a way not previously anticipated. According to investigations performed by the inventors, there is an improved stimulation of the biological tissue in regions lying above or below the perimeter of the coil and not in the regions lying above the center of the coil. Also, the investigations showed that a continuous treatment for longer periods of time (few hours to several days) is often desirable. Hence the efficiency of the biochemical features outlined in the above and giving rise to treatment of biological tissue i.e. bone healing, wound healing, nerve growth and angiogenesis, depends on the induced electrical fields. In order to optimize the effects in the region to be treated, it is desirable to increase the induced electric field in this region and to have a constant average field over the region.
Especially, it has been found that larger B- and/or E-field gradients seem to have a positive effect on the cells, tissue and microorganisms. Such gradients may especially be formed by two coils oppositely polarized and positioned adjacently in relation to the cells. In this manner, especially in the intermediate area of the fields of the coils a larger field gradient is obtained. This effect has not been described hitherto.
The present technique imposes movement of ions and proteins in the tissue from all germinal layers that affects cellular activity in individual cells and in biological tissue as a whole. Important factors are the magnitude of the driving force (through imposing a changing magnetic field strength) with the direction of the magnetic field vectors; the frequency and shape of the pulses and the electrical potential. Those factors determine to which extent a compound possessing a net charge (ions, macromolecules etc.) are affected in a way such that a biological process (proliferation and differentiation) is initiated. The energy level by which the tissue is affected preferably does not cause significant changes in membrane potential and does not evoke action potentials in excitable tissues.
In a first aspect, the invention relates to an apparatus for stimulating living cells, micro organisms, and/or tissue using pulsed electromagnetic fields, the apparatus including a plurality of electrically conducting coils each having center axis, each center axis being directed into the cells, micro organisms, and/or tissue; and a pulse generator operationally connected to each coil for supplying a series of current pulses for conduction in each coil, the series of pulses being adapted to generate a periodically varying magnetic field from each coil for inducing an electrical field, wherein a number of coil pairs, including a first coil and a second coil adjacent to the first coil, exist in each of which, for a given pulse supplied by the pulse generator, the magnetic field at the center of the first coil is directed toward the cells, micro organisms, and/or tissue and the magnetic field at the center of the second coil is directed away from the cells, micro organisms, and/or tissue.
Thus, by providing pairs of coils where the desired E-field gradients are provided, a better influence on the tissue/cells/micro organisms is provided. It should be noted that, naturally, a given coil could be part of a number of pairs in that it will normally have more than one adjacent coil in the apparatus.
In the present context, the center axis of a coil is a symmetry axis normally directed along the central axis of a tubular coil or perpendicularly (positioned centrally) to a plane of a flat coil.
In order to obtain the desired effect over an area exceeding that of merely two coils, it is normally preferred that the number of pairs exceeds half the number of coils in the plurality of coils such as that the number of pairs exceeds 3/4 times the number of coils in the plurality of coils, such as 0.8 times the number of the plurality of coils, such as 0.9 times the number of the plurality of coils, such as being at least substantially equal to the number coils in the plurality of coils. In fact, coil positioning structures exist in which the total number of such pairs exceeds the number of coils in the apparatus by more than a factor of two.
Another manner of defining this manner of obtaining the desired gradients is to provide the apparatus with coils so that, for the given pulse supplied by the pulse generator, in each pair of coils, the first coil is adapted to conduct the current pulse in a clockwise direction and the second coil is adapted to conduct the current pulse in a counter-clockwise direction taken along the center axes of the first and second coils, respectively, in a direction toward the cells, micro organisms and/or tissue.
Again, preferably the first coil of each pair is adapted to conduct the current pulse in a clockwise direction and wherein two, three or more of the nearest neighboring coils of the first cell are adapted to conduct the current pulse in a counter clock-wise direction taken along the center axes of the coils in a direction toward the cells, micro organisms and/or tissue.
Naturally, the number of coils will depend on the actual use of the apparatus—and on the size thereof.
A cross section of each coil, perpendicularly to the center axis, may be at the most 100 cm 2 , such as at the most 50 cm 2 , preferably at the most 25 cm 2 , such as at the most 10 cm 2 , such as at the most 9 cm 2 , preferably at the most 8 cm 2 , such as at the most 7 cm 2 , preferably at the most 6 cm 2 , such as at the most 5 cm 2 , preferably at the most 4 cm 2 , such as at the most 3 cm 2 , preferably at the most 2 cm 2 , such as at the most 1 cm 2 , preferably at the most 0.5 cm 2 , such as at the most 0.4 cm 2 , preferably at the most 0.3 cm 2 . Smaller coils make it possible to use a large number of coils whereas larger coils are able to provide larger fields—such as for use at a larger distance, such as for treating cells, tissue and/or micro organisms inside a container or body.
Normally, the apparatus would include more than 2 coils, and depending on a number of factors, the number of coils may exceed 2, 4, 6, 8, 10, 14, 18, 20, 24 or more.
Naturally, the shape of the coils may be any shape desired. The shape of the coils will be determined on the basis of ease of manufacture, availability and requirements as to the individual positioning.
By using a number of, especially smaller, coils, the induced electric field at a given depth will have many smaller ring shaped maximum regions instead of one large ring shaped maximum region—together with a number of the desired high gradient areas. Thereby the total induced electric field will be more homogeneous and have a higher average value without eliciting any cellular activation potentials. Also the ratio between low field regions within ring shaped maxima and the total region to be treated is reduced.
The current pulses conducted in the coils preferably include rising and declining phases (two, three or more) resulting in the imposition of an electric field on the charges in the region to be treated. The overall duration of these events may vary depending on the pulse pattern. Thus, the events include increasing and declining magnetic fields that cause the appearance of temporally dependent electric fields on charged particles in particular directions in the tissue. These fields gives rise to the currents in the cells and extracellular environment consisting of moving ions and macromolecules such as proteins and nucleotides as well as amino acid, inositol phosphates and other charged signalling molecules. Thereby, cells are activated in fashion different from events such as i.e. action potentials.
Normally, each coil has a part being at least substantially perpendicular to the center axis of the coil and being adapted to face the cells, micro organisms and/or tissue, the parts of the coils being positioned in one or more planes each including a plurality of coil parts.
The coil may be a flat coil where the part will then be a side surface thereof. Alternatively, the coil may be tubular, where the part would then normally be an end portion thereof.
In order to fit in as many coils in the space as possible, it may be preferred that the parts of the coils within a predetermined area in one of the one or more planes are positioned so as to form so-called closest packing. The closest packing being a manner of packing circular elements optimally.
Also, at least one of the coils may have a part within the predetermined area and has a center to center distance to a nearest neighbor being between 1D-1.5D, where D is the diameter of the one coil.
Different structures may be used in order to provide as many pairs as possible providing the desired gradients. In fact, one preferred structure is the above closest packing which, unfortunately, provides also adjacent coils providing fields in the same direction. Another interesting structure is a honeycomb structure where it is possible for all three coils adjacent to a given coil to have the opposite field than the given coil.
In one embodiment, the plurality of coils is embedded in a flat sheet of flexible material for at least partly surrounding the predetermined cells, microorganisms and/or tissue. Thus, a bendable sheet is provided for surrounding a container, a body part or the like.
In another embodiment, the apparatus includes an even number, larger than two, of coils arranged in sets of two, the coils of each set being adapted to be positioned on at least substantially opposite sides of the cells, micro organisms and/or tissue and having at least substantially coincident center axes. In this manner, the coils may be positioned in one or more flexible sheets or more rigidly fixed e.g. in a tong-like device for at least partly encircling the e.g. container or body part.
Each coil may have a ratio between its inductance and resistance resulting in a pulsed current with a rise time in the range from 0.1 ms to 2 ms and a maximum current corresponding to a maximum magnetic field of 0.05-0.1 Tesla at the center of the coil. This has been found suitable for enhancing angiogenesis in biological tissue.
Also, the pulse generator may be adapted to generate pulses with a frequency in the range from 1 to 300 Hz, such as 10-200 Hz, preferably 20-100 Hz.
Normally, the apparatus will include a power supply for supplying power to the pulse generator. Especially in order to provide a portable apparatus, the power supply may be a battery included within the apparatus and supplying an electric potential of 50 V or less.
Normally, the current pulses fed to the coils will be the same pulses. However, it is possible to actually provide different pulses to different coils, such as pulses having different frequencies. In that situation it is desired that those frequencies are multiples of a basic frequency so that the pulses may be provided at least substantially simultaneously.
It is preferred that the phases of the pulses have a temporal separation in order for the biochemical events to occur, and the two events are therefore normally separated by milliseconds. It has been found suitable to provide a delay of 0.01-10 ms, such as 0.05-5 ms, preferably 0.2-2 ms, such as on the order of 0.5 ms between adjacent pulses for the coils. Also, a time duration of 1-100 ms, such as 2-50 ms, preferably 5-20 ms, such as on the order of 10 ms of the pulses has been found preferred for some applications.
Also, it generally may be desired to provide a treatment over a prolonged period of time, such as a period of time exceeding 15 minutes, such as exceeding ½ hour, preferably exceeding 1 hour, such as exceeding 2 hours, such as exceeding 4 hours, preferably exceeding 10 hours, such as exceeding 15 hours, preferably exceeding 1 day, such as exceeding 2 days.
An especially preferred embodiment of the present apparatus is one being adapted to be carried by a person during an operation.
In that and other embodiments, it is desired that the apparatus further includes a fastener for fastening the coils to a body part of a human or animal.
The present invention also relates to two preferred devices that by use of conventional CMOS IC technology create the particular currents in the coils. The devices include timing circuits, made from standard CMOS IC's with low power consumption. They form a free running asymmetric square wave generator that for example produces an output pulse every 18 ms with a pulse with of for example 3 ms. This pulse is applied to the output stage. The pulse pattern can consist of one or two phases. A CMOS IC, that divides the pulse frequency by 100, drives a control lamp by counting the flashes. This makes it possible to make a simple evaluation of the generator functionality and its frequency. In addition in one device, a magnetometer is incorporated to check the battery and the coils for defects. This circuit includes a little sense coil, an amplifier, a peak rectifier and a comparator that, when beyond threshold, drives the control lamp to light permanently. The comparator threshold is passed when the stimulating coil is functioning correctly when held close to the location of the sense coil.
An alternative to the use of the sensing coil is to have the control lamp flash only when the coil current is within the limits that ensures correct functionality.
In another aspect, the invention relates to the use of the above apparatus. In this case in a second apparatus the coil current is sensed.
Especially, the invention relates to the use of the above apparatus for enhancing tissue growth in a human or an animal, the use including positioning the coils adjacently to the tissue in question and operating the pulse generator.
In this situation, the series of pulses and the coils are preferably selected so that the maximum regions of the induced electrical fields in the predetermined portion are sufficiently small in order not to elicit action potentials in living cells. Normally, a muscle cell or nerve is depolarized to an extent that the membrane potential from −90 mV (muscle) or −70 mV (nerve) reaches its threshold around −55 mV whereby an action potential is elicited. Thus, the present apparatus is able to treat the cells etc. without eliciting excitable tissues.
In one embodiment, the use includes positioning of the coils at the upper or lower jaw of the human or the animal for inducing an enhanced bone growth, such as after extraction of a tooth.
In another embodiment, the use includes positioning the coils at the upper or lower jaw of the human or the animal for promoting in-growth of dental implants.
In yet another embodiment, the use includes attaching the coils to a joint region of the human or the animal for treatment of arthritis or pain, and/or for promoting growth of bone and/or cartilage and/or blood vessels (angiogenesis).
In an alternative embodiment, the use includes attaching two or more coils to a joint region of the human or animal to prevent arthritis or pain or to promote bone growth after a bone fracture.
In another embodiment the apparatus can be used for enhancing the biochemical activity of neural tissue. Three or more coils can be attached to the head and transcranial stimulation conducted without eliciting action potentials but enhancing neural activity resulting in an increased neurosecretion and/or in cell division. This can be applied for i.e. the treatment of depression disorders.
Alternatively, the above apparatus may be used for treating microorganisms, the use including positioning the coils adjacently to the microorganisms in question and operating the pulse generator.
The above apparatus may also, as a matter of fact, be used for treating seeds, plants or plant tissue. This use will include positioning the coils adjacently to the seeds, plants or plant tissue in question and operating the pulse generator.
A third aspect of the invention is a method of treating micro organisms with pulsed electromagnetic fields, the method including providing the above apparatus, directing the center axes of the coils into the micro organisms, and operating the pulse generator.
A fourth aspect of the invention relates to a method for treating cells, micro organisms and/or tissue with pulsating electromagnetic fields, the method including providing a plurality of coils each having a center axis directed into the cells, micro organisms and/or tissue; and providing a series of current pulses to each coil, the series of pulses being adapted to generate a periodically varying magnetic field from each coil for inducing an electrical field, wherein for a given pulse of the series of pulses, and for a number of pairs of the coils, each pair including a first coil and a second, adjacent coil, the magnetic field at the center of the first coil is directed toward the cells, micro organisms, and/or tissue and the magnetic field at the center of the second coil is directed away from the cells, micro organisms, and/or tissue.
Again, it may be preferred that the number of pairs exceeds half the number of coils in the plurality of coils, such as that the number of pairs exceeds 3/4 times the number of coils in the plurality of coils, such as 0.8 times the number of the plurality of coils, such as 0.9 times the number of the plurality of coils, such as being at least substantially equal to the number of coils in the plurality of coils.
Also, it may be preferred to also have the step of providing a part of each coil, the part being at least substantially perpendicular to the center axis of the coil and being adapted to face the cells, micro organisms and/or tissue, in one or more planes each including a plurality of coil parts.
The parts of the coils may be provided within a predetermined area in one of the one or more planes are positioned so as to form the closest packing.
Also, at least one of the coils having a part within the predetermined area may be provided to have a center-to-center distance to a nearest neighbor being between 1D-1.5D, where D is the diameter of the one coil.
In one embodiment, the plurality of coils are embedded in a flat sheet of flexible material and at least partly surrounding the predetermined cells, micro organisms and/or tissue with the flat sheet.
In another embodiment, the providing step includes providing an even number, larger than two, of coils in sets of two, and positioning the coils of each set on at least substantially opposite sides of the cells, micro organisms and/or tissue so as to have at least substantially coincident center axes. Again, these coils may be provided within one or more flexible sheets or e.g. within a more rigid, such as a tong like, structure.
Normally, the method would further include providing a power supply for supplying power to the pulse generator. Especially for a portable apparatus or for safety reasons, the power supply may be a battery included within the apparatus and supplying an electric potential of 50 V or less.
Depending on the actual purpose of the method, the coils and the pulse generator may be desired to provide a series of pulses forming a temporal overlap between the varying magnetic fields from individual coils to form a periodically varying total magnetic field having a frequency in the range from 1 to 1000 Hz.
For the given pulse supplied by the pulse generator, in each pair of coils, the first coil may conduct the current pulse in a clockwise direction and the second coil may conduct the current pulse in a counter-clockwise direction taken along the center axes of the first and second coils, respectively, in a direction toward the cells, micro organisms and/or tissue.
Preferably, the first coil of each pair conducts the current pulse in a clockwise direction and two, three or more of the nearest neighboring coils of the first coil conduct the current pulse in a counter clock-wise direction taken along the center axes of the coils in a direction toward the cells, micro organisms and/or tissue.
Depending on the actual use, each coil may receive, in the series of pulses, a pulsed current with a rise time in the range from 0.1 ms to 2 ms and a maximum current adapted to provide a magnetic field of 0.01 Tesla at the center of the coil, and the pulse generator may generate pulses with a frequency in the range from 1 to 300 Hz.
In a number of applications, it is desired to have a number of coils, such as more than 2 coils, and depending on a number of factors, the number of coils may exceed 2, 4, 6, 8, 10, 14, 18, 20, 24 or more. In the same situation, it may be desired to then choose coils with smaller sizes than those normally used today. Therefore, the step of providing the coils preferably includes providing coils having a cross section, perpendicularly to the center axis, that is at the most 100 cm 2 , such as at the most 50 cm 2 , preferably at the most 25 cm 2 , such as at the most 10 cm 2 , such as at the most 9 cm 2 , preferably at the most 8 cm 2 , such as at the most 7 cm 2 , preferably at the most 6 cm 2 , such as at the most 5 cm 2 , preferably at the most 4 cm 2 , such as at the most 3 cm 2 , preferably at the most 2 cm 2 , such as at the most 1 cm 2 , preferably at the most 0.5 cm 2 , such as at the most 0.4 cm 2 , preferably at the most 0.3 cm 2 .
One interesting embodiment of the present aspect is the use thereof for treating human cells or tissue. Then, the method may include actually fastening the coils to a body part of a human or an animal. Alternatively, the coils may be provided fixed to e.g. a building, a wall or a bed or as a separate part, such as part of a mattress or a blanket.
Normally, the method includes positioning the coils adjacently to the cells, microorganisms and/or tissue in question and operating the pulse generator.
Preferably, especially when treating cells or tissue of living beings, the series of pulses and the coils are adjusted so as for the maximum regions of the induced electrical fields in the predetermined portion to be sufficiently small in order not to elicit action potentials in living cells.
In one embodiment, the method includes positioning the coils at an upper or lower jaw of a human or an animal for inducing an enhanced bone growth, such as after extraction of a tooth.
In another embodiment, the method includes positioning the coils at an upper or lower jaw of a human or an animal for promoting in-growth of dental implants.
The method may also include attaching the coils to a joint region of a human or an animal for treatment of arthritis or pain, and/or for promoting growth of bone and/or cartilage and/or blood vessels—so-called angiogenesis.
In a further embodiment, the method may include attaching two or more coils to a joint region of a human or an animal to prevent arthritis or pain or to promote bone growth after a bone fracture.
The method may also be performed for treating microorganisms. Then the method may include positioning the coils adjacently to the microorganisms in question and operating the pulse generator.
Alternatively, the method may be used for treating seeds, plants or plant tissue. Then the method may include positioning the coils adjacently to the seeds, plants or plant tissue in question and operating the pulse generator.
Finally, the invention also relates to a method of treating seeds, plants or plant tissue with pulsed electromagnetic fields, the method including providing an apparatus as described in relation to the first aspect, directing the center axes of the coils into the seeds, plants or plant tissue and operating the pulse generator.
These and other objects of the present invention will become more readily apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating the preferred embodiments 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 apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described with reference to the drawings wherein:
FIG. 1A is a schematic comparison of a prior art system and an electronic diagram thereof.
FIG. 1B is an illustration of an apparatus according to the invention and electronic diagrams of embodiments thereof.
FIG. 2 is a circuit diagram for a preferred pulse generator for use in the apparatus according to FIG. 1 B.
FIG. 3 illustrates the magnetic field lines originating from two coils positioned adjacently with oppositely directed magnetic fields.
FIG. 4A illustrates a measurement of magnetic field intensities.
FIG. 4B illustrates the magnetic field lines originating from the current pulses in a system including two coils as illustrated in FIG. 3 .
FIG. 5 illustrates magnetic field vectors in a situation were four coils are applied as two opposite sets.
FIG. 6A illustrates a measuring of magnetic field intensities from the set-up of FIG. 5 .
FIG. 6B represents the measurements from the measurement of FIG. 6A
FIG. 7 illustrates the increase in voltage of a sensing coil positioned adjacently to a single coil, the upper curve illustrates the current in the sensing coil as a function of time and the lower curve illustrates the electromotive force imposed on charged particles as a function of time.
FIG. 8 illustrates an example of a series of pulses in which +50 V is imposed for 3 ms then followed by −50 V for 3 ms. This results in a rapid change in the current in the coils that causes a rapidly changing magnetic field.
FIG. 9 illustrates the development of small capillaries in chicken embryos using the present invention.
FIG. 10 illustrates images taken of a chicken embryo chorioallantoic membrane with (A) or without (B) exposure for 48 hr of PEMF.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A and 1B illustrate a comparison between a related art apparatus and an apparatus according to the invention. The related art apparatus of FIG. 1A has a coil ( 102 ), having a given number of windings, and a current source 104 . A schematic drawing ( 106 ) reveals its electrical properties with a current source, a resistance and an inductance.
The apparatus according to the invention shown in FIG. 1B includes three coils ( 108 , 110 and 112 ) imbedded in a supporting frame ( 118 ) and connected to a current source ( 104 ). The electronic circuit ( 114 ) reveals the coil characteristics. The coils can be connected in series ( 114 ) and parallel ( 116 ).
Pulse Generator (FIG. 2)
FIG. 2 is an illustration of a preferred circuit for providing current pulses with one phase for the coils and with a sense coil system that detects when magnetic fields are created by the connected coils. This circuit is composed of a 55 Hz oscillator ( 201 ), a one-shot 3 ms circuit ( 202 ), a divider ( 203 ) that provides division of {fraction (1/100)} for a lamp, a front panel ( 204 ) providing output for coils ( 207 ) and external DC power ( 206 ), a magnetic field sense device ( 205 ) with a comparator on the left, a peak rectifier in the middle, and an amplifier at the right location. The circuit for the sense coil system is denoted ( 208 ).
FIG. 7 illustrates measurements performed adjacently to a single coil. Illustrated is the increase in voltage in a sense coil placed underneath a single coil of the type used in this device. The rise in voltage was measured during pulse generations by an oscilloscope.
The upper curve illustrates the current in the coil as a function of time. The rise time for the current flow is a function of the inductance (L) and the resistance (R) of the coil circuit. As described elsewhere, the magnitude of L/R (63% of maximum current) is essential for the characteristics (duration and magnitude) of the electromotoric force induced on charged particles in the tissue.
The lower figure illustrates the electromotoric force (V) imposed on charged particles (or electrons in a wire) as a function of time. The shape of this V/ms relationship is determined by the magnitude of the slope of the A/ms relationship in the upper curve.
The necessary power for the coils is either delivered by a handheld, battery operated pulse generator (FIG. 2) or from a power source yielding up to 50 V and the sufficient amount of current. The device includes electronic circuits, output switch, coil connector and a control lamp. The necessary power for stimulating the coils can be delivered by a handheld, battery operated pulse generator as shown in FIG. 2 (or alternatively a power supply providing up to 50V DC). The device uses conventional CMOS IC technology to create the particular currents in the coils. The device includes a timing circuit, made from standard CMOS IC's with low power consumption. It forms a free running asymmetric square wave generator that produces an output pulse i.e. every 18 ms with a pulse width of i.e. 3 ms. Those characteristics can be varied, and usually the desired frequency for pulse generation is between 1-100 Hz. The duration of the pulse will then change accordingly. This pulse is applied to the output stage, which includes two complementary emitter followers that supply the necessary output current and is able to withstand the transients from the current switching in the coil. An output switch can be made so that it selects different resistors placed in series with the coil in order to vary the output current. A CMOS IC, that divides the pulse frequency width by 100, drives a control lamp by counting the flashes. This makes it possible to make a simple evaluation of the generator functionality and its frequency. In addition, a magnetometer is incorporated to check the battery and the coils for defects. This circuit is formed by a little sense coil, an amplifier, a peak rectifier and a comparator that, when beyond threshold, drives the control lamp to be permanently on. The comparator threshold is exceeded when the stimulating coil is functioning correctly and is held close to the location of the sense coil.
The device can also include a larger cabinet, electronic circuits, power lead and power switch, coil connector and control lamp. Also, a device may use conventional CMOS technology to create the voltage needed for the particular currents in the stimulating coils. The electronic circuit includes a timing circuit that generates free running bipolar square pulse pairs. They can be produced (as in FIG. 8) every 18 ms with a duration of each pulse of 3 ms. These pulse pairs are applied to the output stage, which includes two complementary emitter followers that supply the necessary output current and is able to withstand the transients from the current switching in the coil. By measuring the output current, a control circuit checks the stimulating coils and their connection leads. A control lamp indicates correct function by blinking with 1.8 s intervals. FIG. 8 shows an example of a series of pulses in which +50 V is imposed for 3 ms then followed by −50 V for 3 ms. This results in a rapid change in the current in the coils that causes a rapidly changing magnetic field.
FIG. 8 illustrates voltage applied to the coils from a pulse generator giving + and −50 V. The increase in voltage ( 801 ) + or −50 V drives the current ( 802 ) in the coils that consist of three phases. In the first phase +50 V is applied, causing an increase in current with a rate constant determined by the L/R ratio. After 3 ms, −50 V is introduced and the current is reversed. This event lasts 3 ms, where after +50 V is introduced again. After approximately 10 ms the current is zero. The magnitude of the magnetic field is proportional to the current flow. The magnitude of the electromotoric force (EMF) on charged particles in the cells is proportional to the rate by which the current changes.
The full procedure in FIG. 8 lasts about 10 ms. It is highly desired that the events have a given duration in order for the biochemical events to occur. The 10 ms event can, however, be shortened up to five times by reducing the individual current transients. Thereby, the duration of the event can be as short as 2 ms. The frequency applied for sending pulses (composed of individual transients) can then i.e. vary between 2 and 500 Hz.
Construction of Coils
The basic principles for the construction of coils are shown in FIG. 1 with the pulse generator, the resistance and inductance. When constructing coils, it is important to introduce a large potential change of at least 0.1-10 ms duration in the tissue due to the relative slow on and off rate constants for interactions in biochemical signalling. The induced electric field can be estimated by considering the electromotoric force EMF introduced into a hypothetical circuit in the tissue: EMF = - 1 c Φ t = - 1 c t ∫ S B → · S → ,
Where B is the strength of the magnetic field and Φ is the flux of the magnetic field through the area S. Hence the induced electric field is proportional to the current flow in the coil, whereby t is the time and c is the speed of light.
However, there is a limit as to how rapid a rise in the voltage, and consequently the current, which causes B to rise, can be increased in the coil. This is due to the fact that the coil possesses an induction (L) as well as a resistance (R). L will limit the rate by which the current can be applied since, as the current increases, an electromotoric force of opposite direction will occur originating in the coil material.
The inductance is equal to:
L= 4π k m k′ ( n ) 2 Al
Where L is the self-inductance in Henry (V s/A), k m is a constant equal to 10 −7 (Tesla m/A), n is the number of windings, A is the area, and l is the length (m) of the coil.
The instantaneous electromotoric force induced is:
V=−L dl/dt
where I is the current (amperes) and t is the time (s).
Another important factor to consider for inducing rapid current changes in coils is to evaluate the ratio of the inductance over the resistance in the coil.
The rate of rise of current can be evaluated by integrating the equation (Ohm's law):
V 1 −V 2 −L ( dl/dt )= RI
Resulting in:
I= ( V 1 −V 2 )/ R (1 −e −Rt/L )
The time it takes the current to rise is thus proportional to τ=L/R, where τ (measured in s) is the time it takes to reach 63% of maximal current. Thus, if L becomes small, relative to a given R, by using fewer windings, τ becomes larger and the induced field, EMF=1/c dB/dt, larger. The insertion of iron in the center of the coil will also affect L (increase L) but the field lines will be more centered under and above the coil. Thus, coils should be constructed in such a way that L and R are matched to give the correct ratio, causing tissue currents of a sufficient magnitude and duration.
When the current is interrupted, an equally important event occurs resulting in a rapid decline in the magnetic field thus giving rise to new currents in the tissue in opposite directions. The coil material will now resist the new change in current flow and Ohm's first law gives:
− L ( dl/dt )= RI
or by integration:
I=I
max
e
−(R/L)t
Where I max is the original current flow before interruption, and the other symbols have their usual meaning. Thus, the current flow will stop with the time constant L/R. This factor thus determines the magnitude of current flow in the tissue when the pulse is interrupted. Surprisingly, if R is small, the duration of the current is longer. Since dB/dt thereby becomes smaller, the introduced current peak in the tissue will also be reduced. It is thus important to note the characteristics that create the waveforms that provide the driving force for ions and particles. In this embodiment, the coil positions have been uniquely matched, and the characteristics of the coils constructed in such a way that they together give the maximal effect in the tissue in the appropriate proximity.
The clinically applied pulsed electromagnetic fields normally have peak flux densities in the range of 0.1-5 mT (1-50 Gauss) with rise times in the order of hundreds of microseconds. This results in a typical dB/dt in the range of 1-50 T/s and corresponding peak induced electric fields of 0.1-1 V/m.
Coils
The preferred coils for treatment of i.e. osteoarthritis of the knee have a diameter of 5 cm, and a length of 2 cm. They contain 2800 windings with 0.2 mm Cu-wire and can thus be fitted to the side of the joint providing a frame for the adjacent coil technique. They have an inductance of 210 mHenry. The serial resistance of 140 (coil)+100 Ohm (circuit)=240 Ohm. For example L/R can be: L/R=0.210/240=875 10 −6 s. The device has been constructed in such a way that L/R can vary between 0.3 and 0.9 ms. Opposite those coils are two other coils of the same construction and with currents running in parallel with the opposite coil. Using for example 50 mA for each coil we obtain 45 Gauss in the center or 4.5 mTesla (measured with a Gauss meter). A rise time of half maximal magnetic force in 380 μs yields a dB/dt of 10 Tesla/s (in 0.38 ms). The induced electromotoric force in the tissue will then theoretically amount to 0.025 volts. This number will be reduced to 33% about 2 cm away from the coil surface (see FIG. 4 ). Thus, the rate of increase in the magnetic field will be around 3.3 Tesla/s. Introducing iron in the center of the coils will enhance the magnetic field, an effect that has been implemented in the coil construction.
A different set of coils have been constructed for treatment of bone growth in the jaws for patients that have been exposed for radiation therapy, for inserting implants or for promoting bone growth before the insertion of implants. Those coils have 2200 windings of 0.15 mm Cu-wire, have a width of 2.5 cm and are 1 cm long. With a current of 50 mA they yield 20 Gauss in the center. At a distance of 2 cm from the center they yield 6.6 Gauss. Those coils are placed as two adjacent coils on the surface of the skin. The coils can be constructed and inserted in soft material in such a way that they can be strapped to the tissue for different types of treatment (enhancement of bone growth and angiogenesis, acceleration of in-growth of dental implants).
Principle for the Adjacent Coil Technique
Two Coils
The principle for the adjacent coil technique is shown in FIG. 3 . This figure illustrates the magnetic field lines originating from the current pulses in a system consisting of two coils. A coil ( 301 ) has a current in given direction ( 302 ) creating magnetic fields revealed as magnetic field lines ( 305 ) with a given magnetic field vector ( 304 ). When the current in two coils is in opposite directions as in this figure the field vectors are added together since they have the same directions in the intersection between coils. The filled arrows 304 depict the intense currents that appear in biological tissue in the periphery and under the adjacent coil. In FIG. 3, the surface of the skin of the subject, e.g. a person, is denoted ( 306 ) and the underlying tissue ( 307 ).
In FIG. 4A, measurements of magnetic field intensities (numerical values) along the three lines are depicted. A Gauss meter ( 401 ) (F. W. Bell, Gauss/Tesla Meter model 4048, Transverse probe model T- 4048-001 with the meter in the AC mode) was used to measure field vectors that are parallel to a line connecting the coil centers. Measurements were conducted along the lines ( 404 , 405 and 406 ) that are positioned at a distance from the coils depicted in the figure.
FIG. 4B illustrates magnetic field intensities (numerical values) from the three measurements at a constant distance from the coil surface that is either 1 cm ( 410 ); 1.5 cm ( 411 ); and 3 cm ( 412 ).
This figure illustrates the magnetic field lines originating from the current pulses in a system consisting of two coils. A coil ( 301 ) has a current in given direction ( 302 ) creating magnetic fields revealed as magnetic field lines ( 305 ) with a given magnetic field vector ( 304 ). When current in two coils are ine directions in the intersection between coils. The filled arrows 304 depict the intense currents that appear in biological tissue in the periphery and under the adjacent coils, whereby the surface of the skin is denoted as 306 and the tissue as 307 . Note that at + and −2.5 cm from coil intersection, the field vector changes its numerical value. The coils were receiving current pulses of 75 mA and a duration of 3 ms with a rise time of 0.3 ms (63% of maximum).
With a magnetic field sensor placed perpendicular to the field vectors described above, we conducted measurements over the entire length of the two coils 1, 1.5 and 3 cm above the coils (FIG. 4 B: 410 , 411 and 412 ). In the intersection area, where the coils meet, the magnetic field has its maximum value for the vector parallel to the coil axes. Above the center of the coils, the vector attains the value 0 (as expected from the drawing FIG. 3 ). In the periphery (away from the intersection) the magnetic field strength rises again and has an opposite sign, (but in FIG. 4B numerical values are used). When looking at the individual coils, the magnetic field lines have the highest density below and above the coil center. The magnetic field vectors from both coils (with currents in opposite directions), are added in the intersection and therefore in this location cause relatively large magnetic fields. This can be observed when the field lines are measured parallel to the coils as shown in FIG. 4B where it is evident that a large gradient appears in the tissue underneath the coils. When a third coil is added, two of the coils will have currents in the same direction and in this case a strong gradient appears at the intersections between these coils. All together when three coils are added a smaller or larger magnetic field gradient appears at different distances from the coils. This gradient provides the basis for the treatment of biological tissue. One large coil covering the same area would not provide the same size of the gradient and would therefore not be beneficial to the extent described for this invention.
Four Coils
FIG. 5 illustrates magnetic field vectors in a situation were four coils are applied. Four identical coils ( 501 ) are used with currents in a given direction ( 505 ). Note that both pairs of adjacent coils have currents oriented oppositely (as in FIG. 3 ). The coils that are placed across from each other have currents running in the same direction. Magnetic fields ( 503 ) have vectors ( 502 ) that are added in the intersection as in FIG. 4 A. In FIG. 5, another gradient appears in the center between the four coils due to the oppositely directed vectors. The filled arrows ( 504 ) show the direction of the currents in the tissue.
Magnetic field strength was measured in the space between four coils in which each pair had current in opposite directions and opposite coils had currents in the same directions (FIG. 5 ). Thereby, enhanced field lines will be generated with a larger field gradient that was measured with the magnetic probe. The field line intensity was measured in the intersection between coils with the probe perpendicular to the field lines ( 605 ) measuring vectors parallel to the coil surface. In addition, line vectors perpendicular to the coils were measured at a line 2 cm from the coil center ( 604 ). The distance was set to 10 cm, that is, the distance usually required to i.e. treatment of joints with four coils. Alternatively, this distance can be set to a smaller value giving the same type of data but being applicable for treating elbows or other small joints. Larger distances can be used for treating hips or other, larger joints.
In relation to FIG. 6A, magnetic field intensities were measured originating from four coils with currents in the same direction ( 602 , 603 ) as illustrated also in FIG. 5 . The intensities were measured by a Gauss meter with a sense coil ( 601 ) as described in FIG. 4 A. Field vectors were measured along the line ( 604 ) with the coil oriented in such a way that field vectors perpendicular to the coil surface were determined. In the intersection between the four coils, the vectors parallel to the coils surface was determined along the line ( 605 ). In this figure, 606 indicates a supporting device used for strapping the coils to the surface such as i.e. the knee or elbow.
FIG. 6B illustrates measurements of magnetic field intensities as described in FIG. 6 A. The line ( 604 ) with vectors perpendicular to the coil surface gave intensities as shown ( 610 ) and the line 605 gave field intensities depicted as 611 . Each coil received 38 mA current pulses with characteristics as in relation to FIG. 4 B. FIG. 6B depicts the distance dependency. A strong magnetic field gradient appears also in the center between the four coils ( 611 ) revealing the beneficial effect of this use of four coils with larger gradients. Alternatively, more than two coils can be used adjacent each other—i.e. 3, 4 or more. Opposite those coils could also typically be positioned coils with currents in given directions providing basis for large field gradients.
These described characteristics of line field vectors between adjacent coils are only relevant for the vectors parallel to a line combining the axes of neighboring coils. It should, however, be emphasized that the total field strength, is a consequence of both this vector and the vector perpendicular to it describing the total field strength (B) using the equation:
B= ( x 2 +y 2 ),
where x and y are the two types of line field vectors described above.
Description of Preferred Applications
Use of Coils for Treatment of Biological Tissue
The coil characteristics according to the invention give a new perspective to treatment with pulsed electromagnetic fields. Relatively large changes in magnetic fields can be obtained with 9-50 V using the described technology and consequently large tissue currents can be introduced with resulting beneficial biological effects (bone heeling, wound heeling, cartilage regeneration, bone growth into implants, and other types of treatments). Thus, coils can be used for a variety of treatments, some of which are now approved by the Food and Drug Administration (FDA) in the US, such as heeling of some types of bone fractures such as non-unions.
Angiogenesis (Growth of Small Vessels for Sustaining Blood Circulation)
Reduced blood circulation in the extremities is a complicating factor for a series of diseases i.e. diabetes and psoriasis. It is also seen following excessive cigarette smoking, following a high plasma cholesterol concentration and hypertension. Sustaining synthesis of new vessels is essential for repairing such damaged areas, for wound healing and for generating new blood supply to i.e. bone tissue exposed to radiation therapy. It might also be an important factor for synthesis of new bone material.
In order to characterize the effect of PEMF on angiogenesis we used the previously developed model for testing angiogenesis in chicken embryos. Three days old fertilized eggs were cracked and chicken embryos with intact yolks were placed in plastic dishes. After three days of incubation at 37° C. in 3% CO 2 , they were exposed to PEMF in a set up using three coils for a disc with one chicken embryo. The pulse generator applied + and −50 V with two phases (FIG. 8) and the distance between the egg and the coil surface was 4 cm. The temperature was thermostatically controlled in the incubator.
The synthesis of new blood vessels was analyzed by imaging techniques. The amount of new vessels (small capillaries) of a size from 10 micrometers to several hundred micrometers were evaluated by counting the number of new branches formed (FIG. 9, 701 and 702 ).
FIG. 9 illustrates the number of branches at the small capillaries measured from a chicken embryo chorioallantoic membrane with and without exposure to PEMF using the device giving pulse currents as described in relation to FIG. 8 . An image was taken of the membrane at the depicted time intervals and the number of branches at a 15 mm 2 area was counted either without ( 702 ) or with exposure to PEMF ( 701 ).
FIGS. 10A and 10B illustrate images taken of the chicken embryo chorioallantoic membrane with (A) or without (B) exposure to 48 hr of PEMF. Images were taken with a NIKON Cool Pix digital camera and images analysed by use of Adobe Photoshop software.
The FIGS. 10A and 10B show that it was possible to significantly enhance the number of new vessels synthesized as well as observe an enhanced rate of organization of the newly formed vessels (FIG. 10) using PEMF. These findings have important implications for initiating clinical research on wound healing and initiating attempts to enhance the blood circulation in patients suffering from i.e. diabetes. In addition patients with decomposed bone material due to radiation therapy can also benefit from treatment with this technology. Coils can be attached to the area in question and the bone material treated.
Treatment of Joints
The coils can be fastened to the area of treatment, i.e. the knee, where typically 4 coils are placed opposite each other as described in FIG. 5 . They can be fastened to the knee using Velcro© material or a different type of trapping material, and the current supplied from wire attached to the pulse generator with 9-50 V battery or 12 or 50 V power supply from a transformer supported by 110 V or 220 V. This type of treatment can be conducted on both humans and animals, such as horses, suffering from injuries in joints.
Treatment of Dental Implants
For ingrowth of dental implants, a mask can be fitted to the jaws using 2 or more coils for each area being treated (FIG. 2 ). For this purpose we have constructed coils with a diameter of 25 mm described in the section: Construction of coils. A device can be fitted to the neck and head region of a person and thereby with an elastic material support the coils attached to the skin at the jaws. A particular problem in making implants is that after tooth extraction, there is usually a duration of several months before new bone material has grown into the area. The above-described device can accelerate this process. After insertion of the implant, treatment with pulsed electromagnetic fields can accelerate the growth of bone material onto the implant.
Small Fractures of the Hand
For fractures of small bones in the hand, the small 25 mm coils (in pairs) can be used also applying Velcro© material.
Treatment of Animals
Horses can be treated with pulsed electromagnetic fields using two or four coils as described in FIGS. 2-6, by strapping coils to the joint or to the area with a bone fracture by use of Velcro© material. A pulse generator with a 12-50 V power supply or a battery can be feeding pulses to the coils and be near the animal in a stable.
The Use of the Device for Treatment of Seeds
EXAMPLE 1
Laboratory Germination
600 grams standard calibrated and polished monogerm sugar beet seeds (CV Manhattan) were imbibed in water for two hours, dubbed on filter paper and incubated in a closed plastic bag at 4° C. for 17 hours. After this activation treatment, the seed lot was divided into 3 equal fractions and either left untreated or treated with PEMF for 90 min and PEMF for 240 min, followed by drying in an air stream overnight. The treated lots were then germinated in pleated paper boxes according to the ISTA-guidelines (International Rules for Seed Testing, Seed Sci. & Tech., 27, Suppl.; 1999) for sugar beet, but without pre-washing. Percent germination can be seen from table 1:
TABLE 1
Laboratory germination of naked sugar beet seed lots.
Germination,
Germina-
day 4,
Germination,
tion,
root length >
Germination
Treatment
day 3
day 4
15 mm
day 7
Untreated
39
91
21
96
PEMF, 90 min.
59
95
29
97
PEMF, 240 min.
35
94
40
98
As can be seen from table 1, PEMF treatment enhances the speed of germination of pre-activated seeds in the parameter “4 day germination” with a root length of more than 15 mm, indicating enhanced vigor.
EXAMPLE 2
Effect of PEMF on Pelleted Seed
Three monogerm non-activated sugar beet varieties, Canaria, Manhattan and Marathon were standard pelleted and coated as for the Danish marked. Equally pelleted lots were then PEMF-treated at 25V and 55V respectively. Controls were left untreated. After treatment, seed lots were analyzed for laboratory germination as well as field emergence in a standard split plot design with 3 varieties, 4 replications, 200 seeds/replication.
Percent laboratory germination and final field emergence (FE) is presented in table 2: All data given is an average of the 3 varieties.
TABLE 2
Laboratory germination and final FE (nr) of pelleted sugar beet
seed lots.
Germination,
Germina-
day 4,
tion,
root length >
Germination,
Pct.
Treatment
day 4
15 mm
day 7
Final FE
Untreated control
72
0
96
86,0% (100)
25V PEMF, 90
79
5
98
86,7% (101)
min.
50V PEMF, 90
74
4
99
86,9% (101)
min.
As can be seen from table 2, PEMF-treatment of pelleted seed lots enhances the number of seeds with a root length above 15 mm after 4 days of germination.
EXAMPLE 3
Effect of PEMF on Field Emergence of Naked Seed Lots
Three monogerm non-activated sugar beet varieties, Canaria, Manhattan and Marathon were PEMF-treated at 25V or 50V. Some seed lots were imbibed in water to a relative water content (RWC) on 30%, 45% and 65%, respectively, two hours before PEMF-treatment. Controls to PEMF-treatment were left untreated. After treatment, wet seed lots were air-dried. Seed lots were treated with thiram and mesurol and drilled for field emergence in a standard split plot design with 3 varieties, 4 replications, 200 seeds/replication. Successive seedling emergence was counted 3 times.
Field emergence data are given in table 3: All data given is average of 3 varieties.
TABLE 3
Field emergence data of naked sugar beet seed lots (HCPFE013):
Treatment
Count 3 (final
Count 1
Count 2
emergence)
Pre-Treatment
Control
PEMF
Control
PEMF
Control
PEMF
25V
25V
25V
Untreated
27,9%
28,6%
50,2%
53,2%
80,5%
83,8%
(103)
(106)
(104)
30% RWC
29,0%
29,7%
50,7%
51,2%
83,2%
82,4%
(103)
(101)
(99)
45% RWC
27,8%
29,3%
51,1%
54,4%
82,3%
82,2%
(105)
(107)
(100)
65% RWC
29,1%
29,4%
50,6%
51,0%
82,5%
81,5%
(101)
(101)
(99)
55V
55V
55V
Untreated
27,9%
27,3%
50,2%
51,3%
80,5%
82,2%
(98)
(102)
(102)
As will be seen from table 3, the PEMF treatment increases the speed of emergence (Count 2). In the final emergence (Count 3) PEMF has no effect if seed lots are pre-treated, whereas the non pre-treated naked seed lots gain from PEMF-treatment.
The Use of the Device for Treatment of Micro Organisms
Micro organisms, such as bacteria, can be treated with PEMF by which their survival can be improved under desirable conditions. It is an important technique to be able to code seeds with particular types of bacteria where after, when planted, a correct and not harmful environment supports germination and the formation of roots. Usually, the desirable bacteria are dried from containing 70% water to have only 20% water and subsequently be attached to the seeds. That, however, results in a strongly diminished survival rate of the bacteria, which has been a considerable problem. We have applied our apparatus, using the pulse pattern of FIG. 8, to improve the survival rate of the bacteria. It was done by exposing the bacteria for PEMF for two hours while being exposed to a procedure in which the water content was reduced from 70% to 40%. During this phase it is contemplated that particular intracellular proteins are synthesized (such as classes of heat shock proteins (hsp70)) whereby the bacteria are better withstanding the drying procedure. A subsequent addition of water and counting of colonies resulted in a 50 to 100 times better yield of bacteria when exposed to PEMF.
While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the present invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the invention would be of significant utility without undue experimentation. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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A method for stimulating growth in biological tissue or sprouts, an apparatus and a use thereof employs fluctuating magnetic fields. The apparatus includes a pulse generator and a plurality of coils in which pulsed currents will cause fluctuating magnetic fields in a predetermined region holding the material to be stimulated. The fluctuating magnetic fields will induce an electric field in the material. An enhanced effect has been detected in the regions where the electric fields are largest. The coils include a number of pairs of coils having, during a given pulse, magnetic fields in opposite directions in order to provide field gradients in the cells, micro organisms or tissue. Selecting a suitable number, size and positioning of coils will provide a homogeneous electric field in the predetermined region, which does not have any undesirable peaked maxima. When four or more coils are used, they can be combined in pairs arranged on opposite sides of the predetermined region, and with the adjacent coils conducting current in opposite directions and the opposing coils conducting currents in the same direction. Thereby, the induced electrical fields add constructively inside the regions between the pairs of coils. In an apparatus for stimulating cell proliferation and differentiation, it is a desired feature that the generated fluctuations in the magnetic fields do not elicit action potentials of living cells since this will cause great inconvenience for the patient.
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BACKGROUND
The present invention relates generally to the maintenance and rehabilitation of water wells and specifically to systems and methods for monitoring the change in permeability of the well structure (e.g., screen, gravel pack, and geological formations) surrounding boreholes which can influence the water production capability of water wells.
Bore holes are commonly drilled into the ground in order to locate and extract water from water-bearing geological formations. Specifically, the bore hole allows the extraction of ground water from intergranular pore spaces, fractures and cavities that naturally occur in various geologic formations. Screens, gravel packs, and other structures can be inserted into the bore hole in order to create a well structure. The inherent ability of the well structure to transmit ground water is known as hydraulic conductivity or permeability. Well structures, whether vertical or horizontal, provide a method for the water to collect and be accessed. Various types of pumps can be installed in wells to extract the water or other liquids. Over time, the side walls of the well structure can become clogged or contaminated with matter, thereby inhibiting the ability of the water to flow into the borehole. In order to alleviate this problem, the side walls of the well structurecan be cleaned in order to remove the clogging and/or plugging matter. One such way of removing the clogging and/or plugging matter is by a system known commercially as Airburst® available from Airburst Technology, LLC of Muskego, Wis. The basic principles of this technology are disclosed in U.S. Pat. No. 5,579,845, which is hereby incorporated by reference in its entirety.
In order to determine whether or not existing well-cleaning systems are effective, it is also known to install a pump in the well after cleaning to determine any changes in the permeability of the well, such as by measuring the specific capacity (gallons per minute per foot of liquid drawdown) of the well and thus determine the effectiveness of the cleaning process. This requires removal of the cleaning equipment and can involve many hours or days of intensive labor to install the pump. If it is determined by pumping that additional cleaning is required, the pump must be removed and the cleaning equipment reinstalled in the bore hole. This time and labor consuming procedure is undesirable as an intermediate step in the cleaning process.
It is also known to insert a video camera into the well after the cleaning operation. This commonly involves removing the cleaning apparatus and then inserting the video camera into the well to visually determine the effectiveness of the cleaning operation. It is also known to position the video camera in the well along with the cleaning apparatus so that removal of the cleaning apparatus is unnecessary. In either case, the use of a video camera relies on visual verification of the cleaning operation, which is not the most accurate way to determine the effectiveness of a cleaning operation. In addition, one must wait for the clogged and/or plugged matter in the well (which was removed during the cleaning operation) to settle to the bottom of the well so that the video camera can clearly see the sidewall of the well structure and visually determine the effectiveness of the cleaning operation. This waiting period is undesirable.
SUMMARY
The present invention provides a system and method for monitoring the change in permeability of a water well bore hole. The system comprises a wave generator (e.g., an acoustic wave generator, such as an air gun) adapted to be positioned in the bore hole, a sensor (e.g., a pressure sensor, a seismic sensor, a temperature sensor, or a fluid level sensor) adapted to receive wave data generated by the wave generator, and a processor coupled to the sensor and programmed to compare wave data (e.g., prior and current wave data) in the bore hole (e.g., at a specific location) in order to determine the change in permeability of the well structure. Preferably, the wave generator includes a cable for suspending the wave generator in the bore hole, and the sensor is supported by the same cable.
In one embodiment, the processor is programmed to use the wave data to calculate a correlation value that reflects changes between the wave data. In addition, the processor can be programmed to use the wave data to calculate a waveform decay value that reflects changes between the wave data. Either or both of these values (or some derivative of those calculations) can be displayed for the user to determine the effectiveness of the cleaning operation.
The method comprises creating a pressure wave (e.g., an acoustic wave generated by an air gun suspended in the bore hole) in the well structure, sensing wave data generated by the pressure wave (e.g., using a pressure sensor, a seismic sensor, a temperature sensor, or a fluid level sensor suspended in the bore hole), and comparing the wave data in the bore hole (e.g., at a specific location) in order to determine the change in permeability of the well structure. The step of comparing can include calculating a correlation value that reflects a correlation between the wave data or calculating a decay value that corresponds with the rate of decay of the waveform data. The method can further include displaying the correlation value and/or decay value so that the values can be compared by the user to determine the effectiveness of the cleaning operation.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic partial cross-sectional view of a system for monitoring the production capability of a bore hole according to an embodiment of the invention.
FIG. 2 is a schematic diagram of the system of FIG. 1 .
FIG. 3 is a front view of a processor of the system of FIG. 1 .
FIG. 4 is an exemplary graph of pressure versus time as measured by a sensor of the system of FIG. 1 .
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
FIG. 1 illustrates a system 10 for monitoring the change in permeability of a well structure 12 , which includes the geological formation 34 and other structure (e.g., gravel pack and screen) surrounding a bore hole 14 . The system 10 includes an acoustic wave generator device 18 , a gas source 22 , a sensor 26 , and a processor 30 . The illustrated bore hole 14 is part of a borehole formed in a water-bearing geological formation 34 . The bore hole 14 includes a perimeter wall 38 formed from stone, concrete, clay, sand, or any other suitable material and/or a metal screen (not shown) positioned near the bottom of the bore hole or opposite water bearing formations throughout the length of the bore hole 14 . Over time, the well structure can become coated with fine grained materials, mineral and/or biological debris that impedes fluid flow into the bore hole 14 .
With continued reference to FIG. 1 , the acoustic wave generator device 18 (referred to herein as an “AWG device” or “AWG”) is suspended in the bore hole 14 by a support cable 21 secured to a lifting hoop 25 on the AWG and is moved by a lifting winch 23 . AWG devices are high-velocity, mass movement devices that generate high-amplitude acoustic waves, high-velocity mass movement, and/or seismic waves. The illustrated AWG device 18 is a rapidly-venting gas apparatus, such as a gas gun. One such gas gun is available under the BOLT® trademark, from Bolt Technology Corporation. In other embodiments, any suitable AWG device 18 may be used, such as but not limited to an air/gas gun, water gun, sparker, imploder or steam gun.
The AWG device 18 is actuated via a firing wire 42 coupled between the AWG device and the processor 30 . The AWG device 18 is connected to the gas source 22 by a high pressure gas line 46 routed through a hose reel 44 ( FIG. 2 ). A pressure regulator 48 is disposed between the gas source 22 and the AWG device 18 for controlling the gas pressure supplied to the AWG device 18 . The gas source 22 can be a compressor, a gas storage pressure vessel, or any suitable means for delivering high-pressure gas to the AWG device 18 . The AWG device 18 includes ports 50 configured to explosively release high pressure gas as a gas bubble into a surrounding fluid within the bore hole 14 ( FIG. 1 ). When the AWG device 18 is actuated, a sharp pressure wave is generated by a leading edge of the gas bubble. This wave impacts the well structure and vibrates the screen, gravel pack, and surrounding geological formation 34 . The impact loosens the debris accumulated on the well structure.
As the gas bubble expands, the surrounding fluid is pushed at a high velocity through the well structure and displaces and agitates the debris that had been loosened by the original sharp pressure wave. Eventually, pressure from the surrounding fluid forces the overextended gas bubble to contract or recompress. The displaced surrounding fluid flows back into the bore hole 14 , pulling the loosened debris through the well structure, thereby further clearing the screen, gravel pack, and geological formation 34 from the debris.
Finally, pressure within the recompressing bubble will exceed the hydrostatic pressure of the surrounding fluid, causing a secondary bubble expansion with an associated secondary pressure wave and secondary mass movement, similar to that described above. Thus, the cycle of bubble expansion followed by bubble contraction and the associated pressure and mass movement effect may repeat several times for each activation of the AWG device 18 .
With continued reference to FIG. 1 , the sensor 26 is positioned near the AWG device 18 to measure pressure, seismic data, temperature, or mass flow within and around the bore hole 14 . In the illustrated embodiment, the sensor 26 is mounted on the AWG device 18 with a bracket (not shown). In other embodiments, the sensor 26 is suspended within the bore hole 14 separately from the AWG device 18 . In yet other embodiments, the sensor 26 is positioned outside the bore hole 14 (e.g., at the surface to measure seismic data).
In the illustrated embodiment, the sensor 26 is a pressure transducer, such as the Miniature 4-20 mA Output IS Pressure Transducer, ETM-200-375M series, made by Kulite Semiconductor Products, Inc. or the VersaLine VL1000 Series pressure, depth and level transmitter, made by Process Measurement & Controls, Inc. In other embodiments, the sensor 26 can be a hydrophone or other suitable device. The sensor 26 can include a single device, or the sensor 26 can include multiple devices, including a temperature sensor, employed discretely or within an array.
The sensor 26 provides feedback to the processor 30 to evaluate the change in permeability of the well structure. The sensor 26 communicates with the processor 30 via a sensor cable 52 routed through a cable reel 54 ( FIG. 2 ). The sensor 26 can be configured to measure any of the following, alone or in combination with one another: seismic activity near the well structure, water temperature in the borehole, acoustic energy near the well structure, fluid level or mass movement within the bore hole 14 , pressure waves and/or temperature within the bore hole 14 . As will be described in further detail below, changes in any of these dynamic measurements can be related to positive or negative changes in the permeability of the well structure. As such, the sensor 26 provides feedback relevant to the control and operation of the AWG device 18 .
In the illustrated embodiment, the change in permeability of the well structure is gauged through the measurement of dynamic pressure waves within the fluid of the bore hole 14 . Following activation of the AWG device 18 as described above, the high pressure wave impacts the well structure (i.e., the screen, gravel pack, geological formation, and any other structure surrounding the bore hole). This energy will then be reflected back towards the AWG device 18 . Measurements of the reflected energy (pressure) can be used to determine the resistance of flow through the well structure. A decrease in the reflected wave energy would mean that more energy is being transmitted through the well structure, which would indicate the impediments to fluid flow have decreased. Hence, if the cleaning operation is potentially improving the permeability of the well structure, successive cleaning operations will result in a decrease in the reflected wave pressure. When the decreasing reflected wave pressure stabilizes, it is usually an indication that little or no further permeability improvement can be achieved using the current cleaning operation and parameters. Failure to initially decrease the reflected energy wave can indicate that the well structure cannot be improved or the necessity for changing the AWG operational parameters.
In other embodiments, the change in permeability of the well structure can be gauged through the measurement of mass movement. For the illustrated embodiment of the AWG device 18 , the gas bubble will push displaced fluid through the well structure at a rate corresponding with the permeability of the well structure. The fluid movement not absorbed by the well structure is directed up the bore hole 14 , thereby temporarily raising the fluid level in the bore hole 14 . Accordingly, a large rise in the fluid level within the bore hole 14 would indicate a low permeability through the well structure, indicating the presence of large amounts of deposited mineral and/or biological debris. Conversely, low or decreasing levels of fluid rise in the bore hole 14 would indicate lesser flow resistance and improved permeability. Thus, the measurement of fluid movement resulting from activation of the AWG device 18 can provide feedback to determine the success of the AWG device 18 operation and to ascertain whether modifications to operational parameters of the AWG device 18 are required.
In another embodiment, the change in permeability of the well structure can be gauged through the measurement of water temperature in the bore hole. In this embodiment, the processor receives data from a temperature sensor in the bore hole and would compare the temperature of the water in the bore hole prior to the cleaning operation to the temperature of the water in the bore hole after the cleaning operation. With an increase in permeability, one would expect to see a drop in water temperature caused by an increase in water flow from the surrounding geological formation. Thus, a decreasing water temperature would be an indication of improved permeability of the well structure.
With reference to FIGS. 2 and 3 , the processor 30 can be any suitable computer, mobile device, or computer based control and display unit and is preferably a ruggedized, water resistant unit. The processor 30 is operable to collect and store data from all associated sensors 26 , to control the firing of the AWG device 18 , to set operational parameters, and to display mathematically-processed data. The processor 30 includes a data collection system (not shown), a user interface 56 ( 30 and 56 are physically the same device), and communication ports 58 , 62 , 66 for communicating with the gas source 22 , the AWG device 18 , and the sensor 26 , respectively. Any number of signal conditioners, amplifiers, sensors, or other intermediate devices 68 can be included between the processor 30 and the gas source 22 , the AWG device 18 , and/or the sensor 26 . In other embodiments, the processor 30 can communicate with the gas source 22 , the AWG device 18 , and/or the sensor 26 wirelessly. The processor also includes a power input 70 for receiving power from a conventional AC power source 74 via a power cord 78 . Any other type of power source, such as a battery, can also be used.
The processor 30 records pressure measurements taken by the sensor 26 . In other embodiments, the processor 30 records other measurements, such as seismic and/or acoustic energy near the bore hole 14 , fluid movement within the bore hole 14 , or water temperature in the bore hole. The sensor 26 transmits measurements to the processor 30 for storage in the data collection system, such as solid-state memory and/or mechanical memory (e.g., a hard drive). The processor also includes USB connection docks 82 that allow for attachment of a USB device 86 to download the collected data, including operational parameters and the data collected by the sensor 26 .
The sensor 26 continuously measures the pressure within the bore hole 14 during the AWG activation, and the processor 30 digitizes the continuous measurement into a set of pressure data including a plurality of discrete pressure values over time. An exemplary graph of the set of pressure data for two, successive AWG activations is illustrated in FIG. 4 . The graph includes a solid line 90 representing a set of pressure data corresponding with a first activation of the AWG device 18 and a dashed line 94 representing a set of pressure data corresponding with a second activation of the AWG device 18 following the first activation, within the same bore hole 14 . The number of pressure values in each set of measurement data is a function of the sampling rate of the processor 30 and the duration of a particular AWG activation.
With reference to FIG. 2 , the processor 30 is connected to the AWG device 18 via a firing cable 98 that is routed through a firing cable reel 102 . This connection allows for control of the AWG device 18 through the processor 30 (e.g., through the user interface 56 ). The user interface 56 employs touch screen technology such that some or all user inputs to the processor 30 are achieved through touching an appropriate screen area ( FIG. 3 ). In other embodiments, the user interface 56 can include push buttons, switches, knobs, or other input means in conjunction with a viewing screen or other visual indicator.
Now referring to FIG. 3 , the processor 30 offers both manual and automatic operation options. To manually activate the AWG device 18 , the user simply touches a manual mode icon 106 . To configure automatic operation of the AWG device 18 , the user inputs various operational parameters to the user interface 56 to direct the AWG device operation. In particular, the user can enter a static fluid level 110 (the distance from the ground surface or the top of the bore hole 14 to the static fluid level in the well), a depth 114 of the AWG device 18 below the top of the bore hole 14 , a chamber volume 118 of a firing chamber 103 of the AWG device 18 , a burst interval 122 (time between AWG activations), an internal AWG device cycle time 126 (time that an electrical contact closure provides power to the AWG device 18 ), and an AWG operational pressure 130 .
The user interface also displays a variety of reference values related to the operation of the AWG device 18 , including but not limited to: an incoming line voltage 134 from the AC power source 74 , an incoming line frequency 138 , an AWG activation voltage 142 corresponding with a solenoid 146 ( FIG. 2 ) that fires the AWG device 18 , and a current and a previous sequence burst count 150 , 154 (the number of AWG activations performed in the current and previous sequences).
With continued reference to FIG. 3 , the user interface 56 displays results of the AWG activations in order to indicate to the user the success of the activations in changing the permeability of the well structure. These results include, but are not limited to, a maximum pressure of the measured pressure data set for current and previous activations 158 , 162 , an affect of the current and previous activations 166 , 170 , and a percentage change in the rate of decay (referred to herein as the “P Value”) of the pressure wave of the current and previous activations 174 , 178 . In other embodiments, the user interface 56 can also display changes in water lever and water temperature.
The current value of maximum pressure 158 shown on the user interface 56 is the maximum pressure that was transmitted through the sensor 26 during the most recent AWG activation. The previous value 162 shown is the maximum pressure that was transmitted through the sensor 26 during the previous AWG activation. The current value and the previous value of maximum pressure 158 , 162 illustrated in FIG. 3 are represented in digital units (a unitless quantity). However, the values 158 , 162 can be displayed in any other appropriate unit, such as feet of water. The current and previous values of maximum pressure 158 , 162 offer a basic metric for determining the success or effectiveness of a particular AWG activation. Generally, for an effective AWG activation, the current value of maximum pressure 158 will be lower than the previous value 162 if debris impeding fluid flow is successfully removed. If the current value and the previous value of the maximum pressure 158 , 162 are nearly equal, continued AWG activations would produce little additional improvement. However, variations in the well structure, minor variations in the relative positions of the AWG device 18 and the sensor 26 , and other factors can affect the maximum pressure measured by the sensor 26 during AWG activations. In some cases (such as that illustrated in FIG. 3 ), the current value of the maximum pressure 158 might be higher than the previous value 162 . In such an instance, the user can rely upon the other parameters described below to adjust the operational parameters or determine that the process is complete.
The processor 30 performs calculations with the pressure data sets to provide results in a useful form for indicating the success of a particular AWG activation. For example, in the illustrated embodiment, a set of base data (i.e., a set of dynamic pressure data measured by the sensor during a first activation) is compared with a set of current data (i.e., a set of dynamic pressure data measured by the sensor during a second activation). This comparison is embodied as a correlation value CV. The correlation value CV is calculated using the following equation, where P1 is a discrete measured dynamic pressure within the bore hole 14 during the course of an AWG activation, P2 is a discrete measured dynamic pressure within the bore hole 14 during the course of a subsequent AWG activation, and where n varies from 1 to the total number of dynamic pressure data points d measured by the sensor 26 during AWG activations:
CV
=
∑
n
=
1
d
(
P
1
n
*
P
2
n
)
∑
n
=
1
d
(
P
1
n
)
2
*
∑
n
=
1
d
(
P
2
n
)
2
In the present use of the correlation value, the correlation value ranges from 0 to +1, with 0 indicating that the base data and the current data have totally unrelated waves, and +1 indicating that the base data and the current data have completely identical waves. This correlation value CV (i.e., the correlation value CV for the first and second activations of the AWG device 18 ) is represented on the user interface 56 as the current affect 166 . The affect is calculated according to the following equation:
Affect=(1 −CV )*100
In the present use of affect, the affect value ranges from 0 to 100. The affect value is inversely related to the correlation value CV, meaning that a low affect value indicates that the compared waves are very similar. During a subsequent activation of the AWG device 18 , a third set of dynamic pressure data is measured by the sensor 26 . The current affect 166 calculated for the first and second activations becomes the previous affect 170 displayed on the user interface 56 , and a new current affect 166 , comparing the second and third activations, is calculated according to the equations above. This process continues for each subsequent activation of the AWG device 18 .
A large disparity between the current affect 166 and the previous affect 170 indicates that AWG activation is improving the condition of the well structure, and that AWG activations should continue until the current affect 166 and the previous affect 170 converge. Once the current affect 166 and the previous affect 170 have both been reduced to a value of 10 or less, they are nearly equal and, subsequent AWG activations will provide little more improvement, and the user can decide to change the operational parameters of the AWG device 18 or that the process is complete. In the illustrated embodiment, the user interface 56 includes an indicator bar 182 to indicate to the user whether AWG activations should continue, based on the difference between the previous affect 170 and the current affect 166 .
The processor 30 also calculates the rate of decay of the wave for each AWG activation to provide an additional way to determine the change in permeability of the well structure. With reference to FIG. 4 , the rate of decay D1 for a first AWG activation is a function of a first peak amplitude K1 of the first pressure wave 90 measured by the sensor 26 , a time t K1 corresponding with the first peak amplitude K1, a second peak amplitude K2 of the first pressure wave 90 , and a time t K2 corresponding with the second peak amplitude K2. The rate of decay D1 of the first pressure wave 90 is calculated according to the following equation:
D
1
=
1000
*
ln
(
K
1
)
-
ln
(
K
2
)
t
K
2
-
t
K
1
Similarly, upon a second activation of the AWG device 18 , the rate of decay D2 of the second pressure wave 94 is calculated according to the following equation, where L1 is the first peak amplitude of the second pressure wave 94 measured by the sensor 26 during the second activation, L2 is the second peak amplitude, t L1 is the time corresponding with the first peak amplitude L1, and t L2 is the time corresponding with the second peak amplitude L2:
D
2
=
1000
*
ln
(
L
1
)
-
ln
(
L
2
)
t
L
2
-
t
L
1
(Time in all Equations Above is Expressed in Milliseconds)
After the first two AWG activations, the user interface displays the current P Value 174 , representing the current percent change in decay according to the following equation:
P
Value
=
D
2
D
1
*
100
During a third activation of the AWG device 18 , a third set of dynamic pressure data is measured by the sensor 26 . The current P Value 174 calculated for the first and second activations becomes the previous P Value 178 displayed on the user interface 56 , and a new current P Value 174 , comparing the second and third activations, is calculated according to the equations above. This process continues for subsequent activations of the AWG device 18 .
A P Value greater than 100% indicates an increase in the decay rate of the pressure wave (i.e., a more rapidly attenuating wave). With reference to FIG. 4 , the pressure wave 94 for the second AWG activation attenuates more rapidly than the pressure wave 90 for the first AWG activation. Accordingly, the P Value comparing these two AWG activations would be greater than 100%. A P Value less than 100% indicates a decrease in the decay rate of the pressure wave. An increase in the decay rate between subsequent AWG activations indicates that more fluid is being pushed through the screen and/or geological formation 34 (resulting in a dampening of the flow of fluid and pressure), thus indicating an improved permeability in the screen and/or the geological formation 34 . As the current percent change in decay approaches 100%, subsequent AWG activations will provide little more improvement, and the user can decide to change the operational parameters of the AWG device 18 or that the process is complete.
In operation, the user positions the AWG device 18 within the bore hole 14 . The user then inputs desired operational parameters into the processor 30 using the user interface 56 . For example, the user can enter the static fluid level 110 , the depth 114 , the chamber volume 118 , the burst interval 122 , the cycle time 126 , and the AWG operational pressure 130 . Next, the user repeatedly activates the AWG device 18 . High pressure gas from the gas source 22 flows through the high pressure gas line 46 and is explosively released by the ports 50 of the AWG device 18 . This release generates a sharp acoustic wave and a pressure wave that impacts and vibrates the well structure. The impact loosens mineral debris, bacterial debris, or other debris that impede fluid production.
The sensor 26 measures the pressure during each activation of the AWG device 18 , and the processor 30 records these pressure measurements versus time as pressure data sets. From the pressure data sets, the processor 30 calculates current and previous maximum pressure values 158 , 162 , current and previous affects 166 , 170 , and current and previous P Values 174 , 178 . All of the various values measured and shown on the user interface 56 , and differences in the values between AWG activations, indicate the effectiveness of the process. This allows the user to make changes to the operating parameters of the AWG device 18 to improve process effectiveness while the AWG device 18 is still situated within the bore hole 14 . When activation and monitoring at the selected location within the bore hole 14 is complete, the AWG device 18 can be moved to another location within the bore hole 14 , and the method repeated.
Various features and advantages of the invention are set forth in the following claims.
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A system and method for monitoring the permeability of a well structure defining a bore hole. The system comprises a wave generator, a sensor adapted to receive current wave data, and a processor programmed to compare the current wave data to prior wave data in order to determine the permeability of the well structure. The processor can calculate a correlation value and/or a decay value that reflects changes between the current wave data and the prior wave data, and these values can be displayed for the user. The method comprises creating a pressure wave in the bore hole, sensing current wave data, and comparing the current wave data to prior wave data in order to determine the permeability of the well structure. The step of comparing can include calculating a correlation value and/or a decay value that corresponds with the change in the data, and the values can be displayed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of optical scanning and particularly to bar code laser scanners. More particularly it relates to an apparatus and method for sealing the optical surfaces of bar code laser scanners from spilled liquids and other contaminants to which such scanners may be exposed in normal use in a point of sale environment such as a supermarket.
2. Description of Related Art
Supermarket scanners, referred to herein as bar code laser scanners, typically consist of a lower chassis which houses the optical scan line generating elements, a lower sealed window through which the scan lines may pass which is sealed to the chassis, and an upper window which is removable and field replaceable, for example, upon being scratched or broken. In order for the scanner to operate in an optimal fashion, both windows must be optically transparent and free of scratches, smears, discolorations and other contaminants which would prevent the scanner light beam from passing as relatively unimpeded through the windows as possible. This invention relates to a method and apparatus for sealing the space or gap between the lower window and the upper window from contaminants. This space, or gap, as referred to herein, also includes the lower surface of the upper window and the upper surface of the lower window. The distance between the glass windows has high variability and commercial glass varies in thickness and flatness. This presents a requirement for a device capable of sealing the variable distance between the windows and capable of excluding liquids and dust from the gap. Prior art windows not employing a seal have not been able to adequately keep contaminants away from the gap. If contaminants reach the lower window, the lower window must then be cleaned which is frequently difficult, time consuming, and reduces machine availability.
SUMMARY OF THE INVENTION
The present invention comprises a soft compliant seal attached to either an anchored or loose reinforcement ring to provide a seal for the exclusion of liquids and particulates from a gap between a lower window and an upper window.
Accordingly, it is an object of this invention to provide a seal for sealing from contamination the gap existing between two substantially parallel and spaced apart relatively flat surfaces.
It is a further object of this invention to provide an improved method for sealing from contamination the gap existing between two substantially parallel and spaced apart relatively flat surfaces.
It is a further object of this invention to provide an improved seal for an optical scanner window.
It is a further object of this invention to provide an improved method for sealing an optical scanner window.
It is a further object of this invention to provide an improved compliant seal for sealing a gap between a lower window and an upper window which is capable of restricting particulates and liquids from entering the gap.
Other and further objects and advantages of the present invention will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded top perspective view of a scanner top plate with a removable top window assembly according to the present invention.
FIG. 2 is a top view of a removable top window assembly with window frame according to the present invention.
FIG. 3 is a cross-sectional view taken along lines 3--3 of FIG. 2.
FIG. 4 is an enlarged cross-sectional view of area 5 of FIG. 3 showing a first preferred embodiment of the present invention.
FIG. 5 is an enlarged cross-sectional view of area 5 of FIG. 3 showing a second preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates generally to a window seal for use in an optical scanner. Optical scanners are used, for example, in supermarkets to read Universal Product Code information from product tags. It is desirable to seal the space or "gap" between the lower window of an optical scanner and the upper window so that contaminants are inhibited from entering that space and blocking or impeding the transmission of light rays from within the scanner to without. As used herein the term "gap" includes the surfaces which define the gap. In a preferred embodiment of the present invention the window seal may be employed in a Spectra-Physics, Inc. Model 750-SL bar code laser scanner available from the Spectra-Physics, Inc. Retail Systems Division, 959 Terry Street, Eugene, Ore. 97402-9120. It is to be understood, however, that the window seal of the present invention can be used in many situations where it is desirable to create a non-hermetic seal resistive to the passing of contaminants between two relatively flat, spaced apart and substantially parallel surfaces.
Turning to FIG. 1 of the drawings, an exploded top perspective view of a scanner top plate 10 and window cartridge assembly 20 is shown. In a preferred embodiment, scanner top plate 10 is fastened to the top of an optical scanner unit (shown as 30 in FIG. 3). Scan lines generated by optical scanner 30 are projected through a first window 40 ("lower window") in the optical scanner and then through a second window 50 ("upper window") in the window cartridge assembly. Items bearing information to be scanned, such as, for example, Universal Product Code Information, may be passed over second window 50. The scan lines will reflect off of the information to be scanned and back through windows 50 and 40 where detectors will decode the information for further processing. Scanners of this type are well known in the art and are described in more detail in, for example, U.S. Pat. No(s). 4,713,532 and 4,093,865 which are incorporated herein by reference.
In a preferred embodiment of the present invention window cartridge assembly 20 comprises window frame 60, second window 50 and seal rim 70. Turning to FIG. 2, second window 50 is removably seated upon seal rim 70 and positioned by raised portions 80 of seal rim 70. Spring clips 90 bias second window 50 into correct registration with raised portions 80. Spring clips 90 are held in place by nuts and bolts l00A through holes 100. Second window 50 may be manufactured of tempered glass, regular glass, sapphire, a coated glass, or other optically transmissive material that would be suitable (i.e., hard, resistive to scratches, resistive to breaking). Window frame 60 is, in a preferred embodiment, manufactured of injection molded plastic as well known in the art. As used in a preferred embodiment, second window 50 lies above and substantially parallel to first window 40 which is typically permanently bonded to optical scanner 30 with a silicone based adhesive. A gap or space 110 remains between first window 40 and second window 50 as can be seen in FIGS. 3, 4 and 5. In order to form a seal to exclude contaminants from gap 110 seal rim 70 is provided. Turning now to FIGS. 3, 4 and 5, seal rim 70 comprises a tough plastic outer rim 120 and a soft compliant seal member 130. In a preferred embodiment of the present invention, outer rim 120 is fabricated of injection molded polycarbonate plastic such as, for example, General Electric type GE Lexan 920 available from the General Electric Corporation. In a preferred embodiment, seal member 130 is fabricated of a soft durable silicone rubber having approximately a durometer reading of 15 on the Shore-A scale. An example of an acceptable material is Type GI-570 Silicone Rubber available from Silicones, Inc. of 1020 Surrette Drive, P.O. Box 363, Hypoint, N.C. 27261. Other types are also acceptable as known to those of skill in the art.
In a preferred embodiment of the present invention, the seal member 130 is attached to the outer rim 120 in the following manner, although other methods could be used as well known to those of skill in the art:
First, outer rim 120 is injection molded and includes at its inner periphery a plurality of slots or holes (not shown) therethrough. Second, outer rim 120 is placed in a jig and a two-step injection molding process is carried out whereby seal member 130 is injection molded to the inner periphery of outer rim 120, the material of seal member 130 flowing through the slots and aiding in the attachment of seal member 130 to outer rim 120. This process is well known in the art and therefore will not be described further herein.
In a first preferred embodiment of the present invention as depicted in FIG. 4, seal rim 70 has a tapered region 140 where the rim material tapers from a first thickness to a second lesser thickness at the inner periphery of outer rim 120. It is at the narrow portion of outer rim 120 that seal member 130 is attached. In the tapered region 140 the outer rim material slopes downwardly and away from upper window 50 and toward lower window 40 as shown to allow seal member 130 to be relatively recessed with respect to top surface 150 of outer rim 120.
In a second preferred embodiment of the present invention as depicted in FIG. 5, the downward slope to tapered region 160 is omitted.
The purpose for having tapered region 140 of the first preferred embodiment and tapered region 160 of the second preferred embodiment is to increase the flexibility and compliance of the seal in order to more easily accommodate variations in the thickness and flatness of the glass of first window 40 and second window 50. Accordingly, the seal member 130 can more easily adjust to the variations in distance between the two windows. By narrowing the thickness of the flange material in the above-described manner seal member 130 is more able to conform to irregularities in the shape of windows 40, 50.
Seal member 130, in a one preferred embodiment, comprises a single upwardly depending flange 210 for contacting the upper window and a single downwardly depending flange 220 for contacting the lower window. In another preferred embodiment, more than one upwardly depending flange may be used and in another preferred embodiment, more than one downwardly depending flange may be used. In this manner, additional sealing capabilities may be obtained.
In use, the seal of the present invention conforms well to both the lower window 40 and the upper window 50 providing an improved seal to exclude contaminants such as liquids and dust from entering gap 110 or contacting the upper surface of lower window 40 as the lower surface of upper window 50.
It is to be understood that window frame 60 is insertable into scanner top plate 10 in a preferred embodiment whereby window frame 60 is restrained by snap fasteners l70A, l70B as is well known in the art. Pins 180 position holes 190 in window frame 60 and cutouts 200 in seal rim 70 as well known in the art.
While embodiments and applications of this invention have been shown and described, it would be apparent to those of skill in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.
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A soft compliant seal is attached to either an anchored or a loose reinforcement ring to provide a non-hermetic seal against liquids or particulates in order to maintain a space between two windows substantially free of all foreign matter.
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TECHNICAL FIELD
[0001] This invention relates generally to bottle organizers and, more particularly, to beverage organizers that are incorporated into refrigerated compartments, such as those used on passenger aircraft.
BACKGROUND
[0002] Keeping food and beverages chilled to the proper temperature is important in any context. In certain contexts, such as where space is limited and where quick access to the chilled items is required, proper refrigeration can be a challenge. For example, in the context of a passenger aircraft, bottled beverages such as wine or Champaign are usually stored in a refrigerated compartment near the cockpit. Due to space limitations, however, the compartment tends to be very small and difficult to organize. Furthermore, due to the individual nature of drink orders flight attendants are often hard-pressed to pull bottles out and pour drinks for passengers in a timely fashion. As a result, beverage containers are sometimes quickly placed in the refrigerator, with the containers pushed against a wall of the container and the containers pushed against each other without space between. This results in non-uniform cooling of the containers, and makes it more difficult to cool the space in the refrigerator. Another problem with many refrigerated compartments is that the beverages do not cool to a uniform temperature. Thus, for example, one bottle of chardonnay might be chilled to the appropriate temperature, while an adjacent bottle may be too warm.
SUMMARY
[0003] In accordance with the foregoing, a new and improved bottle organizer is provided. In an embodiment of the invention, the bottle organizer includes a generally vertical wall, a generally horizontal floor proximate to the generally vertical wall, and a spacing member positioned along the generally vertical wall. The spacing member has a portion (which may be curved) that protrudes in a plane that is generally parallel to the horizontal floor and generally perpendicular to the vertical wall. The protruding portion may be disposed at a distance from the floor that corresponds approximately to the height of a shoulder or neck portion of a bottle standing upright on the floor, so as to stabilize and maintain the bottle in an upright and spaced position The spacing member may include alternating straight and curved portions. The vertical wall may be one of two walls, which may be generally parallel and coextensive with each other. The bottle organizer may include a generally cuboid enclosure, in which the spacing member is slidingly disposed. The invention provides for easier and more convenient placement and removal of containers within a refrigeration compartment where the bottle organizer is disposed. The invention will further promote quicker “pull down” (achieving a desired cool temperature) and more even temperature distribution within the refrigeration compartment.
[0004] In one embodiment, the spacing member is generally unshaped, and its side is attached to the vertical wall.
[0005] In another embodiment, the vertical wall is one of at least two vertical walls, and each of the two vertical walls has a bracket attached to it. The brackets are configured to slidingly receive the spacing member.
[0006] In yet another embodiment, the bottle organizer has a generally horizontal floor that extends between and is joined with first and second generally vertical walls, and a back wall that is generally vertical and generally perpendicular to the first and second walls. In this embodiment, the first and second walls, the back and the floor define an enclosure for storing bottles.
[0007] In yet another embodiment, the spacing member is generally cylindrical and elongated, and spacing member runs along first and second vertical walls and along a back wall.
[0008] In another embodiment of the invention, the bottle organizer includes a first generally vertical wall, a second generally vertical wall that is generally parallel to the first wall, a generally horizontal floor extending between the first and second walls and forming a junction with each of the first and second walls, and a generally unshaped, elongated member. The elongated member has a first side that is attached to the first wall, and a second side that is attached to the second wall. Furthermore, the elongated member is oriented in a plane that is generally parallel to the floor and generally perpendicular to the first and second walls. The elongated member also has a curved portion adapted to separate at least two vertically oriented bottles standing on the floor.
[0009] In another embodiment, the bottle organizer includes a pair of supporting members that facilitate the attachment of the elongated member to the first and second walls. In this embodiment, one of the supporting members is secured to the first wall and the other is secured to the second wall.
[0010] In another embodiment, the bottle organizer includes a first enclosure and a second enclosure disposed within the first enclosure. In this embodiment, the second enclosure includes the first and second walls and the floor.
[0011] In still another embodiment, the bottle organizer includes pairs of supporting members that facilitate the attachment of the elongated member to the first and second walls. In this embodiment, one of each pair of supporting members is secured to the first wall and the other of each pair is secured to the second wall. Each pair of the plurality is disposed at a height above the floor to facilitate the storage of a different size of bottle within the elongated member.
[0012] In still another embodiment, the elongated member slides into a compartment defined by the first and second walls and the floor, and engages the first and second walls via one of a plurality of pairs of brackets. In this embodiment, each pair is positioned at a height that corresponds to one of multiple sizes of bottles.
[0013] In still another embodiment of the invention, the bottle organizer includes an elongated member that is generally cylindrical along its length and that is bent into a generally u-shaped configuration along a generally horizontal plane. The elongated member has generally straight portions and generally curved portions that alternate with one another. In this embodiment, at least one pair of the generally curved portions protrude inwardly along the horizontal plane toward one another. The elongated member is disposed at a height that corresponds approximately with the height of a shoulder or neck of a bottle that is oriented in a generally vertical direction.
[0014] In another embodiment, the bottle organizer includes two generally vertical walls that are generally parallel to one another, and brackets attached to each of the walls to support two sides of the elongated member. One side of the elongated member may slide into one bracket and the other side of the elongated member may slide into the bracket attached to the one wall.
[0015] In yet another embodiment, the bottle organizer includes a first generally vertical wall, a second generally vertical wall that is generally parallel to the first wall, and a generally horizontal floor extending between the first and second walls and forming a junction with each of the first and second walls. In this embodiment, the generally curved portions of the elongated member provide spacing between each of multiple bottles.
[0016] In yet another embodiment, the bottle organizer includes a first generally vertical wall, a second generally vertical wall that is generally parallel to the first wall, a brackets attached to the first wall, one of which supports a side of the elongated member, and bracket attached to the second wall, one of which supports another side of the elongated member. In this embodiment, each of the brackets attached to the first wall correspond to one of the brackets attached to the second wall, thereby forming pairs of brackets. Each pair of brackets corresponds approximately to the shoulder or neck height of a different sized bottle than each of the other pairs of brackets.
[0017] In still another embodiment of the invention, the bottle organizer includes a generally horizontal floor extending between the first and second walls and forming a junction with each of the first and second walls. In this embodiment, the generally curved portions of the elongated member provide spacing between each of multiple bottles that are standing on the floor in an upright position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a bottle organizer according to an embodiment of the invention.
[0019] FIG. 2 illustrates a spacing member according to an embodiment of the invention.
[0020] FIG. 3 illustrates a front view of the bottle organizer of FIG. 1 .
[0021] FIG. 4 illustrates a top-down view of the bottle organizer of FIG. 1 .
[0022] FIG. 5 illustrates a side view of the bottle organizer of FIG. 1 .
[0023] FIG. 6 illustrates the placement of bottles in the bottle organizer of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] The invention is generally directed to a bottle organizer. Referring to FIGS. 1 , 3 - 5 , various embodiments of the bottle organizer will now be described. The bottle organizer, generally labeled 10 , is generally cuboid in shape, and includes a first generally cuboid enclosure 12 and a second generally cuboid enclosure 14 located within the first enclosure 10 . The first generally cuboid enclosure may be a variety of things, including a compartment on a passenger aircraft, or a compartment of service cart. The second enclosure 14 has first side wall 16 , a second side wall 18 generally parallel to the first side wall, a floor 20 that is attached to, and extends between, the first and second side walls 16 and 18 . The second enclosure 14 also has a back wall 22 that is attached to the first and second side walls 16 and 18 and to the floor 20 . The back wall 22 is oriented generally perpendicular to the first and second side walls 16 and 18 as well as to the floor 20 . Each of the first and second side walls 16 and 18 has a leaf portion 24 that extends beyond the plane of the back wall 22 . Each leaf portion has a number of holes 26 through which screws, rivets, or other fasteners can be passed for the purpose of securing the second enclosure 14 to the inside of the first enclosure 12 .
[0025] Behind the back wall 20 is refrigeration equipment (not shown), including a compressor unit, expansion valve, cooling coils, and a fan. The back wall 20 has a set 31 of vent holes that permit air that is blown by the fan to pass over the cooling coils and into the second enclosure 14 . A set 28 of bars helps to prevent objects from accidentally being inserted into the set 31 of vent holes.
[0026] Each of the side walls 16 and 18 has at least one set of supporting members attached to it. In the embodiment illustrated in FIG. 1 , each side wall has, attached to it, a first supporting member 30 (at or about 2 inches above the floor 20 ), a second supporting member 32 (at or about 4 inches above the floor 20 ), a third supporting member 34 (at or about 8.2 inches above the floor 20 ), and a fourth supporting members 36 (at or about 12.4 inches above the floor 20 ). Thus, there are four sets of supporting member in the illustrated embodiment. Each supporting member in the illustrated embodiment is a generally u-shaped bracket, although other types of supporting members are possible. At least one of the sets of supporting members on the side walls 16 and 18 holds a spacing member 38 . The spacing member 38 may be inserted and removed by sliding it into the second enclosure using one of the sets of supporting members, starting from the end farthest from the back wall 22 and pushing it toward the back wall 22 .
[0027] Referring to FIG. 2 , an embodiment of the spacing member 38 will now be described. The spacing member 38 includes a cylindrical, elongated member. The elongated member is generally u-shaped and has a thickness of F. The elongated member has a first side, having a length of A, and a second side, opposite the first side, whose length is also A. Starting from the upper right and moving to the left and counterclockwise, the spacing member 38 has a short straight portion 40 , followed by a quarter-circular curved portion 42 , a straight segment 44 , and a half-circular curved portion 46 whose radius is R. The length B includes twice the radius R, plus the length of the short straight portion 40 . These basic elements are repeated until the spacing member 38 turns at or about 90 degrees at a rounded corner 48 . Proximate to the rounded corner is an indentation 49 that cooperates with a protrusion in one of the supporting members to keep the supporting member 38 relatively stationary after insertion. The indent has a thickness of S. The rounded corner has length of C and a width of E. After the rounded corner 48 , the cylindrical member has a long, straight portion 50 , having a length of D, which ends in a second rounded corner 48 , at which point the cylindrical member turns at or about 90 degrees. Following the second rounded corner, the cylindrical member has short straight portions 40 , quarter-circular portions 44 , and half-circular portions 46 in a repeating pattern as shown in FIG. 2 .
[0028] While there are many possible sizes and configurations of the spacing unit 38 , in one embodiment, A=11.56 inches, B=4.12 inches, C=0.94 inches, D=9.55 inches, E=0.66 inches, F=0.15 inches, R=0.44 inches, and S=0.125 inches.
[0029] As can be seen in FIG. 2 , the spacing member 38 has several protruding portions, each of which is made up of two straight segments 44 and one half-circular curved portion 46 . These protruding portions protrude into the plane of the spacing member 38 in pairs, with one of the pair being on one side of the spacing member 38 and the other of the pair being on the opposite side of the spacing member 38 . Each of the protruding portions provides spacing between bottles of the bottle organizer. This is more clearly illustrated in FIG. 6 , in which bottles 60 are show as being placed within the organizer 10 . The bottles 60 are separated by protruding portions of the spacing member 38 . Note that the spacing member is attached to the walls 16 and 18 via the first supporting members 30 , and that the first supporting members are disposed at a height above the floor 20 that corresponds approximately to the height of the shoulders of the bottles 60 . The bottles 60 in this example are 8 inch tall bottles. However, the bottle organizer 10 can also accommodate 10 inch tall bottles (by sliding the spacing member 38 into the second supporting members 32 ) and 12 inch tall bottles (by sliding the spacing member 38 into the third supporting members 34 ). For each size bottle, the spacing member 38 can be placed at a height that corresponds approximately to the shoulder of that size of bottle. Furthermore, multiple spacing members 38 may be put into the bottle organizer 10 so as to accommodate different sized bottles simultaneously. For example, a spacing member 38 may be inserted into each of the first, second, and third supporting members 30 , 32 , and 34 .
[0030] Shown merely by way of example in FIG. 2 is an embodiment of the invention used with bottles having a shoulder. The invention may also be used for bottles, such as a juice bottle, that do not have a shoulder, but have a reduced diameter neck. In that case, the spacing member 38 may be disposed approximately at the height of the neck of the bottle. In either case, according to an embodiment of the invention, the spacing member may be disposed at the neck or shoulder of a bottle—the portion of the bottle having a reduced diameter with respect to the diameter of the bottle at the bottom. In addition, the invention may be practiced to retain, stabilize and space bottles, cans or cartons, such as a substantially cylindrical metal juice can or a substantially cuboid or prism shaped cardboard milk carton, that may not have a reduced diameter portion. In such a case, the spacing member 38 may be disposed at a height less than the height of the substantially cylindrical bottle or can. As should be understood by one of skill in the art, when the term “bottle” is referred to herein, it is meant to be considered broadly and may include a variety of type and shapes, such as a wine bottle, a cuboid shaped milk carton, a cylindrical shaped juice can and other shape and types of bottles.
[0031] It can be seen from the foregoing that a new and useful bottle organizer has been described. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
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A bottle organizer includes a generally vertical wall, a generally horizontal floor proximate to the generally vertical wall, and a spacing member positioned along the generally vertical wall. The spacing member has a portion (which may be curved) that protrudes in a plane that is generally parallel to the horizontal floor and generally perpendicular to the vertical wall. The protruding portion is at a distance from the floor that corresponds to the height of a neck portion of a bottle standing upright on the floor. The spacing member may include alternating straight and curved portions. The vertical wall may be one of two walls, which may be generally parallel and coextensive with each other. The bottle organizer may include a generally cuboid enclosure, in which the spacing member is slidingly disposed.
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BACKGROUND
[0001] The present invention relates to an off-line switched mode control system with fault condition protection.
[0002] Quantum leaps in electronic technology have led to the development of “smart” electrical and electronic products. Each of these products requires a steady and clean source of power from a power supply. One power supply technology called switched mode power supply technology operates at a high frequency to achieve small size and high efficiency. In such a switching power supply, an integrated circuit (IC) regulator is connected in series with the primary winding of a transformer to a rectified and filtered alternating current (AC) power line. The energy is transferred from the primary winding through an output secondary winding to the power supply output in a manner controlled by the IC regulator so as to provide a clean and constant output voltage. Additionally, a third winding called a feedback or bias winding may be used to provide a feedback signal and power to the IC regulator.
[0003] The voltage on the feedback winding tracks the output voltage present on the secondary winding. Thus, when a short occurs on the output of the secondary winding, the voltage on the feedback winding also goes low. Further, in the event of a short circuit condition, an overload condition on the output secondary winding or an open loop condition on the feedback winding, the regulator circuit responds to such conditions by delivering maximum power over a period of time. In such cases, the regulator circuit detects that the power supply is short circuited, overloaded at the output or has encountered an open loop condition. In any of these fault conditions, the regulator circuit goes into a mode called “auto-restart.” In the auto-restart mode, the regulator circuit tries to start the power supply periodically by delivering full power for a period of time (greater than needed for start up) and turns off the power supply for another period of time that is approximately four to ten times longer. As long as the fault condition is present, the regulator circuit remains in this auto-restart mode limiting the average output power to a safe, low value. When the fault is removed, auto-restart enables the power supply to start-up automatically.
SUMMARY
[0004] The invention protects a power supply from fault conditions. The power supply has an output and a feedback control loop, the feedback control loop having a feedback signal which cycles periodically when the power supply operates normally and which remains idle when the power supply is in a fault condition. In a first aspect, the circuit includes a switching device for controlling power delivered to the output and a timer coupled to the switching device and to the feedback signal. The timer disables the switching device to prevent power delivery to the output in a first predetermined period after the fault condition exists.
[0005] Implementations of the invention include one or more of the following. The timer may enable the switching device to deliver power to the output after a second predetermined period. The switching device may be alternately enabled for the first predetermined period and disabled for the second predetermined period when the fault condition exists. The switching device may be enabled upon removal of the fault condition. The switching device may be a power transistor. The timer may be a digital counter. An oscillator with a predetermined frequency may be coupled to the counter. The oscillator may have a control input for changing the predetermined frequency and a first current source coupled to the oscillator control input to generate a first frequency. A second current source may be coupled to the oscillator control input to generate a second frequency. The counter output may be coupled to the fist and second current sources. The timer may be a capacitor which is adapted to be charged at a first rate from a first threshold to a second threshold to generate a first predetermined period. The capacitor may be discharged from the second threshold to the first threshold at a second rate to generate the second predetermined period. The capacitor may also be reset to a voltage below the first threshold each time the feedback signal cycles. The fault condition includes one or more of an output overload fault condition, an output short circuit fault condition and an open feedback control loop fault condition.
[0006] In a second aspect, a method for protecting a power supply having an output and a feedback control loop from fault conditions includes receiving a feedback signal from the feedback control loop, the feedback signal being adapted to cycle periodically when the power supply operates normally and to remain idle when the power supply is in a fault condition; timing the feedback signal to detect whether a fault condition exists in the power supply; and disabling the output after a first predetermined period after the fault condition is detected.
[0007] Implementations of the invention include one or more of the following. A switching device may be enabled to deliver power to the output after a second predetermined period. The switching device may be alternatingly enabled for the first predetermined period and disabled for the second predetermined period. The switching device may be enabled upon removal of the fault condition. The enabling step may enable a power transistor. The timing step includes digitally countering periods of time. A signal may be generated with a predetermined frequency. The generating step includes oscillating at a first frequency and a second frequency. The second frequency may be used when the fault condition exists. The timing step includes charging a capacitor at a first rate from a first threshold to a second threshold to generate a first predetermined period; and discharging the capacitor from the second threshold to the first threshold at a second rate to generate a second predetermined period. The capacitor may be reset to a voltage below the first threshold each time the feedback signal cycles.
[0008] In a third aspect, a circuit for protecting a power supply having an output and a feedback control loop from fault conditions includes means for receiving a feedback signal from the feedback control loop, the feedback signal being adapted to cycle periodically when the power supply operates normally and to remain idle when the power supply is in a fault condition; timing means coupled to the feedback signal to detect whether a fault condition exists in the power supply system; and means for disabling the output after a first predetermined period after the fault condition is detected.
[0009] Implementations of the invention include one or more of the following. The circuit includes a means for enabling a switching device to deliver power to the output after a second predetermined period. A means for alternatingly enabling the switching device for the first predetermined period and disabling the switching device for the second predetermined period when the fault condition exists may be used. The circuit may have a means for enabling the switching device upon removal of the fault condition. The switching device may be a power transistor. The timing means includes a digital counter. The circuit includes means for generating a predetermined frequency. The generating means includes means for oscillating at a first frequency and a second frequency. The circuit may include a means for applying the second frequency when the fault condition exists. The timing means includes a means for charging a capacitor at a first rate from a first threshold to a second threshold to generate a first predetermined period; and a means for discharging the capacitor from the second threshold to the first threshold at a second rate to generate a second predetermined period. A means for resetting the capacitor to a voltage below the first threshold each time the feedback signal cycles may be used.
[0010] In another aspect, a fault protected power supply includes a regulator coupled to a transformer having a primary winding. The transformer has a secondary winding coupled to a secondary output. The regulator receives a feedback signal from the secondary output which cycles periodically when the power supply operates normally and which remains idle when the power supply is in a fault condition. The power supply includes a switching device coupled to the primary winding of the transformer for controlling power delivered to the secondary output; an oscillator for generating a signal with a predetermined frequency; and a timer coupled to the oscillator and to the feedback signal, the timer disabling the switching device after a predetermined period of existence of a fault condition.
[0011] Implementations of the invention include one or more of the following. The power supply includes a means for changing the frequency of the oscillator. The timer alternatively enables and disables the switching means when the fault condition is present.
[0012] In another aspect, a method protects a power supply having a regulator coupled to a transformer having primary winding, the transformer having a secondary winding coupled to a secondary output, the regulator receiving a feedback signal from the secondary output which cycles periodically when the power supply operates normally and which remains idle when the power supply is in a fault condition. The method includes controlling power delivered to the secondary output using a switching device; generating an oscillating signal with a predetermined frequency; and timing the feedback signal with the oscillating signal and disabling the switching device after a predetermined period of existence of a fault condition.
[0013] Implementations of the invention include one or more of the following. The method includes changing the frequency of the oscillating signal. The method also includes alternatingly enabling and disabling the switching device when the fault condition is present.
[0014] In another aspect, a fault protected power supply has a regulator coupled to a transformer having a primary winding, the transformer having a secondary winding coupled to the secondary output. The regulator receives a feedback signal from the secondary output which cycles periodically when the power supply operates normally and which remains idle when the power supply is in a fault condition. The power supply includes a switching device coupled to the primary winding of the transformer for controlling the power delivered to the secondary output; a capacitor; means for charging the capacitor at a first rate from a first threshold to a second threshold to generate a first predetermined period and discharging the capacitor from the second threshold to first threshold at a second rate to generate a second predetermined period; and means coupled to the switching device, the capacitor and the feedback signal for alternately enabling the switching device during first predetermined period and disabling the switching device during the second predetermined period in the presence of a fault condition.
[0015] In yet another aspect, a method protects a power supply having a regulator coupled to a transformer having a primary winding. The transformer has a secondary winding coupled to a secondary output. The regulator receives a feedback signal from the secondary output which cycles periodically when the power supply operates normally and which remains idle when the power supply is in a fault condition. The method includes controlling power delivered to the secondary output using a switching device; charging a capacitor at a first rate from a first threshold to a second threshold to generate a first predetermined period; discharging the capacitor from the second threshold to first threshold at a second rate to generate a second predetermined period; and alternatingly enabling the switching device during the first predetermined period and disabling the switching device during the second predetermined period in the presence of a fault condition.
[0016] Advantages of the invention include one or more of the following. The invention protects the switched mode controller and associated components such as the diode and the transformer from various fault conditions. The feedback winding is not necessary. The protection is provided using a minimum number of components. Further, the power supply properly shuts down when it encounters a fault condition and automatically returns to an operating condition when the fault condition is removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic illustration of a fault condition protection device of the invention.
[0018] FIG. 2 is a plot illustrating the operation of the device of FIG. 1 .
[0019] FIG. 3 is a schematic illustration of a second embodiment of the fault condition protection device.
[0020] FIG. 4 is a plot illustrating the operation of the device of FIG. 2 .
[0021] FIG. 5 is a schematic illustration of a switched mode power supply in accordance with the present invention.
DESCRIPTION
[0022] Referring now to FIG. 1 , a fault-protection circuit 200 is shown. The circuit 200 has a primary oscillator 111 which is connected to a counter 202 . The counter 202 can be reset by a feedback signal which clears registers Q 8 -Q 13 of counter 202 . The feedback signal is explained in more detail below.
[0023] An inverter 204 receives the 13-th bit output of counter 202 . The output of inverter 204 is provided to an AND-gate 206 whose other input is connected to a switching signal. The switching signal is derived from the oscillator 111 output and the feedback signal. This switching signal cycles periodically when the power supply operates normally. The switching signal is idled when the power supply encounters a fault condition. The output of AND-gate 206 in turn is provided to the gate of a switching transistor 208 . Counter 202 eventually causes an AND-gate 206 to shut-off switching transistor 208 and to perform auto-restart.
[0024] Turning now to oscillator 111 , a current source 122 generates a current I from a supply voltage 120 . The output of current source 122 is connected to the source of a p-channel MOSFET transistor 125 , whose drain is connected to a node 123 . Also connected to the node 123 through a p-channel MOSFET 182 is a second current source 184 . Current source 184 can supply current which is ¼ of the current I. The drain of transistor 182 is also connected to node 123 . The gate of transistor 182 is driven by an inverter 180 , whose input is connected to the gate of transistor 125 and to the counter output Q 13 .
[0025] The node 123 is connected to the sources of p-channel MOSFET transistors 126 and 132 . The drain of MOSFET transistor 126 is connected to the drain of an n-channel MOSFET transistor 128 . The source of transistor 128 is grounded, while the gate of transistor 128 is connected to its drain. The gate of transistor 128 is also connected to the gate of an n-channel MOSFET transistor 130 . The source of transistor 130 is grounded, while the drain of transistor 130 is connected to the drain of transistor 132 at a node 131 . Transistors 126 , 128 , 130 and 132 form a differential switch. The input of inverter 124 and the gate of transistor 132 are driven by a hysteresis comparator 136 . Output of inverter 124 drives the gate of MOSFET transistor 126 . Comparator 136 has an input which is connected to node 131 and to a capacitor 134 . The other node of the capacitor is connected to ground. In combination, transistors 126 , 128 , 130 and 132 , capacitor 134 , inverter 124 and hysteresis comparator 136 and current source 122 form an oscillator. The output of hysteresis comparator 136 is provided as an oscillator output and is also used to drive the clock input of counter 202 .
[0026] During operation, the feedback signal periodically pulses between a low state and a high state depending on the amount of power required on a secondary winding 922 ( FIG. 5 ). Every time the feedback signal is low, the feedback signal resets a counter whose states are reflected by outputs Q 8 -Q 13 of counter 202 . The resetting of the counter associated with outputs Q 8 -Q 13 thus occurs regularly when no fault is present in the power supply. The cycling of the feedback signal constantly clears the output bit Q 13 such that the power transistor 208 is controlled by the switching signal when no fault is present. However, in the event of a fault condition, the feedback signal remains high for a sufficiently long time such that the counter associated with output bits Q 8 -Q 13 has enough time to increment output bit Q 13 . The setting of the output bit Q 13 causes inverter 204 output to go low and thus causes the output of AND-gate 206 to be deasserted. The deassertion of AND-gate 206 in turn disables switching transistor 208 . Also, when the counter output Q 13 goes high transistor 125 turns off to isolate primary current source 122 from node 123 . This turns on the transistor 182 via inverter 180 , thus allowing the ¼ I current to flow from the secondary current source 184 to node 123 . The state change of the counter output Q 13 causes the oscillator to switch at one-fourth of its normal frequency to achieve about 20% on time and 80% off time. This operation reduces the power delivered by the power supply under a fault condition as well as avoids the possibility of damage to the regulator device and other power supply components such as the output diode or the transformer (not shown).
[0027] FIG. 2 shows a timing diagram for the device of FIG. 1 . The timing diagram of FIG. 2 shows three periods: 211 , 213 and 215 . Period 211 is normal operation with the feedback signal going “low” more often than a predetermined count such as approximately 4096 clock cycles, thereby resetting the Auto Restart Counter before it counts up to 4096.
[0028] In Period 213 , the feedback signal has been “high” for 4096 continuous clock cycles due to a fault condition such as an output overload or short, so the circuit of FIG. 1 goes into the auto-restart mode. The oscillator frequency is divided by four and switching transistor 208 has been inhibited from switching, remaining in its off state. After 4096 clock cycles, switching transistor 208 is activated and the oscillator frequency switches back to normal frequency. This sequence will repeat itself as long as the feedback signal stays “high.”
[0029] In Period 215 , the overload condition or the short condition on the output of the power supply is removed and the feedback signal goes low, indicating the power supply output is in regulation. The circuit is now in normal operation with the feedback signal going “low” at least once every 4096 clock cycles. It is to be noted that the auto-restart capability as been described may not be used in all applications. Particularly, certain applications may disable the power regulator after detecting a fault condition and the disabling of the power regulator may continue until a user resets the power regulator, or until AC power is cycled OFF and then ON to the power regulator.
[0030] FIG. 3 shows an analog auto restart circuit. A current source 525 produces a fixed magnitude current 530 . Fixed magnitude current 530 is fed into first transistor 535 and mirrored to transistors 540 and 545 . Third transistor 545 is connected to a capacitor 550 via transistor 595 . Transistor 600 is also connected to the capacitor 550 . Transistor 600 is controlled by the feedback signal provided to inverter 605 whose output drives the gate of the transistor 600 . Node 400 is generated by the charging and discharging of capacitor 550 . Capacitor 550 has a relatively low capacitance which allows for integration on a monolithic chip in one embodiment of the IC regulator of the invention. Node 400 is provided to a hysteresis comparator 560 which compares its input with a lower limit of about 1.5 volts and an upper limit of about 4.5 volts. The output of comparator 560 is provided to the gates of transistors 585 and 595 . AND-gate 570 receives at one input the output of comparator 560 . AND-gate 570 enables switching transistor 572 to turn on and off. AND-gate 570 receives at a second input a switching signal which modulates the regulator output.
[0031] In operation, after the feedback signal goes high, capacitor 550 begins to charge from a level below 1.5 volts to an upper threshold of about 4.5 volts. Upon reaching 4.5 volts, the output of comparator 560 switches and discharges the capacitor 550 through transistors 545 and 595 . Node 400 then switches between the upper threshold of about 4.5 volts and the lower threshold of about 1.5 volts.
[0032] Signal 401 output of comparator 560 will be high until node 400 exceeds the upper threshold limit. When signal 400 is high, p-channel transistors 585 and 595 are turned off. By turning off transistors 585 and 595 , current can flow into and steadily charge capacitor 550 and increase the magnitude of node 400 . The current that flows into capacitor 550 is derived from current source 525 because the current through transistor 590 is mirrored from transistor 580 , which current is derived from transistor 540 .
[0033] Referring to FIGS. 3 and 4 , in period 600 feedback signal 402 is switching and the system is in normal operation with switching transistor 572 controlled by the switching signal. At the end of period 600 a fault condition has been detected and the feedback signal stays high for an extended period of time (period 601 ). In period 601 , transistor 600 turns off, allowing capacitor 550 to be charged by current source 590 . When the voltage on node 400 has reached the second threshold, the output 401 of comparator 560 goes low, disabling the switching transistor 572 . Capacitor 550 will be discharged to the first threshold by current source 545 with switching transistor 572 disabled. This mode of oscillation continues until the feedback signal goes low again, indicating that the fault condition no longer exists. When the feedback signal 402 at the end of period 601 goes low, transistor 600 turns on and discharges capacitor 550 to a voltage below the first threshold. Comparator 560 output will go high and enable the switching signal to control the switching transistor 572 . In period 602 , the system has returned to normal operation with the feedback signal 402 going low at least once during a defined time period indicating that the regulator circuit is in regulation.
[0034] Referring now to FIG. 5 , a switched mode power supply is shown. Direct current (DC) input voltage is provided to a Zener diode 912 which is connected to a diode 914 . The diodes 912 - 914 together are connected in series across a primary winding of a transformer 920 . A secondary winding 922 is magnetically coupled to the primary winding of transformer 920 . One terminal of the secondary winding 922 is connected to a diode 930 , whose output is provided to a capacitor 932 . The junction between diode 930 and capacitor 932 is the positive terminal of the regulated output. The other terminal of capacitor 932 is connected to a second terminal of the secondary winding and is the negative terminal of the regulated output. A Zener diode 934 is connected to the positive terminal of the regulated output. The other end of Zener diode 934 is connected to a first end of a light emitting diode in an opto-isolator 944 . A second end of the light-emitting diode is connected to the negative terminal of the regulated output. A resistor 936 is connected between the negative terminal of the regulated output and the first end of the light-emitting diode of opto-isolator 944 . The collector of the opto-isolator 944 is connected to current source 172 . The output of current source 172 is provided to the switching regulator logic 800 .
[0035] Connected to the second primary winding terminal is the power transistor 208 . Power transistor 208 is driven by AND gate 206 which is connected to inverter 204 and switching regulator logic 800 . Switching regulator logic 800 receives a clock signal 101 from an oscillator 111 . A counter 202 also receives the clock signal 101 from the primary oscillator 111 . The output of counter 202 , Q 13 , is used to switch in the current source 184 to supply current in lieu of the current source 122 when Q 13 is high.
[0036] The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape, materials, components, circuit elements, wiring connections and contacts, as well as in the details of the illustrated circuitry and construction and method of operation may be made without departing from the spirit of the invention.
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A circuit protects a power conversion system with a feedback control loop from a fault condition. The circuit has an oscillator having an input for generating a signal with a frequency and a timer connected to the oscillator input and to the feedback control loop. The timer disables the oscillator after a period following the opening of the feedback control loop to protect the power conversion system.
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BACKGROUND OF THE INVENTION
The present invention concerns systems to bring about building bodies as warehouse, storages, garages, hangars, shelters for artisan-, industry-, sport-, military, entertainment-spaces, field hospitals and second line structures and the like, comprising modular, easily in situ to assemble, finished structures.
In a first embodiment, the system according to the invention is substantially comprised of assemblable components like trilateral (i.e. open on one side) frames, wherein the three other sides consists of at least two sub-components which involve standard, easily assemblable elements incorporating suitable form-coupling structures that show diversity of materials selected from the group of the so-called “composites” mainly comprising fibers and synthetic of (co)-polymers, preferably expanded or in foamed form.
Typically the frame-forming elements of said components show an integral structure formed of two side-walls having enlarged upper portions as well as a central core between said terminal walls which are externally defined (together with said core) by continuous film-like layers of composite material (skins) within which is enclosed a polymeric reinforcing material.
According to an advantageous feature of the invention, said structure is able to house all the service elements such as those of the air conditioning, of the general electric apparatus (cables, switchers, etc.), of the lighting, heating etc.
Significantly, at a parity of materials, the volumetric size of the core is critically correlated to the sum of volumetric sizes, defined by said lateral walls. For very big building bodies f.i. with spans higher than 10 meters, a reinforcing ribbing is applied at least on one of the assembled component faces.
PRIOR ART
The need and request of building bodies of the “third type” i.e. of the type different from the classic sky-scrapers for offices, hotels, residences and the like, and from the big industrial factories, is exponentially increased in the last recent decades, in both cases, big buildings are involved which substantially consist of a big self-erecting, in situ formed structure consisting f.i. of metallic and/or reinforced concrete and by plugging panels of preferably reticulated glass.
The field of the above mentioned third type buildings comprises industrial or pseudo-industrial bodies pre-formed and in situ assembled. The components and elements thereof of said “third type” are particularly suitable for the above mentioned structures of f.i. hangar, shelter, field hospital and the like. However the conventional building systems for these constructions have shown gaps and inconveniences which do not consent to satisfy contemporaneously all the exigencies and characteristics requested by a continuously evolving market.
For instance, the Canadian Patent n° 2571958 describes a shelter to be rapidly assembled, formed by semi-circular or semi-elliptic elements of single film layers. Even if such type of construction has undoubted merits, it is nevertheless delicate, not sufficiently resistant to strong winds and inclement weathers, badly insulated, and per se complicated because of said single thin layers. In its complexity, the construction according to said Canadian Patent shows other drawbacks due to the fact that its components are not modular.
Japanese Patent Publication JP 200050744 describes a structure similar to that of the above Canadian Patent, which structure moreover needs compressed air to keep it erected.
The U.S. Pat. No. 6,599,610 describes a multi axial reinforcing laminate in which plural sheets each having plural carbon fiber yarns arranged in parallel, are laminated and stitched integrally by means of threads to ensure that the directions of said yarns are kept at different angles against a reference direction. This laminate can contain at least a layer of woven not-woven fiber. Said patent needs and suggests several sophisticated means to obtain laminates and film layer.
The International Patent Publication WO2008/088815 describes a high strength, light weight composite having: a)—a core comprising a thermo set polymer; b)—a laminate bonded to at least a portion of the core surface, comprising (i) at least one layer of fibrous material and (ii) at least one layer of thermo set binder which is bonded to at least a portion of the surface of said layer (i). Each layer of said binder can comprise a low density filler. Up to to-day the possible embodiments of the above building bodies with said materials and structures have shown several difficulties due to the complexity of the forming operations.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a system whit modular components which are easily assembled in situ, do not show the inconveniences of the Prior Art and consent to bring about buildings and construction bodies capable to satisfy the various requirements of a market undergoing big evolutions.
A second object is to provide systems of high versatility and flexibility to build up bodies of high capacity with span (without intermediate pillars) of at least 25 meters even in the presence of snow and wind charges.
Still another object is to provide modular, ready to be assembled and disassembled (f.i. about 200 m 2 /day/3 persons) structures to embody large buildings.
Another object is to provide modular structures which incorporate (built-in) all service apparatus namely cable, machinery, box, lines, commands, joints, relays, etc. of air conditioning-, power-, lightning-, alarm-, security-, installations; moreover these structures must be easily compactable for f.i. transportation, storage, logistic purposes.
These and other objects are easily reached with the systems, structures, components and minor parts of the invention, whose main characteristics are recited in the claims (at the end of this description) which however are to be considered also here incorporated.
BRIEF DESCRIPTION OF THE DRAWINGS
Features and advantages of the invention will be better understood from the following description of the preferred embodiments shown in the accompanying drawings in which:
FIGS. 1 , 1 A, 1 B, 1 C, 2 , 2 A, 2 B, 6 , 6 B and 9 are schematic front views;
FIGS. 3 , 3 A, 3 B, 7 , 8 , 10 , 11 and 12 are schematic perspective views;
FIGS. 4 , 5 , 5 A, 5 B, 5 C, 6 A, 6 C are cross-section views.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As anticipated, the system according to the invention is, above all, characterized in that is shows high versatility and flexibility as it is applicable not only to the construction of self-standing buildings (see f.i. FIG. 10 ) but also for the covering or closure of bodies and spaces and the like already provided of roof, and roof lines structures ( FIGS. 11 and 12 ). Just to better fix ideas, in the figures from 1 to 1 C are shown (in schematic front views) system of the first type having components C with three sub-components U 1 , U 2 , U 3 :
U 1 , vertical basic sub-component of the pier type; U 2 , shoulder sub-component; and U 3 , roof-line sub-component.
Later on it will be seen from FIGS. 11 , 12 and 13 that U 3 can be optional and thus be omitted. Coming back to the self-erecting buildings comprising components C with three sub-components U 1 , U 2 and U 3 , it can be evicted from the relative figures the further characteristics of flexibility, modularity and composability of the system according to the invention. Indeed already in FIG. 1 the three sub-components U 1 , U 2 and U 3 are formed of one standard single element ES for neither too high nor too wide buildings.
In FIG. 1A the sub-component U 1 of component C 1 is formed of two pier elements (at a parity of shoulder mono elements) E 1 and E 2 in U 1 , and of one element E 5 in U 3 (for the roof); the building is thereby widened (over those of FIGS. 1 and 1A ).
In FIG. 1C both U 1 (pier) and U 2 (shoulder) have additional elements (E 2 respectively E 4 ) whereby the relative systems shall be used for very wide and relatively high buildings. Characteristically all elements E 1 are standard. The standard element of the base are shown in FIGS. 2 , 2 A and 2 B and (in perspective from below) of FIGS. 3 , 3 A, 3 B, each element being formed of a base body BS having parallelepiped or circular cross-sections. Preferably the elements ES of sub-components U 2 and U 3 consist of two portions 3 and 4 , respectively 5 and 6 showing angles higher than 90°. As it can be better seen from FIGS. 3 , 3 A and 3 B all three elements E of U 1 , U 2 and U 3 have, typically, the same structure, i.e. have a body (which we will call vessel or “small basin” for illustrative simplicity) VE U-shaped with a bottom FV, two lateral walls L 1 and L 2 and (there between, an integral central core A.
As it can be better seen from the enlarged cross-section of FIG. 4 , said external side-walls L 1 and L 2 have the form of a flag having a flag-staff portion STE showing a height hs ( FIG. 4 ) and a width equal to the thickness sp, on which there is another widened flag portion B. At each terminal 1 , 2 of ES, a total structure is seen, which can be defined as formed by a core A between two channels defined by the outer faces 7 and 8 external to A and by the internal faces of walls L 1 , L 2 .
Characteristically the external face of vessel or small basin VE (U shaped body) and of the core A is covered by a layer or shell of composite material PC having a thickness “sp”, whereas the inside portion of core A and of the interstices between the common bottom FV and the walls L 1 and L 2 is filled with foamed polymeric material PE; it has been critically found that the volumes and (at a parity of foamed polymeric filler PE and of shell PC), the weights and therefore the values of the stress resistances, shearing stress etc. of core A (having a width WA and a height hA) must correspond to the double of the volumes (weights and resistances) of the lateral bodies L 1 and L 2 and of the bottom FV-FC i.e. substantially (at a parity of depth)
WA×hA= 2( WB hB+ 2 hs×sp+sf×D )
In other words the volume (apparently, major) of the core A i.e. WAhA must substantially correspond to the double volume of the bodies external to A, thus those of the flag portions, of the stems L 1 and L 2 and of the bottom FC-FV.
Consequently, at a parity of film layer, of filler and of volumes it is so possible to obtain a marked equivalence of mechanical characteristics between resistance zone of horizontal extremity O 1 , O 2 , O 3 , O 4 of FIG. 6A as well as an equivalence of stiffening and resistance to shearing stress forces of the (dashed) vertical resistant zones V 1 , V 2 , V 3 , V 4 , V 5 ( FIG. 6B ). Therefore the centroid medial position of FIG. 6A must be exactly on the passage transition TP from the stem to the flag bottom of walls L 1 , L 2 . Practically it is as if the medial line CT be seated on the bottoms 30 - 31 of the flag zone BA 1 of L 1 and BA 2 of L 2 .
Accordingly a resistance on all the system walls is obtained which is compatible with several schemes of loads or stress, even maintaining a same typology of cross-section, f.i. of the type shown in the drawings. This allows a high productive easiness in the production center of the base sub-components. In other words same sub-components can be used to realize different systems.
Preferably the shell or film layer PC is formed of one of the composite cloths or fabrics of Toray, f.i. according to U.S. Pat. No. 6,599,610 (stitched laminates) and the filler PE is selected among the polyurethane, polyepoxy-, polystirene resins and the like, preferably foamed, with the addition of the polymeric glue, f.i. polyurethane. Manufactured articles are thereby obtained which totally consist of synthetic materials and thus are very light, equilibrated and highly resistant to the stress to which are submitted.
According to an advantageous feature, the two film layers (external PCE and internal PCI) are mutually connected through a series of strips STR of the same material PC to increase the under-load stability of the whole shell.
In the FIGS. 5 , 5 A, 5 B, 5 C, the coupling between two elements E n-1 and En is shown, which are drawn near to each other by fitting together the internal faces BA 1 , BA 2 of the flag widened heads. From the contact correct “apposition” of said two elements a quarry CAV is obtained in which is (preferably) inserted the head 17 attached to the stem 16 of a reinforcing body RF ( FIG. 5C ). This connection operation between two standard elements E n-1 and En is also shown in perspective view in the FIGS. 7 and 7A . In FIG. 7 are represented the two separated elements E n-1 and En, the internal wall L 1 of E n-1 being in front of wall L 2 of En. The flag zones BA 1 and BA 2 of said two elements E n-1 and En are put in contact so to form cavity CAV wherein the reinforcing body RF (f.i. the film layer or shell) is inserted. The perspective view of FIG. 8 shows the connection of two elements E n-1 and En both represented with their full faces FP 1 , FP 2 overturned to get f.i. the continuous locus of the exposed faces external to the manufactured article, in contrast to FIG. 10 in which the article shows externally the whole continuous face.
To render more comprehensive the “soldering” between elements, in FIG. 8 are represented internal portions E n-1 of protruding from the continuous face FP 1 , and inserting into the similar portions of FP 2 receding from the external surface FP 2 .
Thanks already to this insertion with form retention, a good connection resistance is obtained which however is increased by using resinous glueing pastes and/or by the insertion of at least one small cable 20 (made of polymeric material such as aramid, dyneema and the like) within the proper holes in the elements En. Even if the gluing per se and the insertion of the polymeric cable 20 can be contemporaneously utilized, the adoption of the sole cable is preferable because it allows a rapid disassembly of the structure. The correct alignment of the two elements is assured by pins 21 positioned on the contact surface; said pins assure advantageously also the continuity of the stress between the jointed pieces.
In the FIGS. 9 and 9A is shown a system of reinforcing ribs desirable in the cases of building bodies having big spans f.i. higher than 10 meters. The rib component consists of sub-components U′ 2 and U′ 3 made of substantially similar elements compatible with those of the not reinforced structure T. The elements E′ shown loose and detached under the vault VOL of frame T in FIG. 9 , are compacted in situ as in FIG. 9A generating the assembled rib structure Cost forced under the internal roof of the starting frame T.
Advantageously also here the element types of the possible sub-component U′ 1 and of the certain U′ 2 , U′ 3 are compatible with the different system “typologies” (f.i. of FIG. 1 ) which are thereby reduced to three.
In FIG. 10 is emblematically represented a self erecting body structure obtained with n components all having the three sub-components U 1 , U 2 and U 3 of FIGS. 1-1C , said n components being assembled by the connections of the FIGS. 4 , 5 - 5 B, 6 - 6 B, 7 - 7 A, 8 preferably “ribbed” as in FIG. 9 in the case of big spans.
From said FIG. 10 appears that the full (smooth) faces EP 1 , FP 2 . . . FPn of the bottoms of elements En of FIG. 9 (equivalent to the bottoms FV of FIG. 4 ) are inside the manufactured article. Obviously an inverted configuration can be used in correspondence of different requirements (changes, utilization etc.).
In the FIGS. 11 and 12 , manufactured articles (f.i. roofing) are shown whose components C′ do not have the optional roofing sub-components, obtained now with elements E′ 3 ,E′ 4 of shoulders (SP) of U′ 2 ( FIGS. 1-1C ). In the top perspective of FIG. 12 (f.i. to cover sport implants, washer vessels and the like) the ridge (sub-component U′ 3 ) is quite absent.
The structures of FIG. 11 (on rectilinear trace) and of FIG. 12 (on circular or elliptic trace) show a further inventive characteristic of extreme utility in the sense that at least some components like C′ 1 -C″ 1 and C′ 1 n -C″n in FIG. 11 , the component group are made of mobile gores, f.i. can be turned around the end of the last pier element E′ 1 of U′ 1 , respectively E′n of U′n opening thereby provisional gaps for the machine movement, for the space ventilation, for their configuration etc.
Among the manufacture articles which can be quickly realized with the system according to the invention, we can mention:—stores, car garages, schools, laboratories, civil and military facilities, hospital especially field hospitals, first and second line structures etc.
Among the advantages of the manufacture articles obtained with the system according to the invention (in particular with the aid of components having three sub-components) we limit our self to mention the 18 following ones:
1. A module consisting of flat, strong, resistant walls can be placed side by side and connected with other modules. 2. Capacity of considerable loads, high specific resistance, thanks to the innovative tubular conception ( FIG. 6B ) of the load bearing shell structure, (instead of separate skins as in the conventional sandwich panels). 3. Possibility of pillar-less high bays up to 25 meters, even under snow and wind. 4. Air-sealed structure which can be de-pressurized for the odours or pressurized against external pollutants. 5. Rapid assembly and disassembly (about 200 m 2 /8 hours/3 persons). 6. Dry assembly thanks to dry restrained joints or gluing. 7. Simple manual assembly with the aid of form joints needing small fixture but without lifting means. 8. Self mounting:—the particular lightness and stoutness allows to hoist the pre-assembled portals and to use them as support for the further pieces. 9. Light and easy transportation (8-12 Kg/m 2 ). 10. Modularity:—it can be manufactured with different highness and width to comply with several requirements ( FIGS. 1-1C ). 11. High thermic insulation with savings of energy. 12. Natural balistic protection (against projectiles) because of the particular form of the structure. Indeed a projectile has to pass through at least two film layers. 13. Electric energy generation by means of solar panels integrated in the external coating without variations of weights and forms. 14. Integrated electromagnetic shielding without weight and form variations. 15. Possible total transparency to the electro-magnetic waves (no form and weight variation). 16. The tubular cross-section of the base module provides a natural space for the lighting, the ventilation and tubular implants. 17. High chemical resistance (naturally inert and not-oxidizable). 18. Easy repairing by substitution of the single damaged elements.
In the specific case of cleaners, (depurators) coverings, the structures of the invention made of composite materials (polyurethanes, carbon- and glass-fibers etc.), obtained with components having two sub-components and showing high resistance and lightness which allow the embodiment of covers and boundary lines of a single span up to (f.i.) 20 meters, show the following advantages and inconveniences.
Advantages:
No interference with the underlying plants like the moving bridges, weir zones etc. Indeed the structure of the invention runs above them and is totally free.
The construction systems imparts stability, resistance and insulating power of the material, which cannot be obtained with the conventional glass resin roof tiles.
Big structures of high dimensions can be obtained with containment of pressed gas, thus in total security (explosion resistant structures).
Easy access under the cover for the inspection and maintenance of the machineries.
High insulation power of the cover (sandwich structure) which consents the temperature stabilization to the optimal values for f.i., the best biological (during the transition seasons and winter). The reflecting finish in combination with the high insulation power keeps to a minimum the heating effect of the summer solar irradiation.
Energetic Recovery:—possibility to integrate heaters/recovers of heat/photovoltaic cells in the structure skin (without external overall dimensions [encumber]). Drawbacks:
Possible higher external encumber to avoid interface with the below implants and consent a free passage under the cover.
For clear illustration scruple, the invention has been described with particular reference to the embodiments shown in the accompanying drawings which are nevertheless, susceptible of those variations, substitutions, additions and the like which, being in the hand reach of a mean technician of this field, are to be considered as falling within the scope of the following claims.
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A system suitable for making buildings, comprising: modular, easily to assemble components which are in the form of polylateral frames and which consist of at least three sub-components, each formed by standard elements having means for reciprocal coupling. Said standard elements having a core made of co-polymeric material and being coated by a common skin-like layer made basically of carbon, glass-fiber compositions.
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This application is related to application Ser. No. 596,492 filed April 4, 1984, now U.S. Pat. No. 4,548,252.
FIELD OF THE INVENTION
This invention is directed to a method for extending radial fractures obtained during controlled pulse fracturing of underground formations or reservoirs.
BACKGROUND OF THE INVENTION
It has been known for some time that the yield of hydrocarbons, such as gas and petroleum, from wells can be increased by fracturing the formation so as to stimulate the flow of hydrocarbons in the well. Various formation fracturing procedures have been proposed and many now are in use. Among these procedures are treatments with various chemicals (usually acids in aqueous solutions), hydraulic fracturing in which liquids are injected under high pressure (usually with propping agents), explosive methods in which explosives are detonated within the formations to effect mechanical fracture, and combinations of the above procedures.
Chemical treatments usually involve the use of large volumes of chemicals which can be expensive and difficult to handle, and which pose problems of contamination and disposal. Hydraulic fracturing ordinarily requires that large volumes of liquids be made available at the well site and that equipment be made available for handling these large volumes of liquid. Again, there can be disposal problems, as well as contamination of the well. Explosive methods can be exceptionally hazardous from the standpoint of transporting and using the necessary explosives. These methods also present difficulties in controlling the effects of such a procedure.
Other suggestions for increasing the yield of existing wells entail heating the formation to induce the flow of hydrocarbons from the formation. Methods and apparatus have been developed by which various combustion devices have been lowered into the borehole of a well to attain heating of the formation adjacent the device. The effectiveness of such devices is limited by the necessity for fitting the devices into a borehole and then obtaining only more-or-less localized effects.
A combustion method designed to stimulate the well through mechanical fracture is known as controlled pulse fracturing or high energy gas fracturing. A good description of this method appears in an article by Cuderman, J. F., entitled "High Energy Gas Fracturing Development," Sandia National Laboratories, SAND 83-2137, October 1983. Using this method enables the multiple fracturing of a formation or reservoir in a radial manner which increases the possibility of contacting a natural fracture. Unfortunately, these radial fractures often do not penetrate deeply enough into the formation. Therefore, a method is needed which will extend the fractures deeper into the formation.
Sareen et al. in U.S. Pat. No. 3,896,879, disclose a method for increasing the permeability of a subterranean formation penetrated by at least one well which extends from the surface of the earth to the formation. This method comprises the injection of an aqueous hydrogen peroxide solution containing therein a stabilizing agent through said well into the subterranean formation. After injection, the solution diffuses into fractures of the formation surrounding the well. The stabilizing agent reacts with metal values in the formation which allows the hydrogen peroxide to decompose. Decomposition of hydrogen peroxide generates a gaseous medium causing additional fracturing of the formation.
Sareen et al. were seeking to enhance the radial propagation of the fracture into the formation around a wellbore. Also, Sareen et al. were seeking to provide a process for extending the fracture distance from the wellbore into the formation.
Using controlled pulse fracturing or high energy gas fracturing can generally cause multiple fracturing into the formation of about 50 to 75 feet. It is generally believed that using the method of Sareen et al. can cause fracturing into the formation of about 50 feet from the well or wellbore. However, this may be too optimistic as existing fractures may be too small to hold a volume of hydrogen peroxide sufficient to generate required fracturing pressure. Also some formations may not contain the metal values necessary to decompose the hydrogen peroxide. Often natural hydrocarbonaceous fluid fractures will occur at distances greater than 75 feet from the well or wellbore. Therefore, a method is needed to contact natural hydrocarbonaceous fluid fractures in those formations which have insufficient metal values to decompose hydrogen peroxide which occur at distances too far to be intersected or contacted with existing methods. Practicing the present invention allows the intersection or connection of natural hydrocarbonaceous fluid fractures at distances greater than heretofore possible while allowing hydrogen peroxide utilization in formations deficient in metal values.
SUMMARY OF THE INVENTION
This invention is a combination of a controlled pulse radial fracturing method and a hydrogen peroxide injection method for creating fractures in a subterranean formation or reservoir deficient in metal values required for the decomposition of hydrogen peroxide. Often neither method alone is sufficient to intersect natural hydrocarbonaceous fluid producing fractures at subtantial distances from the wellbore. Combining the two methods give unexpectedly good results in intersecting natural hydrocarbonaceous fluid producing fractures which are substantial distances away from the wellbore. By combining the two methods, radial fractures are produced by the controlled pulse fracturing method which fractures are sufficiently large enough to contain volumes of hydrogen peroxide greater than heretofore possible. Deteriorating hydrogen peroxide in these fractures generate pressures in the presence of metal values mixed with a proppant sufficient to enlarge and extend the fractures to a greater extent than previously believed possible.
In the practice of this invention, a means for fracturing, by a pressure loading rate sufficient to create multiple fractures, is placed in the well or wellbore near the productive interval. The peak pressure load is maintained sufficiently above the in-situ stress pressure but below the rock yield stress for a time sufficient to allow fluid penetration and extension of fractures.
Thereafter, a proppant containing metal values sufficient to decompose a hydrogen peroxide solution containing a stabilizing agent is injected into the fractures. Subsequently, a hydrogen peroxide solution containing a stabilizing agent and, which solution is of a strength sufficient to generate a pressure to fracture a formation, is injected into said formation. Upon contacting the formation, the stabilizing agent reacts with metal values mixed with the proppant. This reaction results in a substantial reduction of said agent in the hydrogen peroxide solution which causes it to become unstable. The resultant unstabilized hydrogen peroxide decomposes to form a gaseous medium which creates a pressure sufficient to fracture the formation and extend the fractures therein.
It is an object of this invention to create multiple radial fractures, near the wellbore and extend those fractures into a formation deficient in metal values necessary to decompose hydrogen peroxide.
It is yet another object of this invention to avoid damaging rock near the wellbore when creating multiple fractures.
It is still another object of this invention to create multiple fractures large enough to contain sufficient stabilized hydrogen peroxide which can decompose and generate pressure sufficient to extend the multiple fractures.
It is a further object of this invention to extend the multiple fractures into the formation for a distance sufficient to contact at least one natural hydrocarbonaceous producing fracture.
It is a still further object of this invention to obtain increased quantities of hydrocarbonaceous fluids.
It is a yet further object of ths present invention to increase the productivity of damaged wells by multiple fracturing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the preferred embodiment of this invention, it is desired to create multiple radial fractures into the wellbore or borehole and extend the fractures without crushing the wellbore or borehole. It is desired to create multiple extended radial fractures to enhance the possibility for recovering oil or hydrocarbonaceous fluids. To accomplish this a cannister containing a propellant is suspended into a wellbore. This cannister is placed downhole next to the oil or hydrocarbonaceous fluid productive interval.
The propellant in the cannister can belong to the modified nitrocellulose or the modified and unmodified nitroamine propellant class. Suitable solid propellants capable of being utilized include a double-based propellant known as N-5. It contains nitroglycerine and nitrocellulose. Another suitable propellant is a composite propellant which contains ammonium perchlorate in a rubberized binder. The composite propellant is known as HXP-100 and is purchasable from the Holex Corporation of Hollister, Calif. N-5 and HXP-100 propellants are disclosed in U.S. Pat. No. 4,039,030 issued to Godfrey et al. which is hereby incorporated by reference.
A M-5 solid propellant was utilized by C. F. Cuderman in an article entitled "High Energy Gas Fracturing Development," Sandia National Laboratories, SAND 83-2137, October 1983. This article is also incorporated by reference. High energy gas fracturing or controlled pulse fracturing is a method used for inducing radial fractures around a wellbore or borehole. Via this method a solid propellant-based means for fracturing is employed along with a propellant composed to permit the control of pressure loading sufficient to produce multiple fractures in a borehole at the oil or hydrocarbonaceous fluid productive interval. A peak pressure is generated which is substantially above the in-situ stress pressure but below the rock yield stress pressure.
After placing the propellant means for creating multiple fractures downhole near the oil or hydrocarbonaceous fluid productive interval, it is ignited. Ignition of the propellant means for creating the multiple fractures causes the generation of heat and gas pressure. As is known to those skilled in the art, the amount of heat and pressure produced is dependent upon the kind of propellant used, its grain size and geometry. Heat and pressure generation also depends upon the burning rate, weight of charge and the volume of gases generated.
Subsequently, the heat and pressure are maintained for a time sufficient to allow fluid penetration and extension of fractures. As is known, heat generation and pressure maintenance are dependent upon the nature of the formation and the depth it is desired to extend the fractures into the formation. After the heat and pressure have been maintained for a time sufficient to promote the desired fracturing, the heat and pressure dissipate into the formation surrounding the wellbore. The fractures which have been created are of a length and size necessary to hold a sufficient volume of hydrogen peroxide for pressure generation and extension of the fractures. However, in some formations, insufficient metal values are available for decomposing the hydrogen peroxide.
In order to overcome this deficiency and extend the radial fractures caused by the deflagration of the propellant, a proppant with metal values mixed therein is placed into the wellbore and formation. In addition to mixing the metal values with the proppant, the proppant can be coated with a selected metal compound, or ions thereof, prior to placing into the wellbore and formation. The proppant prevents the fractures from closing. Sufficient pressure is then applied to stabilized hydrogen peroxide subsequently injected into the wellbore which causes the stabilized hydrogen peroxide to enter the radial fractures caused by the deflagration of the M-5 propellant. Upon entrance into the formation, the stabilizer in the hydrogen peroxide breaks down in the presence of the metal values mixed with the proppant. Stabilizer breakdown is caused by the stabilizer's contact with metal values in the formation, e.g. iron.
Metal values which can be used in the practice of this invention include chemical compounds selected from metals such as iron, molybdenum, nickel, silver, platinum, gold and the like, and mixtures thereof. Other suitable metal values are readily recognizable by those skilled in the art. It is preferred to use iron compounds such as iron, pyrite and chalcopyrite. The concentration of the metal value utilized in or on the proppant will of course vary with the strength of the stabilized hydrogen peroxide and formation conditions. However, it is expected that the metal values will vary from about 0.5 wt. to about 10.0 wt. percent of the proppant, preferably about 5.0 wt. percent.
After the stabilizer has been substantially used up, the hydrogen peroxide begins to breakdown and forms pressure in the fracture. As the pressure increases it causes an extension of the radial fractures created by the controlled pulse fracturing procedure. Sareen et al. in U.S. Pat. No. 3,896,879, which is incorporated herein by reference, describe the chemical composition of a stabilized hydrogen peroxide mixture. Amino trimethylene phosphonic acid can be used as a stabilizing agent for the hydrogen peroxide. As is known to those skilled in the art, the quantity and concentration of hydrogen peroxide required will be dependent upon the nature of the formation, the number of radial fractures created and the sizes thereof, among others. The concentration of the hydrogen peroxide utilized is generally from about 30% to about 98% based on the total weight of said solution. The pH of the hydrogen peroxide solution will generally be less than about 6.0. As disclosed by Sareen et al., an organophosphorus compound can be used as a stabilizing agent for hydrogen peroxide. This organophosphorus compound will precipitate out of hydrogen peroxide when it comes into contact with metal values in the formation.
After the pressure has dissipated and it is determined that a natural oil producing fracture has not been intercepted or contacted by the extended radial fractures, an explosive slurry can be injected into the fractures created in the formation. This slurry should be placed into the formation at a depth or distance substantially away from the wellbore, so as to avoid damaging it. Once this has been accomplished, the explosive slurry is detonated. Pressures created by the detonation of the slurry will cause additional fracturing of hydrogen peroxide extended radial fractures. Explosive slurries which will work in the practice of this invention are known to those skilled in the art.
The effectiveness of fracturing at each stage of this method can be determined by available methods. One such method is described in U.S. Pat. No. 4,415,805 issued to Fertl et al. This patent is incorporated herein by reference. In this method a multiple stage formation fracturing operation is conducted with separate radioactive tracer elements injected into the well during each stage of the fracturing operation. After completion of the fracturing operation, the well is logged using natural gamma ray logging. The resulting signals are sorted into individual channels or energy bands characteristic of each separate radioactive tracer element. Results of the multiple stage fracturing operation are evaluated based on dispersement of the individual tracer elements.
In another embodiment of this invention, the location and direction of at least one natural hydrocarbonaceous fluid fracture is determined. This determination can be made by geologists and others skilled in the art. After the general location and direction of the natural fracture is determined, the well or wellbore is notched in a manner sufficient to direct pressure induced in the well in the direction of the natural fracture. Notching can be accomplished by methods known to those skilled in the art. One preferred method is the use of hydraulic pressure to cut notches into or near the hydrocarbonaceous production interval of the well. Another method which can be employed is the use of explosive projectiles. These projectiles can be fired into the well or wellbore wall at desired levels to create the desired notches.
After notching the well, a means for fracturing the formation by a pressure loading rate sufficient to create multiple fractures is placed into the well or wellbore substantially near the hydrocarbonaceous productive interval. Later, the in-situ stress pressures are determined. In-situ stress pressures are those pressures which occur naturally in an earth formation from hydraulic and heat sources. In-situ stress pressures are less than the pressures required to fracture rock in the formation.
As mentioned above, a propellant means for creating multiple fractures is placed in the well or wellbore substantially near the hydrocarbonaceous fluid productive interval and ignited. As is known to those skilled in the art, the pressure loading rate is the primary parameter for the production of multiple fractures. The loading rate required to produce multiple fractures is an inverse function of wellbore or borehole diameter. Hot gases are formed in the wellbore or borehole upon ignition of the propellant means creating a pressure. Gas pressurization of the cracks formed plays an important role during fracturing by inhibiting the formation of new cracks, and increasing the length of the existing cracks. As is known to those skilled in the art, the number and length of cracks is reduced when the rock yield stress is exceeded. When the rock yield stress is not exceeded by use of excessive wellbore peak pressure, the length of the longest cracks is increased.
After reaching the peak pressure load, it is maintained sufficiently above the in-situ stress pressure but below the rock yield stress pressure for a time sufficient to allow fluid penetration and extension of fractures. Once the pressure and heat have dissipated, a proppant containing metal values therein is injected into the formation. Afterwards, a hydrogen peroxide solution containing a stabilizing agent therein is forced into fractures in the formation. As mentioned above, the stabilizing agent reacts with metal values contained in said proppant which has been injected into the formation which causes the hydrogen peroxide to decompose and generate pressure, sufficient for further fracturing.
If a natural hydrocarbonaceous fracture has not been intersected, an explosive slurry can be pumped into the formation and detonated to create addition fracturing. Explosives which can be used are similar to those mentioned above.
Each step of this method can be repeated until at least one natural hydrocarbonaceous fracture has been intercepted or connected. Also, the order of the steps can be reversed for maximum fracturing effectiveness.
These embodiments are a combination of known methods for fracturing subterranean formations or reservoirs. As is known by those skilled in the art, neither method alone is adequate to connect or intersect natural hydrocarbonaceous fluid producing fractures located substantial distances from the wellbore. Combining the controlled pulse fracturing method in combination with hydrogen peroxide injection alone or in combination with explosive slurry injection produces enlarged and extended fractures. These enlarged and extended fractures can contain larger volumes of hydrogen peroxide or explosive slurry. Larger volumes of hydrogen peroxide or explosive slurry, properly utilized, can cause the generation of greater fracturing pressures than previously believed possible.
Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of this invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims.
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A method for extending fractures in underground formations obtained by controlled pulse fracturing through the use of a stabilized hydrogen peroxide solution. Controlled pulse fracturing causes radial fracturing near the wellbore. These radial fractures are further extended into the formation or reservoir when stabilized hydrogen peroxide is forced into the radial fractures. Stabilizing agents in the hydrogen peroxide react with metals mixed with a proppant in the formation causing the hydrogen peroxide to breakdown and form gas pressure sufficient to extend the radial fractures. Hydrocarbonaceous fluids are then obtained from the natural fractures in said formation via the extended fractures which contact natural fractures emanating from the wellbore.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a 371 filing of PCT International application no. PCT/EP2008/006378 filed Aug. 1, 2008 and published in English as WO 2009/018979 A1 on Feb. 12, 2009, which claims the priority of European application no. 07015271.5 filed Aug. 3, 2007. The disclosures of these applications and all other patents, published applications and other references cited herein are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
The present invention discloses a new method for patient stratification in stable coronary disease (coronary disease: CAD) according to the patients' individual cardiac risks. Patients in the condition of a stable CAD are typically patients with angiographically proven CAD, i.e. with affected coronary arteries, with plaques on the inner walls of the coronary artery (atherosclerosis) and stenosis in a major coronary artery. CAD is considered a serious cardiac risk. CAD patients are considered as “stable” if the CAD does not manifest itself in the form of acute cardiovascular events.
In view of the imminent risk of future cardiovascular events it would be highly desirable to be able to distinguish within the group of patients with stable CAD between different groups according to their personal cardiac risk such that an “individual state of alert” can be determined for a particular patient in accordance with the risk group to which he has been allotted. Such grouping of patients is usually called “stratification”.
Distinguishing high risk patients from patients at moderate or low risk would allow a better selection of the most appropriate therapeutic strategy for a particular patient, avoiding, for example, underestimation of the cardiac risk and undermedication of high risk patients on the one hand and unnecessary therapeutic interventions, and the associated costs, with low risk patients on the other.
It is, therefore, an object of the present invention to provide a new method by which patients with stable CAD can be stratified in accordance with their personal cardiac risks, i.e. with respect to their individual risks concerning the future incidence of cardiovascular events.
As is further explained in detail below, the inventors have conducted a study to evaluate the potential usefulness of a number of analytes (biomolecules, biomarkers) which can be determined in the circulation of patients for a stratification of patients with stable CAD.
In the course of said study they have surprisingly found that a highly sensitive measurement of the concentration of the peptide procalcitonin (PCT) in the circulation of CAD patients in the range of very low physiological concentrations, which concentrations up to now were considered as being below diagnostic significance and, therefore, concentrations typical for normal healthy individuals, allows a useful stratification of CAD patients, and that the usefulness of such highly sensitive PCT determination can even be increased if the results obtained from PCT are evaluated in combination with the results of the measurement of an analyte of another type action (a vasoactive analyte), exemplified by the so-called B-type (or brain) natriuretic peptide BNP.
Accordingly, the present inventions discloses a method as claimed in any of claims 1 to 6 , and the use of a highly sensitive determination of PCT in the context of the prognosis of cardiovascular diseases for the risk stratification of patients, especially in arteriosclerosis and CAD, according to claims 7 and 8 respectively.
Procalcitonin (PCT), which is to be measured in accordance with the present invention, has become a well-established biomarker for sepsis diagnosis: PCT reflects the severity of bacterial infection and is in particular used to monitor progression of infection into sepsis, severe sepsis, or septic shock. It is possible to use PCT to measure the activity of the systemic inflammatory response, to control success of therapy, and to estimate prognosis (1) (2) (3) (4) (5). The increase of PCT levels in patients with sepsis correlates with mortality (6).
Whereas an increasing number of studies investigates the potential role of PCT in other infectious diseases like pneumonia, bacterial meningitis and malaria (7) (8) (9), no studies reported yet about the potential use of PCT in risk stratification of patients suffering from stable coronary artery disease (CAD). In vitro-studies showed, that PCT plays an important role during monocyte adhesion and migration and further has an effect on inducible nitric oxide synthase (iNOS) gene expression (10) (11) (12). The association between PCT levels and low-grade inflammation of the arterial wall in atherosclerosis and the potential effect on endothelial dysfunction has not been analyzed. Our prospective study examined the prognostic impact of PCT in a large group of consecutively enrolled stable angina patients on cardiovascular outcome to evaluate the potential clinical applicability of PCT measurements in CAD.
In the context of sepsis and related conditions, where the concentrations of PCT reach rather high physiological concentrations, PCT has been measured traditionally by means of an assay of the sandwich type using two monoclonal antibodies binding to different portions of the PCT molecule so that essentially only the complete PCT molecule is detected (see, for example, (1)). The typical functional assay sensitivity (FAS) of the typical two-sided chemiluminescence assay for PCT is 300 ng/L (0.3 ng/ml or 0.3 μg/L).
More recently new highly sensitive assays for the determination of PCT have been developed (28). The functional assay sensitivity (FAS, interassay CV<20%) of this new assay was <7 ng/1 PCT. Using this assay, typical PCT concentrations in healthy individuals could be determined. In 500 healthy individuals the range was <7 to 63 ng/L (<0.007 to 0.063 ng/ml), i.e. a range of concentrations well below 0.1 ng/ml. The determined median was 13.5 ng/L (95% confidence interval for the mean 12.6 to 14.7 ng/L).
In further improved form said sensitive PCT assay is available as PCT sensitive LIA (B.R.A.H.M.S AG, Hennigsdorf, Germany) having an analytical assay sensitivity of 0.01 ng/ml and a functional assay sensitivity (FAS) of at least 0.05 ng/ml. A related assay for the time-resolved amplified cryptate emission (TRACE) technology (Kryptor PCT, B.R.A.H.M.S AG, Hennigsdorf) has a functional assay sensitivity of 0.06 μg/L (0.06 ng/ml).
The more recent sensitive PCT assays have predominantly been used in connection with the guidance of antibiotic therapy in lower respiratory tract infections (community-acquired pneumonia, CAP; exacerbations of chronic obstructive pulmonary disease, COPD: see (29), (30), (31)). In the case of CAP antibiotic treatment is recommended on the basis of measured PCT concentrations as follows: strongly encouraged, greater than 0.5 μg/L; encouraged, greater than 0.25 μg/L; discouraged, less than 0.25 mg/L; strongly discouraged, less than 0.1 μg/L (29). In other words, concentrations of 0.1 μg/L (or 0.1 ng/ml) are considered as concentrations typical for healthy individuals.
The method of risk stratification of patients with stable coronary artery disease (stable CAD) is based on a differential evaluation of measured PCT concentrations which are below the value of 0.1 ng/ml for healthy individuals and which so far have not been used for diagnostic of prognostic purposes.
The invention is discussed in more detail in the following sections and the FIGS. 1 to 3 and Tables 1 to 7 mentioned therein. The Tables mentioned are found on separate pages at the end of the text of the description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : shows Kaplan-Meier survival curves showing cardiovascular events according to quartiles of procalcitonin;
FIG. 2 : shows Kaplan-Meier survival curves showing cardiovascular events according to procalcitonin cut-off value 0.05 ng/ml;
FIG. 3 : Kaplan-Meier survival curves showing cardiovascular events according to procalcitonin and B-type natriuretic peptide in combined analysis:
DETAILED DESCRIPTION OF THE INVENTION
Study Population
Between November 1996 and January 2004, 3326 patients with angiographically proven CAD and at least one stenosis ≧30% diagnosed in a major coronary artery at the Department of Medicine II of the Johannes Gutenberg University in Mainz or the Department of Medicine of the German Federal Armed Forces Central Hospital in Koblenz were enrolled in the AtheroGene registry. Further details on the concept of the AtheroGene study have been described previously (13).
In the present substudy, exclusion criteria were clinical signs of acute coronary syndrome (unstable Angina Braunwald classification class B or C, acute ST-segment elevation, and non-ST-segment elevation myocardial infarction). Patients with coronary artery bypass surgery or coronary revascularization during the last four weeks were also excluded. Further reasons for exclusion were evidence of hemodynamically significant valvular heart disease, surgery or trauma within the previous month, known cardiomyopathy, manifest carcinoma, chronic inflammatory disease, febrile conditions, or use of oral anticoagulant therapy within the previous four weeks.
The history of classical risk factors was assessed as follows. Patients receiving anti-hypertensive treatment or having already confirmed the diagnosis of hypertension (blood pressure above 160/90 mmHg) were considered to have hypertension. Hyperlipoproteinemia was diagnosed in patients under lipid-lowering medication or with a history of cholesterol levels ≧240 mg per deciliter. Patients were classified as currently smoking, as having smoked in the past (if they had stopped more than 4 weeks and less than 40 years earlier), or as having never smoked (if they had never smoked or had stopped 40 or more years earlier). We considered patients receiving dietary treatment or medication for diabetes or whose current fasting blood glucose level was above 125 mg per deciliter to suffer from diabetes mellitus.
1124 patients were followed up during a median period of 3.8 (maximum 6.8) years. Patients either presented themselves at our clinic (78.2%) or were interviewed by telephone by trained medical staff. Follow-up information, including death from cardiovascular causes (n=40), death from causes not related to coronary artery disease (n=30), and non-fatal myocardial infarction (n=32), was obtained from hospital or general-practitioner charts. The primary endpoint was non-fatal myocardial infarction and cardiovascular death.
The AtheroGene study was approved by the local ethics committee of the University of Mainz. Study participants had German nationality and, particularly, were inhabitants of the Rhein-Main-Area. All patients were caucasian. Participation was voluntary, and patients were enrolled after written informed consent was obtained.
Laboratory Methods
Blood samples were drawn under standardized conditions before performance of coronary angiography. Samples were taken when patients entered the catheterization lab after a minimum 12 h-fast. Serum lipid levels were measured immediately. Lipid levels were measured using routine methods (total cholesterol and triglycerides, Roche Diagnostics GmbH, Mannheim, Germany; high-density lipoprotein cholesterol, Rolf Greiner Biochemica, Mannheim, Flacht bei Limburg, Germany; and low-density lipoprotein cholesterol calculated according to the Friedewald formula). The LDL-/HDL-ratio was computed by dividing LDL by HDL levels.
Plasma and serum samples were centrifuged at 4000 g for 10 minutes, divided into aliquots, and stored at −80° C. until analysis. PCT was determined by a highly sensitive immunoluminometric assay (B.R.A.H.M.S PCT sensitive; B.R.A.H.M.S AG, Hennigsdorf, Germany; analytical assay sensitivity: 0.01 ng/ml; functional assay sensitivity (20% inter-assay variation coefficient): 0.05 ng/ml). Data were generated using one lot of chemicals. C-reactive protein (CRP) was analyzed by a latex particle-enhanced immunoassay (Roche Diagnostics, Mannheim, Germany; detection range: 0.1 to 20 mg/l; interassay coefficient of variation, 1.0 percent for values of 15 mg per liter and 6.5 percent for values below 4 mg per liter). Plasma B-type natriuretic peptide (BNP) was determined using a fluorescence immunoassay (Biosite, San Diego, Calif., USA; detection range: 5 to 5000 pg/ml; interassay coefficient of variation of near 10%; negligible cross-reactivity with other natriuretic peptides). All laboratory measurements were performed in a blinded fashion without knowledge of the clinical status of the patient.
Statistical Considerations
The mean values (±standard deviation) and proportions of baseline cardiovascular risk factors, clinical variables, and biomarkers were calculated for study participants according to quartiles of procalcitonin. Due to the small range of the procalcitonin levels, the quartiles comprise not the same number of patients. Variables with a skewed distribution (|skewness|>1) were presented as medians with quartiles. Correlation analysis was done by Spearman rank correlation. In another analysis hazard ratios for the highest versus other quartiles of PCT were dichotomized according to classical risk factors or medians of clinical variables and biomarkers.
The association of the biomarkers PCT and BNP with the primary endpoint according to quartiles was analyzed in different models by Cox regression analysis, the first model adjusting for age and sex and the second adjusting for the potential confounders and classical risk factors (age, sex, body-mass index, hypertension, diabetes mellitus, smoking status, LDL-/HDL-ratio, number of diseased vessels, beta-blocker and statin therapy). The cumulative event plots according to quartiles of PCT concentration were estimated by the Kaplan-Meier method and were compared by use of the log rank test. All survival analyses were conducted for the primary end point of non-fatal myocardial infarction or cardiovascular death. Data of patients who died from causes not related to cardiovascular disease were censored at the time of death.
PCT and BNP were log-transformed to enhance model fit. To compare the predictive power of these biomarkers, hazard ratios per one standard deviation increment were calculated in univariate and multivariate analysis (adjusted for classical risk factors and clinical variables). A backward stepwise Cox regression approach was taken for the multivariate analyses with P=0.10 as the critical value for entering and excluding ten variables (age, sex, body-mass index, hypertension, diabetes, smoking, LDL-/HDL-ratio, number of diseased vessels, statin and beta-blocker therapy) in the model.
Hazard ratios (HR) and 95% confidence interval (CI) are reported with 2-tailed probability values. Proportional hazards assumption was checked using standard methods based on testing for significant slope of the smooth curve through the scatter of the rescaled Schoenfeld residuals versus time.
To further assess the predictive ability of the models, the inventors considered the cardiovascular endpoint at two years as a binary variable and logistic regression was performed. Associated receiver operating characteristic (ROC) curves for predicted probabilities were drawn for a basic model containing classical risk factors and models additionally containing PCT, CRP and BNP. The corresponding areas under the curve along with 95% CI were calculated.
The inventors further evaluated the combined role of PCT and BNP on cardiovascular risk and therefore tested for interaction followed by a dichotomized analysis of both variables by using the highest quartile as cut-off point. Hazard ratios and 95% CI, along with P-values, were reported. Another cumulative event plot was estimated by the Kaplan-Meier method for these four subgroups and compared using the log rank test.
As P-values are not adjusted for multiple testing, they have to be considered as descriptive. All calculations were carried out using SPSS 15.0 for Windows, version 15.0.1 (SPSS Inc., Chicago, Ill., USA).
Results
The mean age of the study population was 61.3±9.5 years, and 80.5% of the patients were male. The patients in the present substudy were divided into four groups according to quartiles of PCT levels (00Table 1). No significant differences for the distribution of the classical risk factors were found. CRP levels were higher in the fourth quartile than in the others (3.66 mg/l vs. 1.81-2.10 mg/l). A moderate correlation between PCT and CRP (r=0.27) was found.
The inventors further evaluated the predictive value of PCT in subgroup analysis (Table 2). Median levels were used to dichotomize continuous variables. In particular, PCT levels were strongly predictive in patients with BNP serum concentration above the median of 37.48 pg/ml with a 2.41-fold increased risk (95% CI 1.32-4.42; P=0.004) for the highest PCT quartile.
Table 3 outlines the association between PCT, CRP and BNP with future cardiovascular events. The percentage of events increased across quartiles ( FIG. 1 ) such as patients in the highest quartile of PCT were associated with an 2.27-fold (95% CI: 1.14-4.51; P=0.02) increase in risk for future cardiovascular events in age- and sex-adjusted model. This association remained significant in models adjusting for most potential confounders. If analyzed as continous variable, an increment of one standard deviation (SD) of PCT revealed a 1.33 higher (95% CI: 1.02-1.74; P=0.04) risk for future cardiovascular events. Levels of BNP have been related independently to the primary endpoint, whereas no significant association between CRP and cardiovascular outcome could be observed in the fully adjusted model.
All classical risk factors and clinical variables were entered in a backward multiple stepwise regression analysis as outlined in table 4. Continous variables were log-transformed and have been treated per increment of one SD. PCT (HR 1.30, 95% CI: 1.00-1.70; P=0.05) was selected as an independent predictor of cardiovascular risk. The final model also revealed LDL-/HDL-ratio, female gender and insulin-dependent diabetes mellitus (IDDM) as predictors for the primary endpoint.
In another subanalysis, a PCT level of 0.05 ng/ml (according to the functional assay sensitivity) was chosen as cut-off value for cardiovascular risk prediction. 25% of the 39 patients with PCT levels above 0.05 ng/ml experienced cardiovascular events and had a significant poorer prognosis ( FIG. 2 ). When entered in a backward multiple stepwise regression analysis, a PCT level above 0.05 ng/ml is associated with a 4.22 higher (95% CI: 2.07-8.59; P<0.001) cardiovascular risk (Table 5).
To further explore whether PCT and BNP added information beyond that obtained from classical risk factors, the inventors computed the area under the ROC curve (AUC) associated with prediction of different logistic regression models, considering the cardiovascular endpoint at 2 years as a binary variable (Table 6). As there were patients with a follow-up of less than 2 years, only 1057 patients were available for this analysis; 46 of them experienced a cardiovascular event. The basic model including classical risk factors such as age, sex, BMI, hypertension, diabetes mellitus, smoking status, LDL-/HDL-ratio, number of diseased vessels, beta-blocker and statin therapy revealed an AUC of 0.74 (95% CI: 0.67-0.81). Table 6 presents analyses comparing this basic model with models additionally including either PCT, or BNP, or two, or all of them. Inclusion of one SD increase of PCT improved the predictive value of the basic model, reporting an increase from 0.74 to 0.77. One SD increase of BNP revealed most additional information beyond application of the basic model. The combination of BNP and PCT with the basic model resulted in the highest prognostic accuracy of this model. Results were similar during a 1-year and 3-year follow-up (data not shown).
Because of the strong predictive value of PCT in patients with BNP levels above the median (Table 2) and the high prognostic accuracy for cardiovascular events when BNP and PCT were combined in a model with classical risk factors (Table 6), the inventors finally explored to what extent PCT might add to the prognostic value of BNP (Table 7). With the test for interaction being negative (P=0.78), the inventors assumed an additive effect for both biomarkers. Patients with elevated levels of both biomarkers in the upper quartile were at the highest risk for future cardiovascular events (HR 7.04; 95% CI: 3.40-14.57; P<0.001). FIG. 3 provides the Kaplan-Meier survival curves according to levels of PCT and BNP in combined analysis.
Discussion
In this prospective cohort of patients with angiographically documented CAD an independent association of PCT with future cardiovascular events has been demonstrated. This association did not change appreciably after adjustment for most potential confounders, indicating that PCT provides important information about cardiovascular prognosis in addition of classical risk factors and other clinical variables. Combined analysis of PCT and BNP improved the prognostic accuracy for future cardiovascular events in the present study.
Yet, only two studies evaluated the potential use of PCT in the setting of CAD. Erren et al. (14) found slightly increased PCT levels only in CAD patients with additional peripheral arterial disease (PAD) and discussed PCT as a marker for the atherosclerotic burden in a multi-marker approach.
Ilhan et al. (15) found higher PCT levels (0.40±0.04 ng/ml as opposed to 0.19±0.02 ng/ml in the control group) among CAD patients experiencing a cardiovascular event. Herein the inventors demonstrated PCT as an independent predictor of future cardiovascular events, in particular adding information on patients with high BNP levels, indicating a potential of PCT to better stratify in high risk individuals.
Local or systemic inflammation affecting certain types of tissue, also a trauma-related host response (16) (17) (18) (19) (20), and consecutive monocytic activation thus are a prerequisite for PCT production (4). The expression of PCT messenger-RNA by peripheral blood mononuclear cells (21) is stimulated in vitro not only by lipopolysaccharides, but also by the proinflammatory cytokines interleukin-1β (IL-1β), interleukin-2 (IL-2), interleukin-6 (IL-6) and tumor necrosis factor-α (TNF-α), which seem to play a pivotal role in the atherosclerotic process (22) (23) (24) (25). Thus, slightly increased PCT levels might be an epiphenomenon of the inflammatory activity within the vascular wall caused by atherosclerosis. However, PCT seems to play a causative role in monocytic activation: as a chemoattractant initially only produced in adherent monocytes, which recruit later parenchymal cells of the inflammated tissue for further PCT production. Thus, PCT could have also an effect on leukocyte migration (4) (10) (11) (14). Further studies have to investigate, if the in vitro demonstrated stimulating effect of PCT on nitric oxide synthesis gene expression (12) also has an influence on endothelial dysfunction caused by atherosclerosis.
In the present study, patients with combined elevation of PCT and BNP levels in the upper quartile had a 7.0-fold increased risk for the primary endpoint compared to a 3.2-fold increased risk when BNP was elevated alone. Thus, PCT significantly improved the AUC of the basic model (classical risk factors) for risk prediction and even obtained additional information on top of the biomarker BNP.
BNP is an established marker for left ventricular dysfunction. The sepsis marker PCT might also be a marker for low-grade inflammation, in particular for monocyte activation or endothelial dysfunction, as shown in several in vitro-studies. The representation of two different pathomechanisms by BNP and PCT would explain the improvement of the prognostic accuracy for future cardiovascular events. Further studies are needed to evaluate the role of PCT for risk prediction in diseases other than severe bacterial infections and to elucidate more its pathophysiological role in the inflammatory cascade.
As the choice of the cutoffs for the analyses in table 7 and FIG. 3 is data driven, the results can only give hints, but have to be validated in independent studies.
In conclusion, PCT is independently related to future cardiovascular events in a population of CAD patients and might add information for risk stratification, in particular, in high risk individuals.
Summary
Background: Procalcitonin (PCT) is a well-established biomarker for the diagnosis and therapeutic monitoring of sepsis. In vitro-studies showed that PCT has an effect on monocyte activation and even on nitric oxide synthesis. The present prospective study examined the prognostic impact of PCT in patients with established coronary artery disease (CAD) on cardiovascular outcome.
Methods: In a substudy of the prospective AtheroGene survey, in 1124 patients with stable CAD, the risk of cardiovascular death and non-fatal myocardial infarction (N=72) over a median follow-up of 3.8 (maximum 6.8) years according to the baseline concentration of PCT has been assessed.
Results: The age- and sex-adjusted hazard ratio for patients within the highest quartile of PCT related a 2.27-fold increase (95% confidence interval (CI): 1.14-4.51; P=0.02) of the relative risk for cardiovascular death and non-fatal myocardial infarction, when compared to the first quartile. Adjustment for classical risk factors and clinical variables did not attenuate this relationship. Inclusion of one standard deviation increase of PCT improved the predictive value of a basic model (classical risk factors) for cardiovascular risk prediction monitored by the area under the curve (AUC) of an % CI: 3.40-14.57; P<0.001) higher cardiovascular risk.
Conclucions: Baseline concentration of PCT is independently related to future cardiovascular events in patients with stable CAD
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TABLE 1
Baseline characteristics of the study population according to quartiles
Q1
Q2
Q3
Q4
Characteristic
(N = 254)
(N = 259)
(N = 301)
(N = 310)
Procalcitonin (ng/ml)
<0.010
0.010-0.013
0.014-0.020
>0.020
Age (yrs)
60.6 ± 10.0
60.5 ± 10.0
61.3 ± 9.5
62.5 ± 8.6
Male sex (%)
72.0
80.3
86.0
82.3
Traditional risk factors
Body-mass index (kg/m 2 )
27.0 ± 4.0
27.4 ± 3.8
27.9 ± 3.7
28.4 ± 4.1
Hypertension (%)
80.3
75.7
79.1
83.2
Diabetes mellitus
Dietetic treatment (%)
4.3
2.7
3.7
6.1
Drug treatment (%)
7.5
8.1
10.3
11.3
Insulin dependent (%)
8.7
5.8
6.6
12.9
Smoking Status
Never smoked (%)
37.8
37.8
38.2
32.3
Ex-smoker (%)
42.9
44.4
46.2
51.3
Current smoker (%)
19.3
17.8
15.6
16.5
Lipid status
LDL cholesterol (mg/dl)
128.0
123.0
118.0
119.0
(98.0-157.8)
(94.0-144.0)
(92.5-143.0)
(95.8-150.0)
HDL cholesterol (mg/dl)
53.0
49.0
47.0
45.0
(43.0-64.0)
(43.0-58.0)
(40.5-56.0)
(39.0-55.0)
Triglycerides (mg/dl)
122.0
117.0
129.0
148.0
(93.8-168.0)
(88.0-156.0)
(97.0-188.0)
(103.0-201.5)
Clinical variables
Multi-vessel disease (%)
74.4
67.2
72.4
72.9
History of myocardial infarction (%)
42.5
44.4
47.5
38.1
Left ventricular ejection fraction (%)
65.0
69.5
66.0
70.0
(53.5-73.0)
(60.0-77.0)
(55.0-74.0)
(58.0-78.0)
Medication
Beta-blocker (%)
58.7
62.2
70.8
62.3
Statin (%)
53.1
51.8
61.4
56.8
ACE-inhibitor (%)
62.2
55.6
58.8
59.0
Biomarkers
C-reactive protein (mg/l)
1.85
1.81
2.10
3.66
(0.97-3.79)
(0.98-4.18)
(1.17-4.02)
(1.76-8.15)
B-type natriuretic peptide (pg/ml)
38.97
40.94
37.64
33.97
(13.79-98.87)
(11.86-92.80)
(12.02-102.15)
(9.88-101.11)
Data presented are percentage of patients, mean ± standard deviation, or median and 25 th /75 th interquartile range for skewed (|skewness| > 1) variables.
Left-ventricular ejection fraction was available for 818 patients and B-type natriuretic peptide for 1032 patients.
LDL denotes low-density lipoprotein, HDL high-density lipoprotein.
To convert values for cholesterol to millimoles per liter, multiply by 0.02586; to convert values for triglycerides to millimoles per liter, multiply by 0.01129.
TABLE 2
Hazard ratios (95% confidence interval) for highest versus other quartiles
of procalcitonin according to traditional risk factors (age- and sex-
adjusted)
Variable
HR (95% CI)
P-value
Age*
≦63 yrs
1.92 (0.98-3.78)
0.06
>63 yrs
1.56 (0.77-3.13)
0.21
Sex**
Female
1.81 (0.73-4.51)
0.20
Male
1.72 (0.97-3.06)
0.07
Body-mass index
≦26.4 kg/m 2
2.22 (0.98-5.01)
0.06
>26.4 kg/m 2
1.54 (0.83-2.83)
0.17
Hypertension
No
1.16 (0.38-3.53)
0.80
Yes
1.98 (1.14-3.43)
0.02
Diabetes mellitus
No
1.64 (0.88-3.09)
0.12
Yes
1.93 (0.86-4.31)
0.11
Smoking
No
1.71 (0.74-3.97)
0.21
Active
1.78 (0.98-3.25)
0.06
LDL-/HDL-ratio
≦3
1.51 (0.79-2.89)
0.21
>3
2.18 (1.01-4.72)
0.05
Multi vessel disease
No
2.73 (0.99-7.57)
0.05
Yes
1.58 (0.90-2.77)
0.11
C-reactive protein
≦2.34 mg/l
1.48 (0.55-3.97)
0.44
>2.34 mg/l
1.58 (0.88-2.83)
0.13
B-type natriuretic peptide
≦37.48 pg/ml
1.19 (0.50-2.86)
0.70
>37.48 pg/ml
2.41 (1.32-4.42)
0.004
Median levels were used to dichotomize continous variables.
*adjusted for sex only
**adjusted for age only
TABLE 3
Hazard ratios for future cardiovascular events according to quartiles of
baseline procalcitonin, C-reactive protein and B-type natriuretic peptide
Events
HR (95% CI)
HR (95% CI)
N
(%)
age-/sex-adjusted
P-value
fully adjusted*
P-value
Procalcitonin (ng/ml)
Q1
<0.010
254
12
(5%)
1
1
Q2
0.010-0.013
259
16
(6%)
1.51 (0.71-3.19)
0.29
1.58 (0.74-3.35)
0.24
Q3
0.014-0.020
301
17
(6%)
1.47 (0.70-3.10)
0.31
1.54 (0.73-3.26)
0.26
Q4
>0.020
310
27
(9%)
2.27 (1.14-4.51)
0.02
2.08 (1.04-4.18)
0.04
Per SD increment
1.41 (1.07-1.86)
0.01
1.33 (1.02-1.74)
0.04
C-reactive protein (mg/l)
Q1
<1.22
282
11
(4%)
1
1
Q2
1.22-2.34
282
14
(5%)
1.27 (0.57-2.80)
0.56
1.08 (0.48-2.42)
0.86
Q3
2.35-4.95
279
19
(7%)
1.65 (0.78-3.47)
0.19
1.33 (0.62-2.87)
0.46
Q4
>4.95
281
28
(10%)
2.48 (1.23-5.02)
0.01
1.87 (0.89-3.92)
0.10
Per SD increment
1.42 (1.14-1.76)
0.002
1.33 (1.05-1.67)
0.02
B-type natriuretic peptide (pg/ml)
Q1
<11.97
258
9
(4%)
1
1
Q2
11.97-37.48
258
8
(3%)
1.04 (0.40-2.71)
0.94
1.08 (0.41-2.83)
0.88
Q3
37.49-99.40
258
15
(6%)
2.03 (0.87-4.71)
0.10
2.11 (0.89-4.99)
0.09
Q4
>99.40
258
32
(12%)
5.16 (2.34-11.39)
<0.001
5.74 (2.51-13.11)
<0.001
Per SD increment
1.84 (1.42-2.38)
<0.001
1.93 (1.47-2.54)
<0.001
*Multivariate risk factor adjustment included age, sex, body-mass index, hypertension, diabetes, smoking status, LDL-/HDL-ratio, number of diseased vessels, statin and beta-blocker therapy.
TABLE 4
Final model of a backward multiple stepwise cox regression analysis for
cardiovascular risk predictors
Variable
Hazard ratio (95% CI)
P-value
Procalcitonin (1 SD increase)
1.30 (1.00-1.70)
0.05
LDL-/HDL-ratio (1 SD increase)
1.32 (1.03-1.70)
0.03
Sex
0.57 (0.34-0.96)
0.03
Diabetes mellitus (IDDM)
2.75 (1.53-4.92)
0.001
TABLE 5
Final model of a backward multiple stepwise cox regression analysis for
cardiovascular risk predictors
Variable
Hazard ratio (95% CI)
P-value
Procalcitonin ≧ 0.05 ng/ml
4.22 (2.07-8.59)
<0.001
LDL-/HDL-ratio (1 SD increase)
1.34 (1.04-1.73)
0.03
Sex
0.60 (0.36-1.00)
0.05
Diabetes mellitus (IDDM)
2.74 (1.54-4.87)
0.001
TABLE 6
Incremental effects of procalcitonin, C-reactive protein and B-type
natriuretic peptide (all log-transformed) on the area under the ROC-curve
in addition to classical risk factors (basic model) for the prediction of the
primary endpoint after 2 years
Model
AUC
95% CI
Basic model
0.74
0.67-0.81
Basic model + PCT
0.77
0.70-0.84
Basic model + CRP
0.75
0.67-0.82
Basic model + BNP
0.79
0.72-0.87
Basic model + PCT + CRP
0.77
0.70-0.84
Basic model + PCT + BNP
0.81
0.74-0.88
Basic model + CRP + BNP
0.80
0.73-0.87
Basic model + PCT + CRP + BNP
0.81
0.74-0.88
TABLE 7
Hazard ratios and 95% confidence interval for future cardiovascular events
according to baseline levels of procalcitonin and B-type natriuretic peptide
in combined analysis (fully adjusted*)
Procalcitonin
B-type
(highest
natriuretic peptide
Hazard ratio
quartile
(highest quartile
95% confidence
N
>0.021 ng/ml)
>99.40 pg/ml)
interval
P-value
654
−
−
1
212
+
−
1.13 (0.56-2.29)
0.74
190
−
+
2.44 (1.30-4.56)
0.005
68
+
+
7.04 (3.40-14.57)
<0.001
*Multivariate risk factor adjustment included age, sex, body-mass index, hypertension, diabetes, smoking status, LDL-/HDL-ratio, number of diseased vessels, statin and beta-blocker therapy.
|
An in vitro method for the risk stratification of patients with stable arteriosclerosis, especially stable coronary artery disease, is disclosed wherein the concentration of procalcitonin is determined in the circulation of such patients using a highly sensitive PCT assay, and wherein within the range of PCT concentrations in the typical normal range of healthy individuals cutoff values are defined which distinguish groups of individual patients with stable arteriosclerosis in accordance with personal cardiac risk, and patients are allotted to one of said risk groups on the basis of their individual PCT concentrations.
| 6
|
GROMMET ASSEMBLY AND METHOD OF DESIGN
[0001] This application claims priority to U.S. Patent Appln. No. 61/974,248 filed Apr. 2, 2014.
BACKGROUND
[0002] The present disclosure relates to a grommet assembly and, more particularly, to a dilution air grommet assembly for a combustor and method of design to enhance flow coefficient.
[0003] Gas turbine engines, such as those that power modern commercial and military aircraft, include a fan section to propel the aircraft, a compressor section to pressurize a supply of air from the fan section, a combustor section to burn a hydrocarbon fuel in the presence of the pressurized air, and a turbine section to extract energy from the resultant combustion gases and thereby generate thrust.
[0004] The combustor section typically includes a wall assembly having an outer shell lined with heat shields that are often referred to as floatwall panels. Together, the panels define a combustion chamber. A plurality of dilution holes are generally spaced circumferentially about the wall assembly and flow dilution air from a cooling plenum and into the combustion chamber to improve emissions, and reduce and control the temperature profile of combustion gases at the combustor outlet to protect the turbine section from overheating.
[0005] The dilution holes are generally defined by a grommet that extends between the heat shield panel and supporting shell with a cooling cavity defined therebetween. Enhanced cooling of the grommets is desirable for improved engine efficiency, robustness, and durability.
SUMMARY
[0006] A grommet according to one, non-limiting, embodiment of the present disclosure includes a core including a chamfered inlet portion having a chamfered ratio equal to or greater than 0.10.
[0007] Additionally to the foregoing embodiment, the chamfered core defines an axial length ratio equal to or greater than 0.25.
[0008] In the alternative or additionally thereto, in the foregoing embodiment, the core includes a cylindrical face and a conical face extending outward from the cylindrical face at a peripheral inner edge, and the cylindrical and conical faces define a hole extending along a centerline through the core.
[0009] In the alternative or additionally thereto, in the foregoing embodiment, the conical face extends transverse to a reference plane normal to the centerline at an angle of about twenty-five to forty-five degrees.
[0010] In the alternative or additionally thereto, in the foregoing embodiment, the conical face is angled from a reference plane disposed normal to the centerline at about thirty degrees.
[0011] In the alternative or additionally thereto, in the foregoing embodiment, a hole communicates through the core along a centerline and is defined at least in-part by a conical face spanning axially and radially outward to an annular end surface carried by the core, and the conical face extends transverse to a reference plane normal to the centerline at an angle of about twenty-five to forty-five degrees.
[0012] In the alternative or additionally thereto, in the foregoing embodiment, a hole communicates through the core along a centerline, and the core carries and extends between opposite annular first and second end surfaces concentrically disposed to the centerline, and wherein the second end surface is located at least in-part radially inward from the first end surface.
[0013] In the alternative or additionally thereto, in the foregoing embodiment, the grommet includes a flange projecting radially outward from the core and spaced axially between the first and second end surfaces.
[0014] In the alternative or additionally thereto, in the foregoing embodiment, the flange includes a peripheral face spanning axially and extending circumferentially around the core, and wherein a plurality of cooling channels are circumferentially spaced from one another and each one of the plurality of cooling channels extends between and communicates through the peripheral face and the second end surface.
[0015] A grommet assembly according to another, non-limiting, embodiment includes a shell having a first side and an opposite second side; a chamfered core projecting through the shell along a centerline and including an annular first end surface spaced outward from the first side and a conical face spanning axially and radially inward from the annular first end surface and axially beyond the second side; and wherein the conical face defines at least in-part a hole in the core and communicating through the shell.
[0016] Additionally the foregoing embodiment, the assembly includes a flange projecting radially outward from the core and spaced axially between the annular first end surface and an opposite, annular, second end surface of the chamfered core.
[0017] In the alternative or additionally thereto, in the foregoing embodiment, the flange carries a peripheral face spanning axially and extending circumferentially around the core, and wherein a plurality of cooling channels are circumferentially spaced from one another and each one of the plurality of cooling channels extend between and communicate through the peripheral face and the second end surface.
[0018] In the alternative or additionally thereto, in the foregoing embodiment, the assembly includes a panel with a cooling cavity defined between the shell and the panel; and wherein the flange is in the cooling cavity.
[0019] In the alternative or additionally thereto, in the foregoing embodiment, the hole is a dilution hole and is in fluid communication between a cooling plenum defined in part by the first side and a combustion chamber defined in-part by the panel.
[0020] In the alternative or additionally thereto, in the foregoing embodiment, the chamfered core has a chamfered ratio equal to or greater than 0.10.
[0021] In the alternative or additionally thereto, in the foregoing embodiment, the conical face spans axially and radially inward to a cylindrical face defining in-part the hole, and the chamfered core has an axial length ratio equal to or greater than 0.25.
[0022] In the alternative or additionally thereto, in the foregoing embodiment, the conical face extends transverse to a reference plane normal to the centerline at an angle of about twenty-five to forty-five degrees.
[0023] In the alternative or additionally thereto, in the foregoing embodiment, the conical face is angled from a reference plane disposed normal to the centerline at about thirty degrees.
[0024] A method of enhancing a discharge coefficient of a grommet assembly design according to another, non-limiting, embodiment includes the steps of choosing an angle between about twenty-five to forty-five degrees wherein an inlet portion of a core of the assembly includes a conical face defining at least in-part a hole extending along a centerline through the core, and wherein the conical face extends transverse to a reference plane normal to the centerline at the angle; choosing a chamfered ratio of a chamfered inlet portion of a core of the grommet assembly; choosing an axial length ratio of the core; choosing a chart based on the chosen angle; and determining the discharge coefficient from the chart displaying axial length ratio verse chamfered ratio.
[0025] Additionally to the foregoing embodiment, the chamfered ratio is equal to or greater than 0.10 and the axial length ratio is equal to or greater than 0.25.
[0026] The foregoing features and elements may be combined in various combination without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, the following description and figures are intended to exemplary in nature and non-limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiments. The drawings that accompany the detailed description can be briefly described as follows:
[0028] FIG. 1 is a schematic cross-section of a gas turbine engine;
[0029] FIG. 2 is a cross-section of a combustor section;
[0030] FIG. 3 is a cross section of a grommet assembly according to one non-limiting example of the present disclosure;
[0031] FIG. 4 is a bottom plan view of a grommet of the grommet assembly;
[0032] FIG. 5 is a partial perspective view of the grommet assembly; and
[0033] FIG. 6 is a graph of an axial length ratio verse a chamfered ratio to determine a discharge coefficient signified by a plurality of charted, curved, lines.
DETAILED DESCRIPTION
[0034] FIG. 1 schematically illustrates a gas turbine engine 20 disclosed as a two-spool turbo fan that generally incorporates a fan section 22 , a compressor section 24 , a combustor section 26 and a turbine section 28 . Alternative engines may include an augmentor section (not shown) among other systems or features. The fan section 22 drives air along a bypass flowpath while the compressor section 24 drives air along a core flowpath for compression and communication into the combustor section 26 then expansion through the turbine section 28 . Although depicted as a turbofan in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engine architecture such as turbojets, turboshafts, and three-spool turbofans with an intermediate spool.
[0035] The engine 20 generally includes a low spool 30 and a high spool 32 mounted for rotation about an engine axis A via several bearing structures 38 and relative to a static engine case 36 . The low spool 30 generally includes an inner shaft 40 that interconnects a fan 42 of the fan section 22 , a low pressure compressor 44 (“LPC”) of the compressor section 24 and a low pressure turbine 46 (“LPT”) of the turbine section 28 . The inner shaft 40 drives the fan 42 directly or through a geared architecture 48 to drive the fan 42 at a lower speed than the low spool 30 . An exemplary reduction transmission is an epicyclic transmission, namely a planetary or star gear system.
[0036] The high spool 32 includes an outer shaft 50 that interconnects a high pressure compressor 52 (“HPC”) of the compressor section 24 and a high pressure turbine 54 (“HPT”) of the turbine section 28 . A combustor 56 of the combustor section 26 is arranged between the HPC 52 and the HPT 54 . The inner shaft 40 and the outer shaft 50 are concentric and rotate about the engine axis A. Core airflow is compressed by the LPC 44 then the HPC 52 , mixed with the fuel and burned in the combustor 56 , then expanded over the HPT 54 and the LPT 46 . The LPT 46 and HPT 54 rotationally drive the respective low spool 30 and high spool 32 in response to the expansion.
[0037] In one non-limiting example, the gas turbine engine 20 is a high-bypass geared aircraft engine. In a further example, the gas turbine engine 20 bypass ratio is greater than about six (6:1). The geared architecture 48 can include an epicyclic gear train, such as a planetary gear system or other gear system. The example epicyclic gear train has a gear reduction ratio of greater than about 2.3:1, and in another example is greater than about 2.5:1. The geared turbofan enables operation of the low spool 30 at higher speeds that can increase the operational efficiency of the LPC 44 and LPT 46 and render increased pressure in a fewer number of stages.
[0038] A pressure ratio associated with the LPT 46 is pressure measured prior to the inlet of the LPT 46 as related to the pressure at the outlet of the LPT 46 prior to an exhaust nozzle of the gas turbine engine 20 . In one non-limiting example, the bypass ratio of the gas turbine engine 20 is greater than about ten (10:1); the fan diameter is significantly larger than the LPC 44 ; and the LPT 46 has a pressure ratio that is greater than about five (5:1). It should be understood; however, that the above parameters are only exemplary of one example of a geared architecture engine and that the present disclosure is applicable to other gas turbine engines including direct drive turbofans.
[0039] In one non-limiting example, a significant amount of thrust is provided by the bypass flow path B due to the high bypass ratio. The fan section 22 of the gas turbine engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet. This flight condition, with the gas turbine engine 20 at its best fuel consumption, is also known as bucket cruise Thrust Specific Fuel consumption (TSFC). TSFC is an industry standard parameter of fuel consumption per unit of thrust.
[0040] Fan Pressure Ratio is the pressure ratio across a blade of the fan section 22 without the use of a fan exit guide vane system. The low Fan Pressure Ratio according to one non-limiting example of the gas turbine engine 20 is less than 1.45:1. Low Corrected Fan Tip Speed is the actual fan tip speed divided by an industry standard temperature correction of (T/518.7 0.5 ), where “T” represents the ambient temperature in degrees Rankine The Low Corrected Fan Tip Speed according to one non-limiting example of the gas turbine engine 20 is less than about 1150 fps (351 m/s).
[0041] Referring to FIG. 2 , the combustor section 26 generally includes an annular combustor 56 with an outer combustor wall assembly 60 , an inner combustor wall assembly 62 , and a diffuser case module 64 that surrounds assemblies 60 , 62 . The outer and inner combustor wall assemblies 60 , 62 are generally cylindrical and radially spaced apart such that an annular combustion chamber 66 is defined therebetween. The outer combustor wall assembly 60 is spaced radially inward from an outer diffuser case 68 of the diffuser case module 64 to define an outer annular plenum 70 . The inner wall assembly 62 is spaced radially outward from an inner diffuser case 72 of the diffuser case module 64 to define, in-part, an inner annular plenum 74 . Although a particular combustor is illustrated, it should be understood that other combustor types with various combustor liner arrangements will also benefit. It is further understood that the disclosed cooling flow paths are but an illustrated embodiment and should not be so limited.
[0042] The combustion chamber 66 contains the combustion products that flow axially toward the turbine section 28 . Each combustor wall assembly 60 , 62 generally includes a respective support shell 76 , 78 that supports one or more heat shields or liners 80 , 82 . Each of the liners 80 , 82 may be formed of a plurality of floating panels that are generally rectilinear and manufactured of, for example, a nickel based super alloy that may be coated with a ceramic or other temperature resistant material, and are arranged to form a liner configuration mounted to the respective shells 76 , 78 .
[0043] The combustor 56 further includes a forward assembly 84 that receives compressed airflow from the compressor section 24 located immediately upstream. The forward assembly 84 generally includes an annular hood 86 , a bulkhead assembly 88 , and a plurality of swirlers 90 (one shown). Each of the swirlers 90 are circumferentially aligned with one of a plurality of fuel nozzles 92 (one shown) and a respective hood port 94 to project through the bulkhead assembly 88 . The bulkhead assembly 88 includes a bulkhead support shell 96 secured to the combustor wall assemblies 60 , 62 and a plurality of circumferentially distributed bulkhead heat shields or panels 98 secured to the bulkhead support shell 96 around each respective swirler 90 opening. The bulkhead support shell 96 is generally annular and the plurality of circumferentially distributed bulkhead panels 98 are segmented, typically one to each fuel nozzle 92 and swirler 90 .
[0044] The annular hood 86 extends radially between, and is secured to, the forwardmost ends of the combustor wall assemblies 60 , 62 . Each one of the plurality of circumferentially distributed hood ports 94 receives a respective on the plurality of fuel nozzles 92 , and facilitates the direction of compressed air into the forward end of the combustion chamber 66 through a swirler opening 100 . Each fuel nozzle 92 may be secured to the diffuser case module 64 and projects through one of the hood ports 94 into the respective swirler 90 .
[0045] The forward assembly 84 introduces core combustion air into the forward section of the combustion chamber 66 while the remainder of compressor air enters the outer annular plenum 70 and the inner annular plenum 74 . The plurality of fuel nozzles 92 and adjacent structure generate a blended fuel-air mixture that supports stable combustion in the combustion chamber 66 .
[0046] Referring to FIGS. 3 and 4 , a dilution hole grommet assembly 102 is illustrated and described in relation to the outer wall assembly 60 for simplicity of explanation; however, it is understood that the same grommet assembly may be applied to the inner wall assembly 62 of the combustor 56 . The grommet assembly 102 includes a portion of the support shell 76 , a portion of the heat shield or panel 80 , and a grommet 104 . The grommet assembly 102 generally functions to flow dilution air (see arrow 106 ) from the cooling plenum 70 , through the wall assembly 60 , via the grommet 104 , and into the combustion chamber 66 . This dilution air generally enters the combustion chamber 66 as a jet stream to improve combustion efficiency generally in a core region of the chamber and further serves to cool and/or control the temperature profile of combustion air at the exit of the combustor 56 .
[0047] The heat resistant panel 80 of wall assembly 60 (which may include an array of panels) includes a hot side 108 that generally defines in-part a boundary of the combustion chamber 66 and an opposite cold side 110 . The shell 76 includes an outer side 112 that faces and defines in-part a boundary of the cooling plenum 70 and an opposite inner side 114 that faces and is spaced from the cold side 110 of the heat shield 80 . An annular cooling cavity 116 is located between and defined by the cold side 110 of the heat shield 80 and the inner side 114 of the shell 76 .
[0048] An aperture 118 may communicate through the heat shield 80 and is defined by a circumferentially continuous surface 120 of the heat shield 80 and spanning axially between the hot and cold sides 108 , 110 . Similarly, an aperture 122 communicates through the shell 76 and is defined by a circumferentially continuous surface 124 of the shell 76 and spanning axially between the outer and inner sides 112 , 114 . A centerline 126 extends through the apertures 118 , 122 and may be substantially normal to the wall assembly 60 and may intersect the engine axis A ( FIG. 1 ).
[0049] The grommet 104 of the grommet assembly 102 has a chamfered core 128 that defines a dilution hole 130 , and a flange 132 that projects radially outward from the core 128 and into the cooling cavity 116 . The core 128 , the dilution hole 130 and the flange 132 may all be substantially concentric to the centerline 126 . The cooling cavity 116 does not generally communicate directly with the dilution hole 130 . Thus, the flange 132 may be in circumferentially continuous sealing contact with the inner side 114 of the shell 76 and may be cast as one piece, brazed, or otherwise adhered to the cold side 110 and/or continuous surface 120 of the panel 80 .
[0050] The chamfered core 128 extends into the aperture 118 of the panel 80 and through the aperture 122 of the shell 76 and into the cooling plenum 70 . More specifically, the core 128 carries opposite annular end surfaces 134 , 136 , both concentric to the centerline 126 , with end surface 134 located in the cooling plenum 70 and spaced outward from the outer side 112 of the shell 76 , and with end surface 136 being substantially flush with the hot side 108 of the panel 80 . The core 128 further includes a substantially conical face 138 , a peripheral inner edge or apex 140 , and a substantially cylindrical face 142 that together generally define the dilution hole 130 . The conical face 138 extends axially and radially inward from the annular end surface 134 and to the inner edge 140 . The cylindrical face 142 extends axially from the inner edge 140 to the end surface 136 . Thus, the chamfered core 128 generally includes a chamfered inlet portion 141 having the conical face 138 and a cylindrical outlet portion 143 having the cylindrical face 142 .
[0051] The grommet 104 further has a plurality of cooling channels 144 spaced circumferentially about the grommet for flowing cooling air from the cooling cavity 116 and into the combustion chamber 66 (see arrow 146 ) for generally cooling the core 128 of the grommet 104 at and/or near the end surface 136 , and which may further enhance penetration of the dilution air jet flow 106 into the combustion chamber 66 . Each cooling channel 144 has an inlet generally defined by an outer circumferential, or peripheral, face 148 of the flange 132 and an outlet defined by the annular end surface 136 of the core 128 . Each channel 144 thus communicates through the flange 132 and the core 128 providing distributed fluid communication between the cooling cavity 116 and the combustion chamber 66 . For ease of manufacturing, each channel 144 may generally be a groove in the grommet 104 , and generally defined between the cold side 110 and continuous surface 120 of the panel 80 , and the flange 132 and core 128 of the grommet 104 .
[0052] Referring to FIGS. 5 and 6 , more traditional grommet assemblies display low discharge coefficients signifying impaired dilution air jet flow penetration into the core regions of the combustion chamber 66 . Such low discharge coefficients may be attributable to hot combustion air recirculation zones at or near the dilution air grommet that may further cause overheating and degradation of the grommet In accordance with the present disclosure, significant grommet performance and durability improvements (e.g. reduced metal temperatures) can be achieved through use of particular dimensional relationships of the core 128 of the grommet 104 and the cooling channels 144 .
[0053] These dimensional relationships may generally be as follows:
[0000] W/D≧ 1/10; L/D≧ 1/4; W≧H; T≧H
[0054] where ‘W/D’ is a chamfered ratio, ‘L/D’ is an axial length ratio, ‘W’ is a distance measured axially (i.e. with respect to centerline 126 ) between the inner edge 140 and the annular end surface 134 , ‘D’ is an outer diameter of the conical face 138 (i.e. where the conical face 138 meets the end surface 134 ), ‘L’ is a distance measured axially between the opposite end surfaces 134 , 136 , ‘H’ is the distance measured between the outer and inner sides 112 , 114 of the shell 76 (i.e. shell thickness), and ‘T’ is the distance measured axially between the end surface 134 and the flange 132 . These dimensional relationships may be combined with an angle (see arrow 150 in FIG. 5 ) of the conical surface 138 (measured from a reference plane that is substantially normal to the centerline 126 ) that falls within a range of twenty-five to forty-five degrees.
[0055] As one non-limiting example, a more traditional discharge coefficient (Cd) can be improved from about 0 . 6 to about 0 . 9 , thereby reducing or eliminating gas recirculation and reducing local metal temperatures from about a melting temperature of the alloy to about a 400 degree Fahrenheit margin below melting temperature when the conical surface angle 150 is about thirty degrees, ‘W’ is equal to or greater than about three times the panel 80 thickness, ‘L’ is equal to or greater than about six times the panel thickness, ‘D’ is equal to or greater than about twenty times the panel thickness, and a hydraulic diameter of the cooling channel 144 (eight illustrated in FIG. 4 ) is about equal to or greater than 0 . 5 times the panel thickness. As a more specific, non-limiting, example: ‘W’ may be about 0.105 inches (2.667 mm), ‘L’ may be about 0.225 inches (5.715 mm), ‘D’ may be about 0.878 inches (22.301 mm), and the hydraulic diameter of each cooling channel 144 may be about 0 . 020 inches (0.508 mm).
[0056] Referring further to FIG. 6 , a graph illustrates the chamfered ratio ‘W/D’ verse the axial length ratio with the conical surface angle 150 at about thirty degrees. Empirical data further depicts discharge coefficient values (i.e. 0.7 through 0.95) as a function of the chamfered ratio versus axial length ratio. That is, each discharge coefficient value is represented by a charted, curved, line gathered empirically. Generally, with increasing chamfered and axial length ratios, the discharge coefficient value also increases. Therefore, with predetermined chamfered and axial length ratios, one can determine the discharge coefficient value when the conical surface angle 150 is thirty degrees.
[0057] It is understood that relative positional terms such as “forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like are with reference to the normal operational attitude and should not be considered otherwise limiting. It is also understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will also benefit. Although particular step sequences may be shown, described, and claimed, it is understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present disclosure.
[0058] The foregoing description is exemplary rather than defined by the limitations described. Various non-limiting embodiments are disclosed; however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore understood that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For this reason, the appended claims should be studied to determine true scope and content.
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A grommet assembly and method of design to enhance the flow coefficient, thereof, includes a shell having a first side and an opposite second side, and a chamfered grommet projecting through the shell along a centerline and including an annular first end surface spaced outward from the first side and a conical face spanning axially and radially inward from the annular first end surface and axially beyond the second side. The assembly may further include a panel spaced from the shell and defining a cooling cavity therebetween with the conical surface defining at least in-part a hole in fluid communication through the shell and panel and isolated from the cooling cavity. A plurality of cooling channels in the grommet are in fluid communication with the cooling cavity and communicate through the panel. The combination of the conical face and the cooling channels improve the discharge coefficient of the grommet while enhancing grommet cooling.
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This is a division, of application Ser. No. 517,665 filed 24 Oct. 1974 now U.S. Pat. No. 3,951,711.
BACKGROUND OF THE INVENTION
The instant invention relates to a system and apparatus for the controlled etching of copper with ferric chloride etchants.
The etching of copper work pieces has attained a farily sophisticated development. Copper work pieces, for use in electronic circuitry, are successfully etched in the existing art; however, the existing techniques are not considered particularly efficient.
Characteristically, the work piece has been introduced into an etching container and a solution of heated ferric chloride is sprayed onto the surfaces to be etched. Although these solutions are quite effective etchants, the etching procedure itself results in a reduction of the ferric (Fe+++) ions to ferrous (Fe++) ions, the latter being totally ineffective as an etchant. As the etching procedures continue, the concentration of the ferrous ions increases, which condition leads to a decrease in the etching effeciency or speed. Thus, the continuous accretion of copper into the etching solution reduces the ability of the etchant to efficiently perform its function. Therefore an efficient etching process must include provision for removal of the copper from the etchant solution.
The prior art includes systems designed to regenerate the solution. By regeneration, it is meant that one component, such as copper, is removed and the fluid is recycled. The solution is treated, such as exposure to chlorine to bring the solution back to its original potency. In U.S. Pat. No. 3,755,202 to Meek, an elaborate recycling system is described, which essentially functions to remove copper and to regenerate the ferric ions by the introduction of chlorine gas into the solution. This approach, along with others in use, calls for the use of auxiliary equipment that provides the controlled etch rate to be sized on the maximum work load in a given unit of time. If the work load tends to be quite variable, these techniques become quite inefficient; they become costly, use excessive amounts of space and are difficult to handle. Maintenance of the equipment of these systems similarly presents a problem.
The instant invention is designed to satisfy the shortcomings of the existing technology. The fluid is rejuvenated by extracting some of the spent etchant and replacing it with fresh etching fluid. In other words, the excess copper is removed along with some solution; fresh etchant is introduced along with an oxidizer, such as chlorine, to reoxidize the ferrous ions to ferric ions.
SUMMARY OF THE INVENTION
It is a primary object of the instant invention to provide an etching system which is efficient and requires a minimum of maintenance.
Another object of the instant invention is the provision of an etching system which is particularly useful where the etched work load is subject to substantial variance.
Yet another object of the instant invention is the automation in controlling the potency of the etchant by continuous rejuvenation thereof.
Still another object of the instant invention is the maintenance of the potency of the etching system by the reoxidizing of the ferrous ions to ferric ions.
A further object of the instant invention is the maintenance of the copper content in the etchant within narrow limits so that the system may be utilized without interruption and independent of work load.
In accordance with the above designs, the system contemplated by the instant invention utilizes the oxidation-reduction-electrical potential (ORP) of the working solution which automatically compared to a standard solution. The reference solution is composed of the appropriate nominal concentration Fe+++, Fe++, Cu+ and Cu++ ions. an ORP controller monitors the differences between the reference and working solutions. The ORP controller energizes a relay control which regulates the introduction of fresh etchant, removal of spent etchant, and introduction of oxidant such as chlorine. In this manner the abrupt changes in the work load are compensated for, automatically, by the system and the potency of the etchant is undiminished.
The above and other aspects and advantages of the present invention will be apparent as the description continues, and when read in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of apparatus utilized in the etchant system of the instant invention;
FIG. 2 is a diagrammatic view of a preferred embodiment of the ORP detector;
FIG. 3 is an alternate embodiment of the ORP detector, set out in a view similar to that of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The etching system hereinafter described may be utilized with a mechanical conveyor system (not shown) which transports work pieces into an etching tank or bath. Examples of the work pieces are printed circuit boards deposited on an insulating substrate. A layer of copper is deposited on one or both sides of the substrate and well known processes, such as photoresistance, effectively shield or coat those portions of the copper surface that are not to be etched. The unshielded portions of the copper surface are etched by being sprayed with etchant which may be passed, in a continuous spray, through nozzles in the etchant supply line. The above etching apparatus has not been illustrated other than by general designation of a schematic system block 10, since the instant invention is not dependent on the equipment configuration for that component. Rather the instant invention is directed to the nature of the fluid utilized in the etching apparatus and to the manner in which the fluid is supplied thereto.
The etchant utilized in this system may be a solution of ferric chloride in water. When the ferric chloride solution is sprayed onto the copper surface the ferric (Fe + + + ) ions react with the copper and are reduced to form ferrous (Fe + + ) ions and cuprous (Cu + ) ions according to the equation: Fe + + + + Cu° Fe + + + Cu +
As a cuprous ion dissolves into solution it immediately reacts with another ferric ion as shown by the following equation:
Fe.sup.+.sup.+.sup.+ + Cu.sup.+→Fe.sup.+.sup.+ + Cu.sup.+.sup.+
As the reaction continues, the concentration of the ferrous ions increases at the expense of the ferric ions. The effect of this reaction is to decrease the oxidation potential of the etching solution. Where the prior art has tried to solve the problem by the recycling or regeneration of the etchant, the system embodying the instant invention, rejuvenates the solution by the selective dumping of the spent solution, and selective addition of fresh etchant solution and reoxidation of the Fe + + ions to Fe + + + ions in the working solution.
The etchant is suitably maintained at a predetermined temperature which is dependent somewhat on the materials utilized in the component parts of the etching machine. As the example described in infra will illustrate, the general temperature range is between 120° to 140°F although temperatures of up to 200°F are sometimes associated with more sophisticated materials.
Reference will now be made to the schematic representation in FIG. 1 for a description as to the manner in which the etchant solution is rejuvenated. Whenever the oxidation potential drops to a predetermined level etchant is pumped via pump 12 from the etching apparatus 10 into line 14 of the system. The fluid is then split into lines 20 and 22 the relative amounts in each line determined by the valves 24 and 26. The fluid in line 20 passes through the ORP detector 28. An ORP control 30 of which more will be described infra monitors the condition of the spent fluid with respect to a standard fluid. The appropriate signals are passed to a relay control 32 which determines how much fluid is to be dumped, how much fresh etchant is to be added, and how much oxidant is to be introduced. The fluid in line 20 flows into line 22 and the relay control 32 signals the pump 34 to dump a quantity of fluid to waste at a fixed rate. At the same time, downstream of the dumping station, the relay control means signals pump 36 to permit the appropriate quantity of fresh etchant to enter line 22 from the etchant reservoir 38. Concurrently, the relay control activates a solenoid valve 40 and flow meter 42 to introduce oxidant into the solution at a fixed rate from a reservoir 39. The oxidant may be chlorine (Cl 2 ), hypochlorous acid (HOCl), ozone/hydrochloric acid (O 3 + HCl), hydrogen peroxide/hydrochloric acid (H 2 O 2 + HCl), ammonium chlorate (as a water solution)/hydrochloric acid (NH 4 ClO 3 + HCl), ammonium perchlorate (as a water solution)/hydrochloric acid NH 4 ClO 4 + HCl), perchloric acid (as a water solution)/hydrochloric acid (HClO 4 + HCl), chlorine monoxide (Cl 2 O), chlorine dioxide/hydrochloric acid (ClO 2 + HCl), among others. This fresh etchant and oxidizer is then pumped into the return line to the etching apparatus and mixed therein with the flowing etchant stream.
The density of the etchant is measured by a density controller 29 which adds water as needed to maintain a constant density. An example of the type of device that would be adequate for this purpose is a float which can trigger a relay operating valve 27.
The oxidizer converts ferrous ions to ferric ions, the excess copper is removed by replacing spent etchant with fresh solution and consequently, the etching procedure continues with undiminished vigor. The chlorine flow rate, is set as high or slightly higher than the maximum stoichiometric rate of copper addition to the etching bath. Thus, the chlorine flows in fast enough to replace ferric ions at least as rapidly as they are formed at the maximum expected etching rate. At lower etching rates, the chlorine feed is intermittent, at such intervals and for such flow periods as are required to maintain the predetermined and desired oxidation potential. Chlorine gas reacts with the ferrous ions to reform the ferric ions according to the equation:
2Fe.sup.+.sup.+ + Cl.sub.2 →2Fe.sup.+.sup.+.sup.+ + 2 Cl.sup.-
As the chlorination proceeds, the ferric ion concentration increases to the detriment of the ferrous ion concentration. Not all the ferrous ions are permitted to be reoxidized since that would result in a tendency for the objectionable corrosive chlorine to escape. This is also true for other oxidants. Therefore, during the process of etching, the ORP control 30 will turn the pumps and valves off as required to maintain ferric to ferrous ion concentration within preset limits.
As the etching procedure continues the copper concentration in the etching solution will also tend to rise. The replacement of etchant means that some of the copper in the solution is dumped. The apparatus is capable of controlling, within predetermined limits, the copper concentration. When adding fresh solution, enough must be added to compensate for that carried out by the etched work piece as well as that discarded under the ORP control.
The change in electrochemical potential is utilized to monitor and adjustably control the etching vigor of the solution. One such method compares the ORP of working solution to that of a standard or reference solution. The reference solution may comprise nominal concentrations of Fe+++, Fe++, Cu+ and Cu++. In this method, the instantaneous ORP, at any point in time, is that produced by the difference generated between an electrically coupled platinum tipped electrode 50 (FIG. 2) and a silver/silver chloride electrode 52, the former immersed in a reference solution 54 confined in container 56 and the latter immersed in the working solution. The reaction between the copper metal and Fe + + + proceeds as follows:
Cu + FeCl.sub.3 →CuCl + FeCl.sub.2 CuCl + FeCl.sub.3 →CuCl.sub.2 + FeCl.sub.2
The change in the ORP is monitored by the ORP control 30. The monitor has two electrically controlling set points zeroed at nominal solution operating conditions as to ion concentrations and temperature. One set point activates the relay control 32 connected to the pumps and valves, while the second deactivates these relays.
As the above reactions occur the ORP changes relatively uniformly with the amount of Cu° reacted, therefore, by choosing any small range of copper ion concentration, Cu + + , the change in ORP will almost be linear with change in Cu + + .
The instantaneous ORP represents the overall system electrochemical condition and is purely relative to changes in the Fe + + +/Fe + + ratio. This is only important from the standpoint of control since the system reactions, in addition, also include:
Cu + CuCl.sub.2 →2CuCl
4NH.sub.4 Cl + CuCl.sub.2 →Cu(NH.sub.3).sub.4 Cl.sub.2 + 4HCl
4NH.sub.4 Cl + CuCl→Cu(NH.sub.3).sub.4 Cl + 4HCl
These equations represent the reactions with ammonium chloride normally added to complex Cu + + and Cu + , decreasing the mass action of these ions and increasing the etch rate.
There is also the slow reaction of Fe + + with oxygen from the air in contact with spray droplets in a spray etch machine.
3FeCl.sub.2 +O.sub.2 +H.sub.2 O→3FeOCL+H.sub.2
in addition there is the reaction of the compound formed in the last mentioned reaction with the HCl formed by the prior referred to reactions as well as any existing in the original etchant, as formulated.
FeOCL+2HCL→FeCL.sub.3 +H.sub.2 O
the range of ORP values selected depend on the concentration of Cu + + to Cu + in the etchant that is desired. The concentration of Cu + + to Cu + will determine the etch rate of the solution and consequently, the operating limits of the system.
The selected range is set for the ORP control 30 so that it will activate the relay control 32 when the ORP representing the maximum concentration of Fe + + is reached. This starts the actions of (1) removal of spent solution via pump 34; (2) introduction of fresh etchant from reservoir 38 via pump 36 and; (3) introduction of Cl 2 or other oxidant via valve 40.
When the ORP value representing the selected Fe + + +/Fe + + ratio is reached, the relay control 32 is deactivated. It is necessary to avoid reducing the Fe + + concentration below the level where Cl 2 is not only completely reacted but also very quickly, to avoid damage to the equipment by nascent chlorine.
When a portion of the operating solution is removed and an equivalent amount of fresh FeCl 3 etchant is introduced and the concentration of Cu + + is reduced, the total Fe + + + plus Fe + + concentration is maintained. The Fe + + + to Fe + + ratio is also maintained by reoxidation of a staichiometric amount of Fe + + ions to Fe + + + ions according to the following equations:
Cl.sub.2 + H.sub.2 O→HCl + HOCl
4FeCl.sub.2 + 4HOCl→4FeCl.sub.3 + 2H.sub.2 O + O.sub.2
similar reactions can be obtained with other oxidants. For example:
2FeCl.sub.2 + O.sub.3 + 2HCl→2FeCl.sub.3 + H.sub.2 O + O.sub.2
2feCl.sub.2 + 2HCl + H.sub.2 O.sub.2 →2FeCl.sub.3 + 2H.sub.2 O
as set forth above, the amount of fresh etchant added at any time must compensate for the fluid lost by "drag-out" of the etched work pieces.
FIG. 2 represents a preferred embodiment of the ORP detector 28. FIG. 3 illustrates a single electrode ORP detector 28a which utilizes a single ordinary silver chloride electrode 52a, immersed in the working solution. The electrode 52a is connected to the ORP control 30a via a Wheatstone Bridge 60. In this method, the instantaneous ORP is that produced between the change in the Ag/AgCl electrode in the working solution, and a predetermined reference voltage as would be produced by a reference solution. Beyond this difference, the function of the ORP detector and the ensuing chemical reactions are identical to those described above. There are several advantages to utilizing the single electrode detector. Firstly, it is easier to compensate for vendor supplied etchant variance than with the dual electrode system. Also, the single electrode system is more readily recalibrated. Further, fouling due to depositing of solids is more readily detected. Finally, the single electrode system is more adaptable for use, on simultaneously operating techant systems. It is worth noting that the ORP detectors described above, are but two examples of appropriate detectors. Any such device would function similar to those described and the chemistry would remain the same. Therefore, the instant invention should not be construed in terms of the detectors thus far presented.
The following example illustrates both the mechanism and the ease of use of the invention.
The condition of the working solution is as follows:
Cu.sup.+.sup.+ = 10.9 oz/gal
Fe.sup.+.sup.+/Fe.sup.+.sup.+.sup.+ =0.95
pH = 0.04
temp. = 135° ± 2°F
orp = 60mv
etch rate = 0.0014 inch/min
To maintain the etch rate within + 0.00002 inch/min it was found that the Cu + + concentration must be maintained within ± 0.1 oz/gal. This corresponds to ± 2 mv. The electrical range of ± 2 mv is sufficiently broad to provide relatively easy control.
The controller 30 is set so that when the ORP equals 62 mv the following occur simultaneously: (1) the discharge pump 34, originally set to remove 0.5 gal/min from the system is started; (2) the replenishment pump 36 is activated to deliver 0.51 gal/min of fresh ferric chloride to the system and; (3) the valve 40 is opened to inject chlorine at a rate of 0.2 ft 3 /min.
The controller is set to shut off at 58 mv at which time the valves and pumps are closed. The ORP detection process continued to monitor the potential of the working solution and to repeat the above sequence as necessary and as determined by the work load in the system.
It will be apparent that the invention described is uniquely adapted to serve both small and large installations and those with variant work loads. It serves well in shops where the regenerative systems are of little utility. The rejuvenation system is strictly dependent on the ORP of the solution and that, in turn, is in lock-step with the amount of Cu° reacted. Therefore, the invention described does not cause size, cost and area penalty that is associated with the regeneration systems when the work load is light or variable. Furthermore, the system of the invention can operate with relatively high concentrations of copper. The system develops and extends the etching art by reducing cost, increasing accuracy, and in general, adding efficiency to the process.
In addition to the previously recited advantages, the system described may be used in association with any etching system wherein the following conditions exist:
a. The solution contains a multivalent ion which acts as an etchant of a metal or non-metal with a resulting reduction in valence of said ion. Examples:
CuCl.sub.2 + Cu→2CuCl
3FeCl.sub.3 + Al→3FeCl.sub.2 + AlCl.sub.3
H.sub.2 Cr.sub.2 O.sub.7 + 6H.sub.2 SO.sub.4 + 3Cu→Cr.sub.2 (SO.sub.4).sub.3 + 3CuSo.sub.4 + 7H.sub.2 O
b. The introduction of the oxidant into the etchant solution causes the reduced ion to be reoxidized to its former valence state.
2CuCl + Cl.sub.2 →CuCl.sub.2
2FeCl.sub.2 + H.sub.2 O.sub.2 + 2HCl→2FeCl.sub.3 + 2H.sub.2 O
cr.sub.2 (SO.sub.4).sub.3 + 3O.sub.3 + 4H.sub.2 O→H.sub.2 Cr.sub.2 O.sub.7 + 3H.sub.2 SO.sub.4 + 3O.sub.2
c. The ORP values change in a continuous manner as the concentration ratio of oxided to reduced ions varies in the etchant solution.
d. Other ions in the etchant solution do not cause a precipitate to form with the reduced ion under the conditions of temperature and concentration required for normal operations.
e. The oxidant reacts readily with the reduced ions.
f. The volume of oxidant, if a liquid, that is required will not prevent maintaining the solution in stoichiometric ion balance.
g. None of the reactants, except water, are lost by evaporation.
Many changes may be made in the details of the instant invention, in the method and materials of fabrication, in the configuration and assemblage of the constituent elements, without departing from the spirit and scope of the appended claims, which changes are intended to be embraced therewithin.
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System and apparatus for the controlled etching of copper work pieces with ferric chloride etchants. The working solution is constantly monitored with regard to its oxidation reduction potential (ORP) by comparison with a standard solution or voltage. To reduce the build up of etched copper in the working solution, an ORP controller activates the removal of specific quantities of that solution which are then replaced in precise stoichiometric proportions with fresh etchant. Simultaneously, oxidant is injected into the fluid to reoxidize ferrous ions to ferric ions. The solution is constantly monitored and the ORP control means repeats the above procedure as often as necessary to maintain the ORP of the fluid within an acceptable range.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority from provisional application 60/808,510 filed on May 25, 2006 and provisional application 60/808,372 filed on May 25, 2006. Additionally this Application claims priority from non-provisional application Ser. No. 11/805,756 filed on May 24, 2007.
BACKGROUND
[0002] One commonly used method for eliminating pests is fumigation. Fumigants are widely used for the disinfestation, and protection against infestation, that is required to protect greenhouse plants, particulate materials (such as grain) and other stored produce (such as tobacco and foodstuff), and spaces (such as buildings). However, because of the need for high volatility in fumigant use, only a small number of chemicals are routinely used.
[0003] The term “fumigant” as used herein refers to an insecticide composition that can be volatilized in the form of ultra small volume droplets (smokes) or vapors to control pests in storage bins, buildings, greenhouses, ships, rail cars, stored products, on foods, plants, other living organisms, or in any closed areas which are prone to attack by pests, i.e., pest infestation. The term “fumigation” refers to the use of such dispersed insecticide compositions to control pests.
[0004] Droplet size determines how long pesticide droplets remain suspended in the air, the number of droplets that will be produced from a given volume of pesticide and the size of the treated surface or area that will be covered by each droplet. The following categories should be distinguished:
a. Coarse sprays, with droplets measuring 400 microns or more in diameter; b. Fine sprays, with droplets of from 100 to 400 microns in diameter; c. Mists, with droplets from 50 to 100 microns; d. Aerosols, fogs, and ultra-low volume (ULV) fogs or smokes with particles or droplets ranging from 0.1 to 50 microns in diameter (which are produced by injection of the pesticide into blasts of hot air (thermal fog), mixing with a liquefied gas and released through a small orifice (aerosol), atomized through very fine nozzles, or spun off high-speed rotors); e. Vapors, in which all particles are less than 0.001 microns in diameter (produced by heat generators). f. Gasses.
DESCRIPTION OF THE INVENTION
[0011] The present invention is directed to a fumigation method utilizing one or more spinosyn compounds.
[0012] In one embodiment the invention is directed to a fumigation method utilizing a spinosyn composition dispersed in the form droplets or particles having a diameter in the range of 0.1 to 50 microns.
[0013] A more specific embodiment the invention provides a method for disinfesting and protecting plants or plant products which comprises: confining the plants or plant products within an enclosed space and dispersing a spinosyn composition in the form of droplets or particles having a diameter in the range of 0.1 to 50 microns within said space.
[0014] Also provided is a method for protecting stored products which comprises confining the stored products within an enclosed space and dispersing in said space, in the form of droplets or particles having a diameter in the range of 0.1 to 50 microns, a composition comprising spinosad and a liquid carrier.
[0015] The spinosyn composition used in carrying out the present invention is preferrably spinosad or spinetoram, or an organic soluble salt thereof, dissolved or suspended in an inert liquid carrier.
[0016] Spinosyn compounds consist of a 5,6,5-tricylic ring system, fused to a 12-membered macrocyclic lactone, a neutral sugar (rhamnose), and an amino sugar (forosamine) (see Kirst et al. (1991)). Natural spinosyn compounds may be produced via fermentation from cultures deposited as NRRL 18719, 18537, 18538, 18539, 18743, 18395, and 18823 of the stock culture collection of the Midwest Area Northern Regional Research Center, Agricultural Research Service, United States Department of Agriculture, 1815 North University Street, Peoria, Ill. 61604. Spinosyn compounds are also disclosed in U.S. Pat. Nos. 5,496,931, 5,670,364, 5,591,606, 5,571,901, 5,202,242, 5,767,253, 5,840,861, 5,670,486 and 5,631,155. Derivatives of natural spinosyn compounds, sometimes referred to as spinosoids, are disclosed in U.S. Pat. No. 6,001,981. Spinosyns can be isolated in the form of salts that are also useful in the methods of this invention. The salts are prepared using standard procedures for salt preparation. For example, spinosyns can be neutralized with an appropriate acid to form acid addition salts. Representative suitable acid addition salts include salts formed by reaction with either an organic or inorganic acid, for example, sulfuric, hydrochloric, phosphoric, acetic, succinic, citric, lactic, maleic, fumaric, cholic, pamoic, mucic, glutamic, camphoric, glutaric, glycolic, phthalic, tartaric, formic, lauric, stearic, salicylic, methanesulfonic, benzenesulfonic, sorbic, picric, benzoic, cinnamic and like acids. As used herein, the term “spinosyn” includes spinosoids and acid addition salts.
[0017] Spinosad is an insecticide produced by Dow AgroSciences (Indianapolis, Ind.) that is comprised mainly of approximately 85% spinosyn A and approximately 15% spinosyn D. Spinosyns A and D are natural products produced by fermentation of Saccharopolyspora spinosa , as disclosed in U.S. Pat. No. 5,362,634. Spinosad is an active ingredient of several insecticidal formulations available commercially from Dow AgroSciences, including the TRACER, SUCCESS, SPINTOR, and CONSERVE insect control products. For example, the TRACER product is comprised of about 44% to about 48% spinosad (w/v), or about 4 pounds of spinosad per gallon. Spinosyn compounds in granular and liquid formulations have established utility for the control of arachnids, nematodes, and insects, in particular Lepidoptera, Thysanoptera, and Diptera species.
[0018] Because spinosyns are large molecules with low volatility, their utility as fumigants was previously unsuspected.
[0019] Other spinosyn compounds of particular interest for practice of the present invention are 5,6-dihydro-3′ ethoxy spinosyn J and 3′-ethoxy spinosyn L. These two compounds are disclosed as examples A25 and A38 in U.S. Pat. No. 6,001,981. They are derivatives of natural spinosyn compounds spinosyn J and spinosyn L.
[0000]
(I)
Factor
R 1′
R 2′
R 3′
R 4′
R 5′
R 6′
R 7′
Spinosyn J
H
CH 3
C 2 H 5
CH 3
H
CH 3
Spinosyn L
CH 3
CH 3
C 2 H 5
CH 3
H
CH 3
[0020] Spinetoram (previously known as DE-175) is a mixture of 5,6-dihydro-3′ ethoxy spinosyn J (major component) and 3′-ethoxy spinosyn L being developed by Dow AgroSciences. The mixture can be prepared by ethoxylating a mixture of spinosyn J and spinosyn L, followed by hydrogenation. The 5,6 double bond of Spinosyn J and its 3′-ethoxy is hydrogenated much more readily than that of spinosyn L and its 3′-ethoxy derivative, due to steric hindrance by the methyl group at C-5 in spinosyn L and its 3′-ethoxy derivative.
[0021] Surprisingly, spinosyn compositions can be dispersed in adequate concentrations as ULV aerosols or fogs to effectively control pests using conventional fumigation devices, e.g. ULV foggers and cold misters, thermal foggers, combustible fumigation products (such as smoke canisters or coils like mosquito coils) and thermal vaporizers, such as foggers and mat type devices.
[0022] Spinosyn compositions used in the present invention can be solutions or emulsions of a spinosyn or an organic soluble salt of spinosyn in a non-aqueous solvent. Examples of suitable non-aqueous solvents are alkylalcohols having 1 to 10 carbon atoms such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, sec-butyl alcohol, tert-butyl alcohol, isobutyl alcohol, amyl alcohol, hexyl alcohol, heptyl alcohol, octyl alcohol, nonylalcohol, decyl alcohol, etc.; hydrocarbon solvents such as hexane, octane, cyclopentane, benzene, toluene, xylol, etc.; halogenated hydrocarbon solvents such as carbon tetrachloride, trichloroethylene, tetrachloroethane, dichlorobenzene, etc.; ether solvents such as ethylether, butylether, ethylene glycol diethylether, ethylene glycol monoethylether, etc.; ketone solvents such as acetone, methylethylketone, methylpropylketone, methylamylketone, cyclohexane, etc.; ester solvents such as ethyl formate, methyl acetate, propyl acetate, phenyl acetate, ethylene glycol monoethylether acetate; etc.; alcohol solvents such as diacetone alcohol, etc.; and high-boiling hydrocarbon solvents.
[0023] ULV foggers, also known as aerosol generators or cold foggers, since no heating of the formulation is necessary, and thermal foggers in which the pesticide is injected into blasts of hot air, are suitable for use in practicing the invention, are well known in the art, and are available commercially, for example, from Curtis Dyna-Fog Ltd., PO Box 297, Westfield Ind. uu46074, United States http://www.dynafog.com, and Industrial Chemical Cleaner, 6333 Sidney Street, Houston Tex., 777021, http://www.iccfoggers.com/index.htm.
[0024] U.S. Pat. No. 4,871,115, and discloses a smoke generating apparatus suitable for use in practicing the present invention.
[0025] U.S. Pat. No. 4,777,032 discloses a combustible fumigation device suitable for use in carrying out the present invention. The device comprises paper into which a pesticide has been incorporated. The paper is burnt to disseminate the pesticide. To ensure an efficient and rapid dissemination by means of a large volume of combustion gas containing only a little smoke and originating from a special combustion reaction at a limited temperature so as not to decompose the active compound, this paper is a nitrocellulose-based paper in which the proportion of nitrogen is greater than 5% and in which the fibers consist of a mixture of cellulose and nitrocellulose fibers, this mixture comprising at least 18% of cellulose fibers and the active compound having a decomposition temperature above 130. degree. C.
[0026] Combustible coils are another known method for vaporizing materials (e.g. pesticides, incense, etc.) Representative patents describing combustible coils are U.S. Pat. Nos. 3,248,287, 3,723,615, 3,819,823, 4,144,318, 5,657,574, and 6,419,898. These devices are coils of slowly burnable solid material that contain an insect control ingredient such as a repellent, an insecticide, or an insect growth regulator. When they burn, heat vaporizes (and thereby disperses) the insect control ingredient. Small amounts of smoke also help to disperse the insect control ingredient. Such devices are one means conventionally used to control mosquitoes. Mosquito coils are often used to knock down or repel flying insects in living quarters. Traditional mosquito coil compositions include approximately 25% or more of a residue from preparing pyrethrum known as pyrethrum marc, as it is thought this material is a necessary ingredient to produce an acceptable mosquito coil. In addition to the pyrethrum marc, the prime burning agent or fuel used for mosquito coils is coconut shell flour, tabu powder, sawdust, ground leaves, ground bark, starch, etc.
[0027] Thermal vaporizers include those of the mat type wherein a mat impregnated with an insecticidal solution is used as placed on a heat plate to vaporize the insecticide into the ambient air. See U.S. Pat. Nos. 6,031,967 6,551,560. Such devices are also conventionally used in mosquito control.
[0028] In the case where an insecticide coil is used, the inert support can be, for example, pyrethrum marc compound, Tabu powder (or Machilus thumbergii leaf powder), pyrethrum stem powder, cedar leaf powder, sawdust (such as pine sawdust), starch and coconut shell powder. The dose of active ingredient can then be 0.03% to 1% by weight. In the case where an incombustible fibrous support (mat) is used, the dose of active material can be 0.03% to 95% by weight.
[0029] The invention can be used, for example, to protect stored grain, or stored foods such as flour or meal or animal feed.
[0030] In one embodiment, the present invention provides a method of disinfesting agricultural products such as tobacco by fumigation with a spinosyn. A major pest of stored tobacco and tobacco products is the cigarette beetle, Laisoderma serricorne . During the past 50 years, toxic fumigants such as hydrogen cyanide, methyl bromide, and hydrogen phosphide have been used to fumigate tobacco and other agricultural products for control of the cigarette beetle and other stored product insects. Usage of these and other fumigants has become increasingly restricted during the past several years because of regulatory agencies' concern with worker exposure to pesticides, pesticide residue on agricultural products, fumigant flammability, and contamination of air and water.
[0031] The fumigation method of this invention can be used to control pests of the Phylum Arthropoda.
[0032] In one embodiment, the invention can be used to control pests of the Subphylum Hexapoda. More specifically, the invention can be used to control pests of the Class Insecta. For example, the fumigation method of this invention can be used to control Coleoptera (beetles), Dermaptera (earwigs), Dictyoptera (cockroaches), Diptera (true flies), Hemiptera (true bugs), Homoptera (aphids, scales, whiteflies, leafhoppers), Hymenoptera (ants, wasps, and bees), Isoptera (termites), Lepidoptera (moths and butterflies), Mallophaga (chewing lice), Orthoptera (grasshoppers, locusts, and crickets), Phthiraptera (sucking lice), Siphonaptera (fleas), and Thysanoptera (thrips).
[0033] In another embodiment, the fumigation method of this invention can be used to control pests of the Subphylum Chelicerata. More specifically, the fumigation method of this invention can be used to control pests of the Class Arachnida. For example, the fumigation method of this invention can be used to control Acarina (mites and ticks).
Examples 1-10
[0034] Lab trials were conducted to test spinosad and spinetoram for insecticidal activity via thermal fogger delivery. Test insects included Aedes aegypti , yellow fever mosquito; Drosophila melanogaster fruit fly; Musca domestica house fly; and Plodia interpunctella , Indian meal moth.
[0035] Test Chambers. The test chambers were developed by suspending polyethylene (PE) bags from a PVC pipe support structure. The bags were 3 mil PE pallet covers measuring 48″W×48″D×102″H (ULINE product # S-8366) with an enclosed internal volume of approximately 100 ft 3 . The chambers were sealed at floor level to a flat 4 mil PE sheet. Five chambers were made to accommodate 4 treatment replicates and one solvent blank control. All chambers were used once per application and then discarded.
[0036] Holding Cages. For yellow fever mosquito, house fly, and Indian meal moth, holding cages were made from 18×16 mesh standard aluminum insect screening. A circular cage was made to measure 3.5″ in diameter and 5.5″ high. The floor and ceiling of the holding cages were sterile acrylic Petri dish covers and bottoms. In each holding cage insects were supplied with a 10% sucrose solution from a 7.5 ml glass vial and sterile cotton wick. For fruit flies, white polyester mosquito netting with a 0.8 mm mesh opening was glued to the lid of a fruit jar and placed into the bottom of the Petri dish to create a suitable holding cage. Sugar water was provided from a 2 ml vial.
[0037] Thermal Fogger Device. A Dynafog Trailblazer Model 2600E, series 3 thermal fogger was used for application. The fogger is designed to deliver up to 19 liters of formulation per hour with a particle size in the range of 0.5-50 microns. It is designed for application to enclosed spaces greater than 500 ft 3 . As a result, the fogger was modified to deliver smaller volumes which could be adjusted to accommodate the 100 ft 3 test chamber.
[0038] All hoses that delivered the formulation were reduced to 3.2 mm OD 2.0 mm ID nylon tubing. The formulation tank was reduced to a 250 ml HDPE bottle with appropriate fittings to accommodate the tubing. The fogger on/off switch was bypassed and replaced with a manual toggle switch. This configuration was calibrated with a needle valve adjustment to deliver approximately 4.0 liters per hour.
[0039] Insect Handling. Collection of Indian meal moth was achieved by selecting carbon dioxide-anesthetized individuals from culture jars. Adult yellow fever mosquitoes, house flies, and fruit flies were aspirated from culture jars into a 50 ml holding jar and then anaesthetized with carbon dioxide and collected. All insects were allowed to recover from anesthesia for at least 1 hour before testing began. Fifty adults were used for each replicate. Any insects that were dead or injured from handling were noted as pre-treatment mortality data.
[0040] Application. The formulation used in the testing consisted of 1.1% spinosad (90% purity), 1.5% Isopropyl Myristate (Cognis Corporation; Cincinnati, Ohio), 4.0% Emersol 213 (Cognis Corporation), and 93.4% Exxsol D80 (ExxonMobil; Houston, Tex.) or 1.2% spinetoram (81% purity), 1.5% Isopropyl Myristate (Cognis Corporation), 4.0% Emersol 213 (Cognis Corporation), and 93.3% Exxsol D80 (ExxonMobil). A blank treatment with just the solvent mixture was one of the control treatments. The other control treatment was the absence of active ingredient and solvent.
[0041] All applications were done at room temperature of approximately 71-72° F. All insect holding cages were positioned from hangers in the corners of the test chambers just prior to treatment, or in the case of the fruit flies, the test holding cages were put on the floor.
[0042] The fogger was charged and run to clean out lines with solvent only. The flow rates were adjusted after calibration to deliver approximately 1 ml per second.
[0043] The following steps 1-11 are considered one trial for one formulation:
1. The fogger was turned on and allowed to warm up to temperature (3-5 minutes). 2. The toggle valve was opened to allow the formulation to charge the line before each treatment run (˜50 ml). 3. The amount of formulation in the formulation tank was weighed on a Sartorius BL1500 scale and then reattached to the fogger. 4. The fogger was positioned in front of a rectangular opening cut into the treatment chamber. A digital timer was turned on and the toggle valve opened to apply the formulation or solvent. 5. After 5 to 7 seconds, the toggle valve was closed and the fogger turned off 6. The rectangular opening was immediately sealed with packing tape. 7. The formulation tank was weighed and the difference in mass was recorded as was the application time in seconds. 8. The tank was reattached and steps 4-7 were repeated for the next three treatment chambers. 9. When the four treatment chambers were done, the fogger was flushed with clean solvent (˜50 ml) to remove formulation from the fogger. 10. A new formulation tank with solvent only was then reattached after weighing. 11. The fogger was charged with solvent and then steps 3-7 were performed for the solvent blank treatment chamber.
[0055] The untreated control test cages were kept in an adjacent room under identical temperature and light conditions.
[0056] Efficacy evaluation. The effectiveness of the applications was recorded at 1 hour, 4 hours, 18 hours, and 24 hours. The number of live and dead insects was recorded at each interval for all treatments, solvent control, and the untreated control test cages.
Example 1
Control of Adult House Flies, Musca domestica , with Spinosad
[0057]
[0000]
Spinosad
Percent mortality
Solvent
Concentration
1
Treatment
volume
(g/m 3 )
hr
4 hr
18 hr*
24 hr*
Untreated
0 ml
0
0
0
—
—
Solvent blank
8.8 ml
0
0
16
—
—
Spinosad
7.3 ml
0.026
14
76
—
—
Spinosad
9.5 ml
0.034
14
90
—
—
Spinosad
9.0 ml
0.032
26
90
—
—
Spinosad
8.2 ml
0.029
24
94
—
—
*high mortality occurred in the untreated and solvent blank treatments.
Example 2
Control of Adult Fruit Flies, Drosophila melanogaster , with Spinosad
[0058]
[0000]
Spinosad
Solvent
Concentration
Percent mortality
Treatment
volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
0
0
Solvent blank
8.8 ml
0
0
2
2
2
Spinosad
7.3 ml
0.026
12
100
100
100
Spinosad
9.5 ml
0.034
2
100
100
100
Spinosad
9.0 ml
0.032
4
100
100
100
Spinosad
8.2 ml
0.029
0
100
100
100
Example 3
Control of 2 Day Old Adult Indian Meal Moths. Plodia interpunctella , with Spinosad
[0059]
[0000]
Spinosad
Solvent
concentration
Percent mortality
Treatment
volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
0
0
Solvent blank
8.2 ml
0
0
0
2
2
Spinosad
6.8 ml
0.024
4
4
51
61
Spinosad
8.9 ml
0.031
2
4
41
47
Spinosad
11.0 ml
0.039
4
10
83
88
Spinosad
9.1 ml
0.032
0
8
58
60
Example 4
Control of 4 Day Old Adult Indian Meal Moths, Plodia interpunctella , with Spinosad
[0060]
[0000]
Spinosad
concentration
Percent mortality
Treatment
Volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
3
5
Solvent blank
2.9 ml
0
0
6
30
30
Spinosad
5.4 ml
0.019
2
31
96
100
Spinosad
5.7 ml
0.020
2
36
96
98
Spinosad
8.1 ml
0.029
11
56
100
100
Spinosad
7.9 ml
0.028
7
40
98
100
Example 5
Control of Adult Yellow Fever Mosquitoes, Aedes aegypti , with Spinosad
[0061]
[0000]
Spinosad
concentration
Percent mortality
Treatment
Volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
0
0
Solvent blank
8.6 ml
0
0
0
0
0
Spinosad
10.2 ml
0.036
0
7
93
100
Spinosad
11.7 ml
0.041
0
47
100
100
Spinosad
12.6 ml
0.044
0
100
100
100
Spinosad
12.6 ml
0.044
0
100
100
100
Example 6
Control of Adult Yellow Fever Mosquitoes, Aedes aegypti , with Spinosad
[0062]
[0000]
Spinosad
concentration
Percent mortality
Treatment
Volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
5
10
10
Solvent blank
8.8 ml
0
0
10
14
24
Spinosad
7.3 ml
0.026
12
48
96
100
Spinosad
9.5 ml
0.034
2
100
100
100
Spinosad
9.0 ml
0.032
4
97
100
100
Spinosad
8.2 ml
0.029
0
62
100
100
Example 7
Control of Adult House Flies, Musca domestica , with Spinetoram
[0063]
[0000]
Spinetoram
Solvent
concentration
Percent mortality
Treatment
volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
0
16
Solvent blank
7.5 ml
0
0
0
0
14
Spinetoram
6.7 ml
0.024
4
84
100
100
Spinetoram
6.7 ml
0.024
2
84
100
100
Spinetoram
5.7 ml
0.020
0
0
64
80
Spinetoram
11.0 ml
0.039
0
86
100
100
Example 8
Control of Adult Fruit Flies, Drosophila melanogaster , with Spinetoram
[0064]
[0000]
Spinetoram
Solvent
concentration
Percent mortality
Treatment
volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
0
0
Solvent blank
7.5 ml
0
0
0
8
12
Spinetoram
6.7 ml
0.024
0
88
100
100
Spinetoram
6.7 ml
0.024
0
70
100
100
Spinetoram
5.7 ml
0.020
0
16
76
90
Spinetoram
11.0 ml
0.039
0
72
100
100
Example 9
Control of 2 Day Old Adult Indian Meal Moths, Plodia interpunctella , with Spinetoram
[0065]
[0000]
Spinetoram
Solvent
concentration
Percent mortality
Treatment
volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
0
2
Solvent blank
9.0 ml
0
0
0
2
2
Spinetoram
4.2 ml
0.015
0
0
6
8
Spinetoram
5.8 ml
0.020
2
2
14
22
Spinetoram
4.6 ml
0.016
0
0
18
31
Spinetoram
5.7 ml
0.020
0
0
16
24
Example 10
Control of 4 Day Old Adult Indian Meal Moths, Plodia interpunctella , with Spinetoram
[0066]
[0000]
Spinetoram
Solvent
concentration
Percent mortality
Treatment
volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
0
0
Solvent blank
11.3 ml
0
0
0
2
2
Spinetoram
8.7 ml
0.031
0
0
4
38
Spinetoram
7.8 ml
0.028
1
1
10
70
Spinetoram
9.0 ml
0.032
0
0
9
42
Spinetoram
7.9 ml
0.028
0
0
11
41
Example 11
Control of Adult Yellow Fever Mosquitoes, Aedes aegypti , with Spinetoram
[0067]
[0000]
Spinetoram
Solvent
concentration
Percent mortality
Treatment
volume
(g/m 3 )
1 hr
4 hr
18 hr
24 hr
Untreated
0 ml
0
0
0
0
0
Solvent blank
9.3 ml
0
0
0
0
0
Spinetoram
8.1 ml
0.029
3
97
100
100
Spinetoram
8.2 ml
0.029
0
53
100
100
Spinetoram
7.3 ml
0.025
0
94
100
100
Formulation Example 1
Combustible Coil
[0068] First, 0.5 g of spinetoram is dissolved in 20 ml of acetone. The solution is uniformly stirred and mixed with 99.4 g of a carrier for mosquito coil (a mixture of camphor powder:lees powder:wood meal at 4:3:3). Thereto is added 120 ml of water and the mixture was well kneaded, followed by shaping and drying to obtain a combustible coil.
Formulation Example 2 Coil
[0069] First, 0.5 g of each of spinetoram is dissolved in 20 ml of acetone. The solution is uniformly mixed with 99.4 g of a carrier for mosquito-coils (prepared by mixing Tabu powder, pyrethrum marc powder and wood flour in the ratio of 4:3:3) under stirring. The mixture is well kneaded with 120 ml of water, molded and dried to give a combustible coil.
Formulation Example 3
Electric Mat
[0070] Acetone is added to 0.5 g of spinetoram and 0.4 g of pipenyl butoxide to dissolve the ingredients to prepare a solution in an amount of 10 ml in total. A substrate for electric mat (fibrils of a mixture of cotton linter and pulp which were hardened into a sheet) of 2.5 cm. by 1.5 cm. by 0.3 cm thick is uniformly impregnated with the above solution to obtain an electric mat.
Formulation Example 4
Heat Smoking Agent
[0071] First, 100 mg of spinetoram is dissolved in a suitable amount of acetone. A porous ceramic sheet of 4.0 cm. by 4.0 cm. by 1.2 cm thick is impregnated with the resulting solution to obtain a heat smoking agent.
[0072] Electrically heated mats impregnated with spinosad have demonstrated the ability to control adult mosquitoes when tested in accordance with standard protocols (SANS Method 6136).
[0073] All patents and publications referred to above are incorporated by reference herein.
|
Methods of controlling arthropod pests by dispersing spinosyn compositions in the form of aerosols, fogs, smokes, or vapors are disclosed.
| 0
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CROSS REFERENCES TO RELATED APPLICATIONS
This is a continuation and claims priority benefit under 37 CFR § 1.20 from U.S. patent application Ser. No. 10/794,159, at the time of this application and filed Mar. 5, 2004 now U.S. Pat. No. 7,377,441.
The present application claims priority from and incorporates by reference the co-pending application entitled “ELECTRONIC DEVICE WITH AUXILIARY INTERFACES”, Ser. No. 10/794,159 applied for on Mar. 5, 2004, invented by Wiklof et al.
TECHNICAL FIELD
The present disclosure relates to wireless interfaces, and more particularly to radio interfaces with portable electronic devices.
BACKGROUND
Automatic data collection is used in many sectors of our economy. In many applications, data collection devices such as bar code scanners or radio frequency interrogators are connected to a host or client computer system that processes the data they collect. Some data collection devices communicate through a wired interface. Other models may be used in a store-and-forward or batch mode. Still others interface to the host or client computer via a wireless interface such as a radio or infrared interface.
While there are many choices of interfaces available to the user, they are often not interchangeable. For example, if a user wishes to have a bar code scanner with a radio interface, that scanner may not operate or may not be convenient to operate in a directly connected wired mode.
In other cases, if a user wishes to have an option of using various interfaces in the future, it may be necessary to purchase a more expensive scanner than might otherwise be required or else purchase a completely new scanner to make such a change. For example, if a user purchases a portable scanner in a batch mode, collecting data for subsequent upload to a host or client system, but later decides it best to operate in a wireless mode, it is frequently necessary to purchase a completely new scanner, thus effectively losing the original investment in the batch scanner.
In some cases, adapters may be available for adding a new interface. In particular, there are some third-party radios that a wired-interface data collection device may be connected to add a wireless interface. Unfortunately, such adapters are frequently bulky or ungainly so as to harm the ergonomics of the data collection device. In addition, there may be problems with interface reliability when switching between interface modes. For example, a third-party radio adaptor may be prone to dropping messages, a flaw that may be quite significant in many applications.
With data collection devices and other portable electronic devices that do have a radio interface, there may be shortcomings in operation that adversely affect the use experience. For example, it is frequently inconvenient to add devices, change end device to host pairing, and un-pair devices for use with a different host. Other systems suffer from the inconvenience of dropping and not restarting communication sessions when the end device temporarily moves out of radio range. Still other systems, consume more power than is optimum by staying in a “sniff” or other mode for long periods of time when there is no data transmitted. Other systems may suffer from end devices that re-pair with the wrong host rather than making a strong enough connection to the intended host to prevent such a possibility.
Several radio interface standards are available for use with portable electronic devices. These include spread-spectrum radio standards that are especially immune to interference and may be used in unlicensed environments. These include IEEE 802.11a, 802.11b, 802.11g, and Bluetooth™. The book entitled, “Bluetooth™ Connect Without Cables”, by Jennifer Bray and Charles F. Sturman, published by Prentice Hall PTR, 2001, hereby incorporated by reference, contains information useful for understanding radio data interfaces, and particularly Bluetooth.
OVERVIEW
Various aspects according to the present invention are related to data collection devices and other portable electronic devices that communicate via a variety of interfaces. In some embodiments, an auxiliary interface may be added at any point during the device's operational life by substituting an interchangeable door, such as a battery door, with another that is equipped with elements of the auxiliary interface.
In other aspects, radio interface systems, such as Bluetooth radio systems, are provided with enhanced capabilities and reduced human interface hardware cost while maintaining good user feedback.
An aspect according to the invention relates to an end device such as a bar code scanner that has a native interface. An auxiliary interface may be used in place of or as an adjunct to the native interface. In some embodiments, and interface, memory, or other module may be easily connected to the end device. When an end device includes a battery compartment with the door, the battery door may be made replaceable and interchangeable with accessory battery doors. According to one embodiment, the battery door includes a Bluetooth radio module.
In another aspect according to the invention, data integrity may be maintained by the implementation of various levels of transmission guarantee. In one level of guaranteed transmission, an ACK/NAK protocol may be used between the end device and a host application to ensure receipt of data transmitted. In another level of guaranteed data integrity, a low level host program such as a Bluetooth Manager may be used to monitor transmission sequence numbers from the end device. By labeling each transmission with a sequence number, the Bluetooth Manager may ensure that duplicate messages are not received by the host application.
In another aspect according to invention, various pairing strengths between and devices and computers may be enabled. In some embodiments, a hardware-independent code may be issued to identify a particular pairing. In other embodiments a hardware-specific number such as a host Bluetooth Device number (or BD number) may be used to label the connection and ensure pairing between a particular host and a particular end device.
In another aspect according to the invention, a bar code scanner with a radio may alter its laser scanning modes upon completing a decode.
In yet another aspect according to the invention, a data collection device or other end device may be particularly energy efficient through the use of various low-power modes of operation.
In another aspect, an end device and host computer system will may allow for roaming in and out of radio range with automatic reconnection when the scanner reenters radio range.
In another aspect according to the invention, an end device can differentiate between whether or not a set of data reached its intended host computer, storing non-received data in memory until connection can be made. Connection may be automatically re-attempted at intervals under control of the user.
In still another aspect according to the invention, an end device with no display is able to provide the user with information about its wireless connections status, status of data flow, and receipt of data by a host application.
In another aspect, the user may easily un-pair from particular host computer and re-pair as wished with another host. Such un-paring may be accomplished without keystrokes or access to a complex input device such as a touch screen, accomplished instead by the push of a trigger or button used to initiate data collection.
In another aspect according to the invention, multiple Bluetooth data collection devices may be used in a single environment, each data collection device being paired according to the application needs. The system ensures that end devices do not disconnect from their intended host and reconnect with an unintended host, ensuring integrity of the data connection and associating scan data with an appropriate host and appropriate application.
In another aspect according to the invention, an end device may receive pairing information via a secure wired connection and maintain pairing until unpaired via a secure connection.
In another aspect, an end device may contain a list of qualified hosts. The device may then pair with any of the qualified hosts but refuse to pair with hosts that have not been assigned.
In still another aspect according to the invention, an end device may be enabled to pair with a host within range, allowing it to roam about an environment, collecting data whether or not it is in a radio range, and then pairing with the first qualified host it encounters. The number of qualified hosts may be large or as small as one.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a simple bar code scanner.
FIG. 2 is a block diagram of a bar code scanner having a scan engine architecture.
FIG. 3 is a block diagram of a portable data collection apparatus that is powered by a battery.
FIG. 4 is a block diagram of a bar code scanner having an auxiliary interface.
FIG. 5A is an isometric view of a bar code scanner.
FIG. 5B is an isometric view of the bottom of a bar code scanner showing a removable battery door and an auxiliary interface connector into the battery compartment.
FIG. 5C is an isometric view of the battery door of a bar code scanner having an auxiliary interface module, such as a Bluetooth radio module, installed.
FIG. 6 is a block diagram of a system having a bar code scanner and host computer communicating via a Bluetooth auxiliary interface.
FIG. 7 is a block diagram of a system showing multiple end devices and multiple host computers in proximity to one another.
FIG. 8 is a flow chart showing logic for determining when to transmit data, when to store data, and how to choose an interface for data transmission.
FIG. 9 is a flow diagram illustrating various operation modes for a remote Bluetooth module.
FIG. 10 is a flow diagram illustrating interrelationships between an end device and host software.
FIG. 11 is a flow chart showing logic for transmitting data using an ACK/NAK protocol over a wireless data link.
FIG. 12 is a flow chart illustrating operation of a host-based Bluetooth manager.
FIG. 13 is a flow diagram illustrating various states for a host system.
FIG. 14 is a flow diagram illustrating various states for a host system that may go to sleep at intervals.
FIG. 15 is a block diagram illustrating interrelationships between various levels of host software.
FIG. 16 is a flow chart illustrating the program progression of a bar code scanner.
DETAILED DESCRIPTION
Many aspects according to the invention relate to portable electronic devices in general. Other aspects may relate more specifically to portable data collection devices. Several forms of portable data collection devices are in widespread use, the most familiar likely being portable bar code scanners and portable radio frequency identification (RFID) interrogators. For convenience and clarity, many of the examples in this document are drawn to bar code scanners.
To aid the reader in understanding the exemplary field of data collection as applied to bar code scanning, a review of that technology is offered beginning with FIG. 1 , which shows a block diagram of a bar code scanner 102 . An illuminator 104 creates a first beam of light 106 . A scanner 108 deflects the first beam of light across a field-of-view (FOV) to produce a second scanned beam of light 110 . Taken together, the illuminator 104 and scanner 108 comprise a variable illuminator 109 . Instantaneous positions of scanned beam of light 110 may be designated as 110 a , 110 b , etc. The scanned beam of light 110 sequentially illuminates spots 112 in the FOV. Spots 112 a and 112 b in the FOV are illuminated by the scanned beam 110 at positions 110 a and 110 b , respectively. While the beam 100 illuminates the spots, a portion of the illuminating light beam 100 is reflected according to the properties of the object or material at the spots to produce scattering or reflecting the light energy. A portion of the scattered light energy travels to one or more detectors 116 that receive the light and produce electrical signals corresponding to the amount of light energy received. The electrical signals drive a controller 118 that builds up a digital representation and transmits it for further processing, decoding, archiving, printing, display, or other treatment or use via interface 120 .
According to one aspect of the invention, the light source 104 may include multiple emitters such as, for instance, light emitting diodes (LEDs), lasers, thermal sources, arc sources, fluorescent sources, gas discharge sources, or other types of illuminators. In one embodiment, illuminator 104 comprises a red laser diode having a wavelength of approximately 635 to 670 nanometers (nm). In another embodiment, illuminator 104 comprises three lasers; a red diode laser, a green diode-pumped solid state (DPSS) laser, and a blue DPSS laser at approximately 635 nm, 532 nm, and 473 nm, respectively. While laser diodes may be directly modulated, DPSS lasers generally require external modulation such as an acousto-optic modulator (AOM) for instance. In the case where an external modulator is used, it is typically considered part of light source 104 . Light source 104 may include, in the case of multiple emitters, beam combining optics to combine some or all of the emitters into a single beam. Light source 104 may also include beam-shaping optics such as one or more collimating lenses and/or apertures. Additionally, while the wavelengths descried in the previous embodiments have been in the optically visible range, other wavelengths may be within the scope of the invention.
Light beam 106 , while illustrated as a single beam, may comprise a plurality of beams converging on a single scanner 108 or onto separate scanners 108 .
Scanner 108 may be formed using many known technologies such as, for instance, a rotating mirrored polygon, a mirror on a voice-coil as is used in miniature bar code scanners such as used in the Symbol Technologies SE 900 scan engine, a mirror affixed to a high speed motor or a mirror on a bimorph beam as described in U.S. Pat. No. 4,387,297 entitled PORTABLE LASER SCANNING SYSTEM AND SCANNING METHODS, an in-line or “axial” gyrating, or “axial” scan element such as is described by U.S. Pat. No. 6,390,370 entitled LIGHT BEAM SCANNING PEN, SCAN MODULE FOR THE DEVICE AND METHOD OF UTILIZATION, a non-powered scanning assembly such as is described in U.S. patent application Ser. No. 10/007,784, SCANNER AND METHOD FOR SWEEPING A BEAM ACROSS A TARGET, commonly assigned herewith, a MEMS scanner, or other type. All of the patents and applications referenced in this paragraph are hereby incorporated by reference
A MEMS scanner may be of a type described in U.S. Pat. No. 6,140,979, entitled SCANNED DISPLAY WITH PINCH, TIMING, AND DISTORTION CORRECTION; U.S. Pat. No. 6,245,590, entitled FREQUENCY TUNABLE RESONANT SCANNER AND METHOD OF MAKING; U.S. Pat. No. 6,285,489, entitled FREQUENCY TUNABLE RESONANT SCANNER WITH AUXILIARY ARMS; U.S. Pat. No. 6,331,909, entitled FREQUENCY TUNABLE RESONANT SCANNER; U.S. Pat. No. 6,362,912, entitled SCANNED IMAGING APPARATUS WITH SWITCHED FEEDS; U.S. Pat. No. 6,384,406, entitled ACTIVE TUNING OF A TORSIONAL RESONANT STRUCTURE; U.S. Pat. No. 6,433,907, entitled SCANNED DISPLAY WITH PLURALITY OF SCANNING ASSEMBLIES; U.S. Pat. No. 6,512,622, entitled ACTIVE TUNING OF A TORSIONAL RESONANT STRUCTURE; U.S. Pat. No. 6,515,278, entitled FREQUENCY TUNABLE RESONANT SCANNER AND METHOD OF MAKING; U.S. Pat. No. 6,515,781, entitled SCANNED IMAGING APPARATUS WITH SWITCHED FEEDS; and/or U.S. Pat. No. 6,525,310, entitled FREQUENCY TUNABLE RESONANT SCANNER; for example; all commonly assigned herewith and all hereby incorporated by reference.
Alternatively, illuminator 104 , scanner 108 , and/or detector 116 may comprise an integrated beam scanning assembly as is described in U.S. Pat. No. 5,714,750, BAR CODE SCANNING AND READING APPARATUS AND DIFFRACTIVE LIGHT COLLECTION DEVICE SUITABLE FOR USE THEREIN which is incorporated herein by reference.
In the case of a one-dimensional (1D) scanner, the scanner is driven to scan output beams 110 along a single axis. In the case of a two-dimensional (2D) raster scanner or scanned-beam imager, scanner 108 is driven to scan output beams 110 along a plurality of axes so as to sequentially illuminate a 2D FOV 111. 2D raster scanners generally output a series of vertically spaced-apart scan lines while 2D imagers output a large enough number of scan lines to illuminate substantially the entire FOV with vertical spacing between scan lines approximately equal to horizontal spacing between pixels (although 2D scanned beam imagers need not pixelate on the horizontal axis). The alignment of the fast scan axis horizontally and the slow scan axis vertically may be reversed or otherwise altered according to application needs or designer preferences.
For the case of 2D imaging, a MEMS scanner is often preferred, owing to the high frequency, durability, repeatability, and/or energy efficiency of such devices. A bulk micro-machined or surface micro-machined silicon MEMS scanner may be preferred for some applications depending upon the particular performance, environment or configuration. Other embodiments may be preferred for other applications.
A 2D MEMS scanner 108 scans one or more light beams at high speed in a pattern that covers an entire 2D FOV or a selected region of a 2D FOV within a frame period. A typical frame rate may be 60 Hz, for example. Often, it is advantageous to run one or both scan axes resonantly. In one embodiment, one axis is run resonantly at about 19 KHz while the other axis is run non-resonantly in a sawtooth pattern to create a progressive scan pattern. A progressively scanned bi-directional approach with a single beam, scanning horizontally at scan frequency of approximately 19 KHz and scanning vertically in sawtooth pattern at 60 Hz can approximate an SVGA resolution. In one such system, the horizontal scan motion is driven electrostatically and the vertical scan motion is driven magnetically. Alternatively, both the horizontal scan may be driven magnetically or capacitively. Electrostatic driving may include electrostatic plates, comb drives or similar approaches. In various embodiments, both axes may be driven sinusoidally or resonantly.
Several types of detectors may be appropriate, depending upon the application or configuration. For example, in one embodiment, the detector may include a PIN photodiode connected to an amplifier and digitizer. In this configuration, beam position information is retrieved from the scanner or, alternatively, from optical mechanisms, and image resolution is determined by the size and shape of scanning spot 112 . In the case of multi-color imaging, the detector 116 may comprise more sophisticated splitting and filtering to separate the scattered light into its component parts prior to detection. As alternatives to PIN photodiodes, avalanche photodiodes (APDs) or photomultiplier tubes (PMTs) may be preferred for certain applications, particularly low light applications.
In various approaches, photodetectors such as PIN photodiodes, APDs, and PMTs may be arranged to stare at the entire FOV, stare at a portion of the FOV, collect light retro-collectively, or collect light confocally, depending upon the application. In some embodiments, the photodetector 116 collects light through filters to eliminate much of the ambient light.
The device may be embodied as monochrome, as full-color, and even as a hyper-spectral. In some embodiments, it may also be desirable to add color channels between the conventional RGB channels used for many color cameras. Herein, the term grayscale and related discussion shall be understood to refer to each of these embodiments as well as other methods or applications within the scope of the invention. In the control apparatus and methods described below, pixel gray levels may comprise a single value in the case of a monochrome system, or may comprise an RGB triad or greater in the case of color or hyperspectral systems. Control may be applied individually to the output power of particular channels (for instance red, green, and blue channels) or may be applied universally to all channels, for instance as luminance modulation.
Frequently, modern designs of bar code scanners use a modular approach such as that shown in the block diagram of FIG. 2 . Analog output scan engine 202 comprises a laser scanner 104 that produces a beam 106 . Beam 106 impinges on scan mirror 108 , which forms scan beam 110 . Scan beam 110 scans back and forth across the field of view 112 . Spots are illuminated by scanning beam 110 produce scattered light 200 , a portion of which returns to scanner 108 as scattered signal 100 . In some scan engines the return light is de-scanned by the scanner and focused upon the detector 116 . In the example of FIG. 2 , scattered signal 100 is reflected by scan mirror 108 , onto gathering mirror 206 , and then onto detector 116 .
Electrical circuit 212 creates an output signal 214 from weak signals 210 typically produced by a detector 116 . In some embodiments, electrical circuit 212 may be integrated into detector 116 . The output signal 214 may be analog or digital. To make a digital signal, electrical circuit 212 may include an analog-to-digital converter.
While a retro-collective schema is shown in FIG. 2 , other arrangements including staring detection and confocal detection may be desirable for some embodiments.
The assembly comprising laser diode 104 , scan mirror 108 , gathering mirror 106 , detector 116 , and electrical circuit 212 may be packaged inside a chassis 202 . Outgoing scan beam 110 and return signal 100 may pass through a front window 208 . Frequently, window 208 is made of a filter material that passes light at the wavelength of the laser diode 104 and attenuates light at different wavelengths. This helps to reject ambient light and improve the signal-to-noise ratio at detector 116 .
Detector 116 outputs a raw analog signal 210 , which may or may not be exposed, depending upon whether or not electrical circuit 212 is integrated into detector 116 . Electrical circuit 212 may include an amplifier and, optionally, may also include analog to digital converter. Electrical circuit 212 outputs signal 214 , which may be either analog or digital according to the preference of the designer. Signal 214 is fed to decoder 216 , which decodes the image of the indicia into a character string. For the case of a linear bar code scanner and a linear or 2D stacked symbol, the information is decoded from the widths of the bars and spaces of the symbol. For the case of a 2D imager and a 2D matrix symbol, the information is decoded from the sense (mark or absence of mark) in the matrix positions of the symbol. OCR, laser card, mark-sense forms, and other forms of printed or marked indicia have their own decode algorithms that may be applied by decoder 216 .
Scan engine 202 represents one type of data collection engine that may be used in a hand-held or other device. It is anticipated that data collection engine 202 could be either linear scanning or 2D scanning, including a 2D imaging scanner. Alternatively, data collection engine 202 could be another type of data collection engine, including but not limited to a radio frequency interrogator, a CCD or CMOS imager, a microphone or other audio pick-up, a magnetic stripe reader, a MICR reader, or other device.
In some embodiments scan engine or data collection engine 202 may be combined with decoder 216 into an assembly 218 . In many cases, assembly 218 is also referred to as a scan engine or data collection engine. The terms of art may be differentiated by reference to assembly 202 as an undecoded scan engine (or data collection engine) and assembly 218 as a decoded scan engine (or data collection engine).
Decoder 216 outputs decoded signal 220 , which is received by microcontroller 118 . In addition to receiving the decoded signal, microcontroller 118 also controls the functions of the data collection engine including those of the light source 104 , the scanner 108 , detector 116 , electrical circuit 212 , and decoder 216 . The functions controlled by microcontroller 118 may range from as simple as turning on the components to more sophisticated functions such as establishing operational parameters, fault monitoring, etc.
In some applications it may be advantageous to combine decoder 216 into microcontroller 118 . In those cases microcontroller 118 may receive output line 214 directly from electrical circuit 212 .
It may be convenient to control the actions of microcontroller 118 with a trigger 222 . When trigger 222 is pulled, microcontroller 118 energizes the data collection engine. For the example of FIG. 2 , this may include energizing the laser diode 104 , scan mirror 108 , detector 116 , electrical circuit 212 , and decoder 216 . As an alternative to microcontroller 118 directly controlling the activities of all components of data capture engine 202 or 218 , the image capture engine itself may contain a microcontroller that performs functions otherwise associated with microcontroller 118 .
As an alternative to triggered operation, the device may be automatically triggered, such as by a low power detection mode, a photocell, a proximity sensor, or other methods known to the art.
It is also possible to trigger the device through the main or auxiliary interface. For example, a Bluetooth trigger, proximity sensor, photocell, etc. could transmit the trigger signal via a Bluetooth interface.
When a good decode is made, indication may be made on indicator 224 , which may include a display, one or more LEDs, a beeper, and/or other means to notify the user that a decode has been made. After decoding, microcontroller 118 may transmit the decoded message to host computer via interface 120 . Alternatively, microcontroller 118 may include memory to store decoded symbols, doing so preferentially or when communication cannot be established with a host computer. In that case it may be advantageous to accumulate a number of scans in memory, for instance as the user moves through a warehouse, manufacturing floor, or other facility, and then later upload the decoded symbols as a batch through interface 120 . When the memory accumulates multiple decodes and then later uploads the data through an interface, it may be referred to interchangeably as batch mode or store-and-forward mode.
For convenience, data collection engine 202 or decoded data collection engine 218 may be shown in block diagram form such as is indicated in FIG. 3 . Microcontroller 118 may be connected to data collection engine 202 or 218 via a bus 302 . Here and elsewhere, objects 202 and 218 may be referred to interchangeably as a scan engine or a data collection engine. As described earlier, a primary difference between a scan engine 218 and scan engine 202 is that scan engine 218 includes the components of scan engine 202 plus a decoder 216 . Button 222 may comprise a trigger, a button, an emitter/detector apparatus, or other feature for instructing the data collection device 102 to collect data. Indicator 224 may be used to notify the user of a good decode and other functions. Decoded symbols may be passed to host system via interface 120 . A battery, fuel cell, or other power source 304 may be used to power the data collection device 102 when the system is not connected to host computer.
Microcontroller 118 may include memory 306 . Alternatively, memory may be embodied as a separate device on bus 302 . The memory is preferably nonvolatile, although in some applications a volatile memory may be used.
FIG. 4 is a block diagram of an alternative embodiment of data collection apparatus 102 that includes an auxiliary interface 404 . Microcontroller 118 is connected to scan engine 202 , button 222 , indicator 224 and interface 120 as shown in earlier figures. Interface 120 may be used to communicate either directly to a host computer via data communication line 402 , or alternatively may communicate with auxiliary interface 404 . Auxiliary interface 404 may include any of several interfaces. These may include various radio modules, alternative wired interfaces, infrared interfaces, or other interfaces for communicating with an attached or remote host.
A portable hand held bar code scanner may have a physical embodiment such as that of FIG. 5A . Scanner 102 includes a body 502 which may be hand held. A button 222 is placed at a location accessible to the user. Front window 208 protects the mechanism inside body 502 from exterior forces such as dust, shock, heat, and other insults, while allowing for the passage of light at the wavelength emitted by the laser diode. An indicator LED 224 is mounted on the top of body 502 front of button 222 , were may be easily seen by the user. A battery door 504 covers a compartment that may contain one or more batteries to power the scanner 102 . Not visible in FIG. 5A is physical interface port 506 on the back of the scanner. While in principle many different connectors could be used, the scanner of FIG. 5A uses a stereo jack variant of a serial interface to couple to a host computer.
FIG. 5B is an isometric view of the bottom of a bar code scanner 102 .
Body 502 includes a window 208 in its front surface. Battery door 504 is shown in an exploded position above battery compartment 508 . Battery compartment 508 may receive AAA batteries for example. Auxiliary interface communication apertures 510 a and 510 b B are shown at the back of body 502 . Apertures 510 a and 510 b , which may be left open for easy exposure to the circuit boards, are covered by battery door 504 when the door is in place. Auxiliary interface connector 512 may be inserted through auxiliary interface communication apertures 510 a and 510 b to couple to corresponding connectors on the printed circuit board inside. Auxiliary interface connector 512 may include a plurality of electrical contacts 514 on its top surface to facilitate communication with an auxiliary interface inside battery compartment 508 (auxiliary interface not shown). In some embodiments, auxiliary interface connector 512 may be deleted from the base scanner and be included on the bill-of-materials of an auxiliary interface accessory product. This has an advantage of reducing the cost of the base unit.
FIG. 5C shows the inside of battery door 504 with an auxiliary interface 404 installed. Auxiliary interface 404 has a plurality of spring contacts 514 for making physical contact with the pads 514 of interface connector 512 when the battery door is slid onto the scanner.
The placement of an auxiliary interface 404 in the battery door facilitates easy field installation and removal by the user. The user may purchase a scanner having no auxiliary interface, and then later purchase an auxiliary interface kit for installation on the existing scanner. An auxiliary interface kit may include, for example, the battery door of FIG. 5C having a radio module installed and an auxiliary interface connector 512 of FIG. 5B . Battery door 504 with auxiliary interface board 404 may be referred to as an auxiliary interface 516 .
Several auxiliary interfaces may be offered for use with a base scanner product. The particular auxiliary interface depicted in FIG. 5C is a Bluetooth radio interface. Alternatively, other interfaces and/or auxiliary input/output modules may be offered including alternative wired interfaces, alternative radio interfaces, auxiliary memory, an auxiliary display, an auxiliary keypad, etc.
FIG. 6 is a block diagram showing a scanner 102 and host computer 602 in radio communication with one another. Scanner 102 is packaged in a body 502 having a button 222 and an indicator LED 224 a on its upper surface. The button and indicator are placed for easy access by user. Additionally, the scanner of FIG. 6 is equipped with a second indicator device, a beeper 224 b . Button 222 and indicator 224 are in communication with the microcontroller 118 . Microcontroller 118 in turn communicates with scan engine 202 , which is optical communication with the field of view (not shown) via a scan window 208 . Microcontroller 118 is further in communication with an interface 120 . Interface 120 communicates with the external portion of body 502 via physical jack 506 , which may for instance, comprise a stereo jack.
An auxiliary interface 404 , which may for instance be a Bluetooth module having an antenna 604 , may be permanently or removeably coupled to interface line 605 . Bluetooth module 404 may be in communication with host computer 602 via radio waves 606 . Radio waves 606 may be physically transmitted and received by scanner antenna 604 and host antenna 608 . Host antenna 608 may be part of a host Bluetooth module 610 . Host Bluetooth module 610 may be integrated into host 602 or alternatively may comprise an external adapter or dongle.
The scanner embodiment 102 of FIG. 6 may be uncoupled and used in a batch mode or may be temporarily, permanently, or semi-permanently coupled to an interface cable (not shown).
FIG. 7 is a block diagram showing an application having a plurality of scanners 102 in wireless communication with a plurality of host computers 602 . In this example, scanner 102 a is in communication with host computer 602 a . Bar code scanner 102 b is in communication with host computer 602 b . Host computer 602 a and 602 b may in turn be in communication with a network 702 . Network 702 may comprise a radio network, a local area network, a wide area network including the Internet, or other network.
In a system such as that of FIG. 7 , it may be desirable for end devices 102 to send their data to their assigned host 602 , and not have their data intercepted or improperly received by the wrong host. In the case of Bluetooth and other network standards, various conventions are used to ensure appropriate pairing between end devices 102 and individual hosts 602 . Such pairings may comprise one-to-one, many-to-one, or one-to-many connectivity.
Bluetooth standards may use an assigned identification number, commonly called a PIN, to identify a particular pairing. In some applications, and particularly in applications where there is a chance of encountering another connection with the same PIN, it may be desirable to define a stronger pairing than a PIN-based pairing. For such applications, a longer and/or more specific pairing identifier may be desirable. One example of a stronger identifier is the host Bluetooth device number, commonly referred to as a BD number. Thus, for stronger pairing, the host and end device may use a strong identifier such as the host BD number.
While the host computers 602 shown in FIG. 7 are depicted as desktop computers, other types of host computing devices may be interchanged. For example, wireless PDAs may be used to provide mobile computing capabilities. The PDAs may serve as a host to the end devices 102 , while themselves operating as clients to other remote hosts. In this sense, the term “host” is not necessarily limited to a computer that is itself performing computing, but rather refers to a relationship in the communication schema. In Bluetooth systems, a host 602 may be a “master” end of the link and an end device 102 a “slave” end of the link. In alternative architectures, the devices may be in the form of a peer-to-peer, client-server, or other logical relationship.
FIG. 8 is a flowchart showing logic for selecting a communication mode in a device having a plurality of communication modes. In decision step 802 , it is determined whether or not a cable is connected to the interface port. If the cable is connected, the routine proceeds to procedure 804 and data from the scanner is transmitted to the host via the cable. After executing data communication step 804 , the program returns to other tasks.
If, in decision box 802 it is decided that a cable is not connected, the program proceeds to decision box 806 . In decision box 806 , it is determined whether or not an auxiliary interface is present. An exemplary auxiliary interface is one such as the end device module 404 shown in FIGS. 4 , 5 c , and 6 . As discussed above, a Bluetooth radio module is one example of an auxiliary interface 404 .
If decision box 806 determines that no auxiliary interface is present, the program proceeds to procedure 808 where the data is stored in memory. After executing step 808 , the program returns to other tasks.
If decision box 806 determines that an auxiliary interface is present, the program proceeds to decision box 810 . Decision box 810 determines whether a data link is ready to accept data communication. A data link may, for example, comprise a memory card that has capacity, a display that is turned on, a wireless interface that has a connection with the host, or other means for transmitting, storing, displaying, or otherwise processing data. Some interfaces such as radio interfaces may have power saving modes where the data link is not kept active when no data is being transmitted. Examples of power saving states will be discussed in conjunction with FIG. 9 . For auxiliary interfaces having such power saving states, decision step 810 may involve the auxiliary interface powering up and testing or attempting to reestablish communication with the host.
If the data link is ready, the program proceeds to step 812 where the data is transmitted to the auxiliary interface. If the auxiliary interface is a link to a host computer, the auxiliary interface then transmits the data to the host computer. The program may then proceed to optional transmission validation procedure 814 . As will be described elsewhere, several levels of transmission validation are available depending upon user or administrator preference. If the transmission is validated, the program returns to other tasks. If the transmission is not validated, a transmission validation sequence may be enabled. A transmission validation sequence may comprise one or more retries, an ACK/NAK algorithm, a message sequencing algorithm, and/or other processes. If, after executing transmission validation, it is found that the transmission cannot be validated, the program may proceed to step 808 where the message is stored in memory.
In some embodiments, step 808 may not involve actually storing data in memory, but rather not deleting data already stored in memory. In some implementations, the data may be saved in memory until a command is received to delete the data from memory. Such a command may, for example, be issued by the microcontroller after receipt of an ACK from the host, may be issued after an acknowledgement by the auxiliary interface, may be issued by the user as a command to delete the display, or may be issued upon other appropriate conditions. As an alternative to the deletion command being issued by the microcontroller, such a command may be issued by the auxiliary interface itself or by the host computer.
If it is determined in decision box 810 that the data link is not ready, the program proceeds to decision box 816 . Decision box 816 determines whether the user has enabled a transmission retry. The transmission retry is not enabled, the program proceeds to process 808 and the data is stored in memory. After storing the data, the program returns to other tasks. If decision box 816 determines that retry is enabled, the program proceeds to procedure 818 in the retry routine is executed.
An example retry routine is described in conjunction with FIG. 9 . As an alternative to separate decision steps 810 and 816 and procedure 181 , retry may be enabled as part of a sequence executed elsewhere such as in optional transmission validation procedure 814 .
The procedure of FIG. 8 ensures that a scanner will respond first to a physical connection made via its input port. This maintains such a physical connection as the highest priority connection. The physical connection may be used for a variety of purposes including programming the auxiliary interface. Alternatively, the user may change the default setting such that decision box 802 is executed at the end of the flow chart, resulting in the end device trying alternative interfaces prior to trying the wired interface. In another alternative, the cable connection may be disabled altogether and the unit forced to communicate via an auxiliary interface.
As described above, an auxiliary interface may comprise a real-time interface to a remote host, or alternatively may comprise and auxiliary memory, a display, voice synthesis, or other local auxiliary interface that does not immediately communicate with a host.
FIG. 9 is a flow diagram showing various operational states for an auxiliary interface comprising a Bluetooth radio. A similar flow diagram may be applied to other types of auxiliary interface. An INITIAL STATE 902 may exist in a new unit issued from the factory or when the unit has not been paired in DISCOVERABLE MODE 1 after predetermined period of time (including after an un-pair command has been issued).
DISCOVERABLE MODE 1 904 is the mode used when the unit has not been paired or when its pairing has been canceled. DISCOVERABLE MODE 1 may be entered from INITIAL STATE 902 by pressing the scan button 222 . In DISCOVERABLE MODE 1 , the Bluetooth radio 404 listens for an inquiry from a host computer. If the inquiry is not heard for a period of time T listen , the radio returns to INITIAL STATE 902 . In some embodiments, the default time for T listen may be five minutes, for example. If the radio receives a host inquiry while in DISCOVERABLE MODE 1 , it may pair with that host.
The link may be identified by a PIN issued by the host. A PIN may be used for standard strength pairing. For some applications, it may be preferable to have a stronger pairing between host and end device. For example, in environments with many active links, the standard strength pairing offered by PIN-based identification may be susceptible to interception or mis-pairing. This may be ameliorated by use of a more unique pairing identifier such as a very long PIN or a hardware-specific identifier. Thus, as an alternative or addition to standard strength pairing, the end device may receive the host Bluetooth Device address, or BD address, which may be used to ensure stronger pairing with a given host. Alternatively, the end device BD address, some other specific hardware identifier, or a user-assigned long PIN may be used to strongly identify the link.
After making connection with a host in DISCOVERABLE MODE 1 904 the program moves to ACTIVE MODE 906 with the host. During ACTIVE MODE, data may be transmitted to and received from the host. After data is sent and received in ACTIVE MODE 906 , the Bluetooth module negotiates lower power with the host and moves to SNIFF MODE 908 . During SNIFF MODE, which conserves battery power, a minimal ping rate is maintained to ensure a continuous data link. If additional data is received from the scanner, the Bluetooth module moves from SNIFF MODE 908 back to ACTIVE MODE 906 , and transmits the data. The Bluetooth module may also move from SNIFF MODE 908 to ACTIVE MODE 906 if the host indicates it has data to transmit to the scanner. After the data is received or transmitted, lower power is again negotiated with the host and the unit moves back into SNIFF MODE 908 .
To further conserve battery power, the Bluetooth module may be set to move from SNIFF MODE 908 to SLEEP MODE 910 after a period of time T connect . In some embodiments, the default period for T connect is five minutes, a value that may be changed by the user or an administrator. In SLEEP MODE 910 the electronic device (e.g. scanner, PDA, imager, telephone, etc.) disconnects power to the Bluetooth module. In SLEEP MODE, the data link to the host is lost, and must therefore be re-established to enable communication. Pressing the button on the scanner causes the program to proceed from SLEEP MODE 910 to DISCOVERABLE MODE 2 912 . In DISCOVERABLE MODE 2 , the Bluetooth module listens for a host inquiry. Because it has been associated or paired with a particular host, the Bluetooth module listens for an inquiry only from that particular host, ignoring inquiries from other possible hosts. If an inquiry is received from the paired host while in DISCOVERABLE MODE 2 912 , a connection is made and the system reenters ACTIVE MODE 906 , transmits data received from the scanner, negotiates lower power with a host and moves back into SNIFF MODE 908 . The program then either reenters SLEEP MODE 910 after a period T connect or reenters ACTIVE MODE 906 if more data is received from the scanner or the host attempts to send data.
The period that the Bluetooth unit will remain in DISCOVERABLE MODE 2 912 while not receiving a ping from its paired host is referred to as T limit . In some embodiments, the default value for T limit is one minute, although T limit may be changed by the user or an administrator.
A retry routine may be enabled for the case when the scanner holds data to be transmitted but the data link to its host computer cannot be established. A period T sleep may be set to retry data transmission. If T sleep is set to 0, retry mode is disabled and the Bluetooth module will not attempt to reconnect with a host until another button press is received from the scanner. If T sleep is set to another value, the scanner will look for data to be sent and, if appropriate, wake the Bluetooth module to attempt reestablishing a data link. This procedure is shown as decision box 914 and associated arrow. After T sleep , the program enters decision box 914 where the microcontroller examines whether or not there is data waiting to be sent to the host computer. If there is not data waiting to be sent to host computer, T sleep is reset and the Bluetooth module is not awakened. If decision box 914 determines that there is data waiting to be sent to the host computer, the Bluetooth module is awakened and the program reenters DISCOVERABLE MODE 2 912 and attempts to make a pairing with its host.
In some applications, the default time for T sleep is 60 minutes. Thus, while the scanner holds data intended for the host, the Bluetooth module will wake up every 60 minutes, reenter DISCOVERABLE MODE 2 , and attempt to make connection with its host computer.
Operation of the Bluetooth interface may be optimized for various use environments by adjusting the parameters T listen , T connect , T sleep , and T limit . These parameters, their default values, and some modified values for exemplary environments are given in the table below:
Parameter
T listen
T connect
T sleep
T limit
Definition
Period waiting to
Period
Interval
Period waiting to
be discovered by
staying in
between
be discovered by
any host in
SNIFF
entering
paired host in
DISCOVERABLE
MODE
SLEEP
DISCOVERABLE
MODE 1
before going
MODE and
MODE 2
to sleep
attempting to
reconnect (if
data)
Default Value
5 minutes
5 minutes
60 minutes
1 minute
PDA Host
0
0.2 minute
Warehouse/
2 minutes
0.5 minute
Desktop Host
Supermarket
0
240 minutes
The default values provide reasonably good performance for a wide variety of use environments. As discussed below, longer or shorter periods may be appropriate depending upon the configuration and environment. For example, longer periods for T connect and T limit , may yield better responsiveness in exchange for decreased battery life.
Alternatively, different timer values may be appropriate for various application environments. For example, a PDA may be used as a portable host for the end device 102 . In that case, it may be assumed that the PDA and end device are always within radio range of one another. Thus, if a connection is dropped, it may not be because the end device has wandered out of range, but rather because the PDA went into its sleep mode to conserve battery power. In this case, it would be inadvisable for the end device to automatically wake periodically and attempt to reconnect. Similarly, it may be expected that the radio link, when up, is relatively strong and therefore it should not take very long to be discovered by the PDA in DISCOVERABLE MODE 2 . Thus, as may be seen from the table, it may be appropriate to set T sleep to 0 (causing no automatic attempts at reconnection) and to set T limit to a low value such as 0.2 minute. To attempt to reconnect with these settings, the user would wake the PDA, start the PDA Bluetooth search routine, and push the button on the end device. Any unsent data would then be sent to the PDA after the manual reconnection. In some applications, the PDA Bluetooth link may be set to automatically attempt to link on start-up so the user would simply wake the PDA and push the button on the end device.
For other applications it may be preferable to use other timer values. For example, in a warehouse environment with a host computer that is not programmed to go to sleep, it may be preferable to set T sleep to a relatively short interval, such as 2 minutes, and set T limit to a correspondingly short time such as 0.5 minute. Such settings would anticipate the end device being moved in and out of radio range, while providing reasonably timely transmissions of data that had been collected while out of range, owing to the short sleep periods.
For an application requiring rapid response, such as a grocery checkout counter for example, it may be advantageous to keep the end device in SNIFF MODE for long periods, even during inactivity. Because the latency in moving from SNIFF MODE to ACTIVE MODE is very short compared to the latency of moving first to DISCOVERABLE MODE 2 and then into ACTIVE MODE, such a setting could help ensure immediate availability for processing customer transactions. An example of such a setting would be to set T connect to a long duration such as 240 minutes.
The examples above show a conceptual framework for setting the timer settings for variations on these applications and other applications.
The scanner and its Bluetooth module may be un-paired from its host by a long button press. For example, if the user presses the button 222 for 10 seconds or more, the scanner interprets that as a command to un-pair. After receiving the un-pair command the program enters un-pair mode 916 , where the host identification is reset. In the case of standard strength pairing, the PIN is reset to 0000. In the case of strong pairing, the host BD address may be discarded.
A list of multiple eligible hosts may be maintained in the end device. When multiple hosts are listed, the end device may pair with any one of such eligible hosts that sends an inquiry while the end device is in DISCOVERABLE MODE 2 . Such a list of multiple eligible hosts allows a roaming end device to establish successive pairings as it moves through the radio ranges of the multiple hosts. While operating in a point-to-point mode at any one time, such a schema provides the user with functionality akin to a multi-point network architecture.
For facilities where pairing with any host is an acceptable host, the end device may include wildcard characters in its list of eligible hosts. Alternatively, the device may be set to always return to DISCOVERABLE MODE 1 after breaking contact with a particular host.
During movement between the states of FIG. 9 , the indicator 224 may show the various states to the user. In discoverable modes 904 and 912 , the LED gives two short blanks every two seconds. When the scanner is connected and in range, as in sniff mode 908 , the LED gives one short blink every two seconds. This arrangement of only a single blink when in sniff mode 908 helps to conserve power, since this mode may be entered more often than are discoverable mode 904 and 912 . When data is being transmitted or received, and unit is in active mode 906 , the (LED) indicator 224 blinks at 2 hertz.
Additionally, the indicator 224 may be set to indicate when a portable data carrier has been decoded properly, and/or when the host application has received and acknowledged the decoded data. Additionally, error conditions, such as an improper data type being scanned may be flagged to the user by issuing error blinks, beeps or other indications.
The end device Bluetooth module 404 may be initially paired with a host computer by entering DISCOVERABLE MODE 1 904 , receiving a radio query from and pairing to the host as described above, or alternatively may receive host pairing information via a wired interface such as interface 120 (and physical connection 506 ). Wireless pairing may be accomplished by the user momentarily pressing the button on the scanner in the vicinity of the computer with which he wants to pair. The momentary button press acts as a command to move from INITIAL STATE 902 to DISCOVERABLE MODE 1 904 . If the end device had previously been paired with a different host computer, an alternative input may be used to issue an un-pair command, moving the program from DISCOVERABLE MODE 2 912 to UN-PAIR MODE 916 , and from there to DISCOVERABLE MODE 1 904 . In some embodiments such an alternative input may comprise a longer duration button press (acting as a “one-click” disconnect), a double button press, the scanning of a disconnect-from-host symbol, or other input means available at the end device. In some preferred embodiments according to the invention, a button press of approximately ten seconds duration comprises the command to un-pair.
Upon receiving a local un-pair command, the LED and beeper, which together may comprise indicator 224 , may give feedback to the user that the un-pair command has been received and/or executed. In some applications, the administrator may wish to disable the local un-pair and/or local pair commands. For those applications, the end device can issue a different response, indicating the command was not executed. For example, a brisk double beep and concurrent double LED blink may indicate pairing has been accomplished. A high-low beep and brief flashing LED blink may indicate un-pairing. A triple beep and triple LED blink may indicate the command was not executed.
For cases where the administrator wishes to have more control over pairing and un-pairing, for cases having multiple Bluetooth hosts potentially querying for end devices within radio range, and for other cases, it may be preferable to establish pairing and/or un-pairing via a non-radio link. For such cases, the scanner and Bluetooth module may receive host information over a cable connection. Receiving host information over cable connection can help prevent the possibility of pairing with the wrong host when several hosts are present in the environment.
In alternative embodiments, the scanner may be placed in a shielded area, such as a Faraday cage for example, in communication with its desired host computer, thus preventing pairing with unwanted hosts.
Various integrity levels are available for ensuring data transfer to the host computer. Level 1 implements no data integrity and therefore the connection is not guaranteed. Level 2 uses an application level ACK/NAK between the scanner and an application to guarantee no data is lost. Under Level 2 integrity, it is possible that a data transmission could be duplicated. This can happen if the radio connection goes down after the host receives the transmission and before the end device receives an ACK. In this case, the end device will attempt to resend the data to the host when the radio connection is resumed, resulting in duplicate data at the host.
Level 3 uses the application level ACK/NAK and packet serialization to guarantee the data will be neither duplicated nor lost.
FIG. 10 is a flow diagram illustrating the relationship between the end device 102 with Bluetooth interface 404 , an optional host-based Bluetooth manager program 1002 , and a host application 1004 . The host application 1004 may, for example, be a software wedge program or custom application. As described above, Level 1 uses no data integrity means and therefore does not guarantee transmission between the end device 102 and the Bluetooth manager 1002 or the host application 1004 .
Level 2 uses an ACK/NAK protocol between the scanner 102 and host application 1004 . Level 2 may be convenient, for example, when a hardware dongle is used in the host computer and host application is set up to communicate via (what it thinks is) a serial port. In this case the application sets its port to ACK/NAK protocol and receives data in the normal way, as if the scanner were cabled to the computer.
Under ACK/NAK protocol, the scanner 102 waits for a response from the host application prior to taking action with the data being transmitted. For example if the end device 102 receives an ACK, it means that the host application has received the data. The data is erased from end device memory after receiving an ACK. If, on the other hand, the scanner receives a NAK, it recognizes that the host application has not received the data and the data is retained in memory until a successful transmission occurs. If the end device 102 receives no response from the host, it treats the event as a NAK and attempts to resend a predetermined number of times. In addition, the Bluetooth interface 404 goes through its reconnection and/or retry routine.
When data integrity level 3 is selected, the system uses both an ACK/NAK protocol and a transmission sequence protocol. The scanner 102 transmits its data (via the Bluetooth radios in the end device and host) to the Bluetooth manager 1002 with an attached sequence number. The Bluetooth manager 1002 compares the received sequence number with the previously received sequence number. If the sequence number does not match the previous sequence number, the Bluetooth manager sends the data to the application 1004 . The Bluetooth manager then replaces the previous sequence number with the new sequence number and repeats the process for the next received message.
Alternatively, the Bluetooth manager 1002 can buffer a plurality of received sequence numbers and search its buffer for a duplicate number. If the sequence number does not match a previously received number in the Bluetooth manager 1002 buffer, the Bluetooth manager sends the data to the application 1004 .
The application, upon receiving the message responds with an ACK or NAK, according to its ability to receive data. If able to receive data, the application software 1004 sends an ACK to the Bluetooth manager 1002 , and the Bluetooth manager 1002 relays the ACK back to the end device 102 . If the application software 1004 is not able to receive the data present, it sends a NAK Bluetooth manager 1002 , which in turn relays the NAK back to the end device 102 . In various embodiments, the Bluetooth manager 1002 may then keep the original previous sequence number, delete the transmission sequence number that it had placed in its buffer, or set a flag to indicate the transmission sequence number is still valid. Following receipt of the NAK, the end device attempts to resend the data and the procedure is repeated.
In some embodiments, the Bluetooth manager 1002 may act as a virtual end device, always responding to the real end device with an ACK when it has received the data and then attempting to pass the data on to the host application 1004 , acting as a proxy for the end device during transmission, retries, etc.
If, when the Bluetooth manager 1002 searches its buffer for a duplicate number, a duplicate number is found, the Bluetooth manager 1002 sends an ACK to the scanner 102 and deletes the message. Rather than a duplicate message being sent to the host application, the Bluetooth manager 1002 has recognized the message as duplicate and deleted it. Thus, in data integrity level 3 , the end device 102 simply appends a sequence number and attempts to resend the data until it receives an ACK from the host. Because each message is permanently assigned its own sequence number, the Bluetooth manager 1002 will not allow a particular message to be transmitted to and received by the host application twice.
FIG. 11 illustrates an end device algorithm for Level 2 data integrity. After a data collection engine reads a portable data device, and data is decoded (for example after a bar code scan engine scans a bar code symbol and the symbol is decoded), the process enters decision box 806 to determine if the radio is connected. If the radio is not connected, the data is retained memory as shown in step 808 . If decision box 806 determines that the radio is connected, the data is transmitted to the host via the radio in procedure 812 . After sending the data the program proceeds to decision box 1102 , which determines if either level 1 data integrity or level 2 data integrity is enabled, i.e. whether or not ACK/NAK protocol is enabled. If ACK/NAK is not enabled, the program goes to decision box 1004 to determine if the radio is still connected at completion of the transmission. If the radio is still connected, it is assume the data was received. The data is erased from memory and the program proceeds back to procedure box 812 in preparation for the next data. If the radio is not connected at the end of transmission as determine by decision box 1104 , the scanner assumes that the link was lost prior to or during transmission and that the data did not reach the host computer. In this case the program proceeds to procedure 808 , retaining the data in memory and going to sleep.
If in decision box 1102 ACK/NAK is determined to be enabled, the end device waits for brief period (two seconds for example) and then proceeds to decision box 1106 and determines if it has received a response from the host. If the end device receives an ACK, signifying receipt of the data by the host application, the data is erased from memory and the program proceeds back to procedure 812 . If in decision box 1106 it is determined that a NAK was received from the host computer, indicating that the host application did not received the data, the program proceeds directly back to the Send Next Data box 812 without erasing the data. The “next data” in that case is the message that received a NAK, which is subsequently resent and the procedure repeated.
If at decision box 1106 it is determined that there was no response from the host computer, the scanner keeps the data in memory and goes to sleep as indicated by the procedure 808 .
The procedure of FIG. 11 may be repeated until all data in the buffer has been sent. After all data has been sent and there is no additional activity requiring processing, the system may go to an idle state and thereafter go to sleep. Receipt of another button press moves the system from idle or sleep to the start, and the procedure is repeated.
FIG. 12 is a flowchart indicating the logic flow of Bluetooth manager 1002 . Bluetooth manager 1002 starts in idle mode 1202 , generally remaining there until data is received. When data is received, the program proceeds to decision box 1204 where determines where the data is from. If the data is from the host application, Bluetooth manager sends the received data to the end device, as shown in procedure 1206 , receives an acknowledgement from the end device, sends an ACK to the application, and returns to idle mode 1202 . The ACK sent to the application may be a literal relay of an ACK received from the end device or may be generated based on another acknowledgement event such as a low level handshake, for example.
If in decision box 1204 the data is determined to have been received from the end device, the Bluetooth manager examines the transmission sequence number attached to the message and determines whether or not it is different than the last sequence number. This is shown in decision box 1208 . If the sequence number is greater than the last sequence number. The Bluetooth Manager sends the data to the application and, upon receipt of an ACK from the application, sends an ACK back to the end device, as shown in procedures 1210 and 1212 , respectively. After executing procedures 1210 and 1212 , the Bluetooth Manager returns to Idle State 1202 .
Additionally, the end device, auxiliary interface, or other device may packetize the information with a header or other flag that identifies the source and/or nature of the payload. The Bluetooth Manager may then route information in a context-sensitive manner. For example, when a packet is received indicating it is a transmission from the end device auxiliary interface to the associated host interface, the Bluetooth Manager may delete the message (knowing it has already been received by the lower level device) or route it to a device manager. Alternatively, when the header indicates the message contains configuration or other information related to the end device (but not related to application data), the Bluetooth Manger may route the information to an end device configuration manager or may use the information internally as appropriate. In another example, a packet header indicating bar code or RFID data may be routed to an application layer for further processing. ACK/NAK and/or transmission sequence protocols may be enabled and applied or not enabled according to individual application requirements. For example, application data transmissions may be selected to operate with level 3 data integrity while end device management transmissions operate with level 2 protocol. Thus, the contents of the packet can be used to select between protocols.
If in decision box 1208 it is determined that the sequence number is not greater than the last sequence number, indicating that it is a duplicate transmission, the Bluetooth manager sends an ACK to the scanner, as shown by the procedure 1214 , but does not send the data to the host application. After executing step 1214 , the program returns to idle state 1202 .
FIG. 13 is a flow diagram showing states of the host software that occur while the procedure of the flow diagram of FIG. 9 is being executed by the end device. Initially, the system is un-paired, as shown by initial state 1302 . Upon receiving a command to search for Bluetooth clients, or upon boot-up if so enabled, the host computer enters UN-PAIRED PAGE MODE 1304 . In UN-PAIRED PAGE MODE 1304 , the host computer issues pings and listens for a response from a Bluetooth client. If the host makes contact with a Bluetooth client that has already been paired or has the wrong pairing code, the host software returns to initial state 1302 . After that point the scanner may automatically reenter UN-PAIRED PAGE MODE 1304 or may alternatively disable its Bluetooth driver. When in UN-PAIRED PAGE MODE 1304 the host computer makes contact with a device that is not paired and does not have the wrong code, it sends a PIN code (or BD number if so enabled) to the device, and enters CONNECTED MODE 1306 . In CONNECTED MODE 1306 , which corresponds to end device modes 906 and 908 , the host may send and receive application data to and from the end device and the host application.
If the host loses connection with the Bluetooth client, it enters PAIRED PAGE MODE 1308 . The connection may be lost for a variety of reasons including the end device timing out and entering sleep mode or the end device roaming out of radio range. By moving directly into PAIRED PAGE MODE 1308 , the host remains ready to reattach to the end device when the end device moves back into range or when the end device captures new data and attempts to reconnect. In those cases, the scanner reenters DISCOVERABLE MODE 2 , which allows it to reconnect to the host. The host then moves back into CONNECTED MODE 1306 , again able to transmit and receive data to and from the host and end device.
If the user issues an un-pair command to the scanner, for example by pressing the button for 10 seconds, and the scanner enters UN-PAIR MODE 916 of FIG. 9 , an un-pair request is received from the end device. When an un-pair request is received, the host software enters UN-PAIR MODE 1310 . UN-PAIR MODE 1310 clears pairing information from the host and puts the host back in its INITIAL STATE 1302 . Alternatively, if the user issues an un-pair command at the host, the software issues an un-pair command to the end device, moving from CONNECTED MODE 1306 to UN-PAIR MODE 1310 , where the un-pair procedure is executed.
If the host is set to go to sleep after a period of idleness, it may execute the host program with modes according to FIG. 14 . INITIAL STATE 1302 , UNPAIRED PAGE MODE 1304 , CONNECTED MODE 1306 , PAIRED PAGE MODE 1308 , and UN-PAIR MODE 1310 are executed as per the procedure of FIG. 13 as long as the host computer remains awake. If the host goes to sleep while in CONNECTED MODE 1306 it enters SLEEP STATE 1402 . When the host is awakened by the user or by another program, the host enters decision box 1404 and determines if the Bluetooth Manager is present. If the Bluetooth Manager is not present, the user may manually issue a command to move the computer from its INITIAL STATE 1302 to UNPAIRED PAGE MODE 1304 or PAIRED PAGE MODE 1308 , as shown in procedure 1406 . If during decision procedure 1404 is determined that the Bluetooth Manager is present, then the computer automatically attempts to reconnect to its paired end device by entering PAIRED PAGE MODE 1308 and executing the program as indicated earlier. The Bluetooth Manager, may thereby eliminate the need for manual re-pairing of the system after exiting SLEEP STATE 1402 .
FIG. 15 is a block diagram that illustrates the interrelationships among various levels of host hardware and software. The Bluetooth device 610 occupies the lowest level. The Bluetooth Stack 1502 is generally embedded in the Bluetooth device 610 and handles the low-level Bluetooth-specific protocol. The Bluetooth Stack 1502 comprises a virtual communications port, illustrated as box 1504 . The optional Bluetooth Manager 1002 occupies the space above the Bluetooth Stack 1502 and may provide a number of functions including automatic re-connection, message sequence management, and others. The Bluetooth manager 1002 may act as a virtual communication port or as keyboard emulation, as shown by block 1506 . The optional software wedge 1004 acts as a virtual keyboard as shown by block 1508 . The software wedge 1004 may alternatively interface with Bluetooth Manager 1002 or directly with Bluetooth Stack 1502 when the Bluetooth Stack acts as a virtual communications port. The software wedge 1004 acts to turn received data into keystrokes for entering data into high-level applications such as databases, spreadsheets, etc. Software wedge 1004 thus provides a convenient way for a user to set up and use a data collection device such as a bar code scanner with existing high-level applications software. The Bluetooth manager 1002 , in addition to providing automatically connection as shown in FIG. 14 , may also be used to implement Level 3 data integrity, tracking transmission sequence numbers to ensure no redundant data is received by software wedge 1004 and thereby erroneously entered into the high-level host software (not shown). As an alternative to software wedge 1004 , Bluetooth manager 1002 may communicate directly with custom host software or other software appropriately enabled to communicate with it.
FIG. 16 is a flow chart showing the operation of and end device embodied as a bar code scanner. A button press 1602 initiates system wake-up procedure 1604 . By keeping the system normally asleep, power savings may be realized. If the system is already operating, step 1604 may be omitted. After the system is awoken, the laser is turned on (step 1606 ) and the scan is started (step 1608 ). As the detector receives the reflected signal, decoding is attempted, as indicated by step 1609 . The system continues to attempt to decode until decision box 1610 determines that a good decode has been made or decision box 1611 determines that either the maximum scan time has been reached or the user has released the button. If either condition is true, the laser is turned off as indicated by procedure 1612 and the program progresses to other activities.
If a good decode is made, the program proceeds to procedure 1614 where the laser is modulated with intermittent power. Such laser modulation creates a visible feedback to the user that a good decode has been made while maintaining a faint laser line that may be used to aid in alignment of the scanner with the next symbol to be scanned. The laser is modulated until either the maximum scan time is reached or the user releases the scan button, after which the laser is turned off as per procedure 1612 .
After step 1614 begins, the program proceeds to step 1616 and turns on the indicator LED. Then the program proceeds to step 1618 and beeps a sound source that gives an audible indication of a good decode. The program then proceeds to step 1620 and turns off the LED. This arrangement results in an LED blink that is somewhat longer than the beep. After step 1620 , the data is transmitted to the host or stored in memory, as indicated by step 1622 . The methods for accomplishing step 1622 are discussed in detail elsewhere in this document.
The preceding overview, brief description of the drawings, and detailed description describe exemplary embodiments according to the present invention in a manner intended to foster ease of understanding by the reader. Other structures, methods, and equivalents may be within the scope of the invention. As such, the scope of the invention described herein shall be limited only by the claims.
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A portable end device, such as a bar code scanner, may be equipped with auxiliary interfaces. The auxiliary interfaces may be easily added to the end device as a replaceable cover, such as a replaceable battery door. A signal path conducts signals to and from the replaceable cover. One auxiliary interface is a Bluetooth radio. Data integrity protocols may be selected to guarantee delivery and guarantee no duplicate deliveries. Host pairing algorithms may provide standard or strong pairing with a host computer. Ergonomic interface features allow a user to control and monitor the operation of the end device and the data link with minimal hardware cost and battery life impact. Host software programs provide data routing, automatic reestablishment of the data link, and other functions. The system is adaptable to a wide array of use environments through the selection of timer parameters in the end device.
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FIELD OF THE INVENTION
This invention relates generally to superconductive materials and devices and, in particular, to a superconducting plane fabricated so as to enable the controlled levitation and positioning of magnetic bodies.
BACKGROUND OF THE INVENTION
The levitation of a magnet above a superconductor has been demonstrated, particularly with regard to high temperature superconductors. When the magnet is levitated above the superconducting plane, the superconductor operates to exclude the magnet's field in accordance with the Meissner effect. Eddy currents occur in the superconductor such that a mirror image effect is produced and the magnet is repelled. This phenomenon is demonstrated in FIG. 1 where a magnet 1 is levitated above a superconducting plane 2.
The magnitude of the flowing current (I) in the superconducting plane is limited by the critical current of the superconducting material employed to fabricate the superconducting plane 2. In FIG. 1 the height at which the magnet 1 is levitated above the superconducting plane 2 is not controlled, and assumes an equilibrium position.
The following chronologically ordered U.S. Patents and journal articles are referenced as describing various aspects of superconductor-induced levitation and related issues.
In U.S. Pat. No. 3,327,265, issued Jun. 20, 1967, entitled "Superconductive Device for Causing Stable and Free Floating of a Magnet in Space", van Geuns et al. describe a suspension system that suspends a permanent bar magnet over a plate of superconductive material. The plate includes apertures 3 and 4 that locally eliminate a mirror-image effect for attenuating the induced magnetic field near the poles of the magnet.
In U.S. Pat. No. 3,951,074, issued Apr. 20, 1976, entitled "Secondary Lift for Magnetically Levitated Vehicles", Cooper discloses an arrangement of magnets for providing a secondary lift effect for a magnetically levitated vehicle.
In U.S. Pat. No. 4,797,386, issued Jan. 10, 1989, entitled "Superconductor-Magnet Induced Separation", Gyorgy et al. describe superconductivity-magnetic induced separation in which a need for geometry and/or ancillary elements for lateral stabilization are said to be avoided. Superconducting elements are made of Type II superconductors such as barium-yttrium copper oxide. A magnet is levitated over a superconducting support body and induces vortices 5 and 6 for laterally stabilizing the magnet.
In an article entitled "Levitation of a Magnet over a Flat Type II Superconductor", Journal of Applied Physics, Vol. 63, pages 447-450 (Jan. 15, 1988) F. Hellman et al. disclose the levitation of a magnet over a Type II superconductor in a manner similar to that described in the immediately preceding U.S. Patent.
In U.S. Pat. No. 4,843,504, issued Jun. 27, 1989, entitled "Superconductor Devices Useful for Disk Drives and the Like", Barnes describes superconducting materials for use in magnetic recording devices. Superconducting Josephson junction devices are shown to be used for detecting magnetic field changes.
In U.S. Pat. No. 4,879,537, issued Nov. 7, 1989, entitled "Magnetic Suspension and Magnetic Field Concentration Using Superconductors", Marshall et al. describe a device for suspending a load by the use of a magnetic field and superconductive material. A magnetic is suspended over a superconductor so as to provide a magnetic field that penetrates the superconductor. A superconducting disk is comprised of a Type II superconductor comprised of YBa 2 Cu 3 O x and the magnet is comprised of Neodymium-Iron-Boron. In col. 3, a discussion is made of levitation forces for a Type II superconductor, as described by F. Hellman et al. in the above referenced Journal of Applied Physics article.
In U.S. Pat. No. 4,892,863, issued Jan. 9, 1990, entitled "Electric Machinery Employing a Superconductor Element" Agarwala describe a superconductor bearing comprised of Type I or Type II superconducting material.
In an article entitled "Observation of Enhanced Properties in Samples of Silver Oxide Doped YBa 2 Cu 3 O x " Applied Physics Letters, Vol. 52, pages 2066-2067 (Jun. 13, 1988), P. N. Peters et al. describe the addition of silver oxide to YBa 2 Cu 3 O x to provide a material that exhibits attractive forces in gradient magnetic fields, both normal and tangential to the surfaces, which are more than twice the sample weight. This is shown to enable the suspension of a sample of this material below a rare earth magnet.
In an article entitled "Magnetic Hysteresis of High-Temperature YBa 2 Cu 3 O x AgO Superconductors: Explanation of Magnetic Suspension", Modern Physics Letters B, Vol. 2, pages 869-874 (August, 1988) C. Y. Huang et al. discuss in greater detail the characteristics of the silver oxide doped YBa 2 Cu 3 O x superconductor described in the immediately preceding article. The presence of extremely strong pinning centers in the superconductor is discussed.
In an article entitled "Levitation Effects Involving High T c Thallium Based Superconductors" Applied Physics Letters, Vol. 53, pages 1119-1121 (Sep. 19, 1988) Harter et al. describe a stabile levitation equilibria exhibited by the superconductor Tl 2 Ca 2 Ba 2 Cu 3 O 10 .
In an article entitled "Friction in Levitated Superconductors" Applied Physics Letters, Vol. 53, pages 1554-1556 (Oct. 17, 1988) E. H. Brandt describes the levitation of Type I and Type II superconductors above a magnet. The author points out that, in contrast to Type I superconductors, levitated Type II superconductors with flux pinning exhibit a continuous range of stable positions and orientations.
In an article entitled "Magnetic Suspension of Superconductors at 4.2K" Applied Physics Letters, Vol. 53, pages 2346-2347 (Dec. 5, 1988) R. Adler et al. describe suspension at low temperature for a Type II superconductor such as Nb 3 Sn.
And, in an article entitled "Flux Penetration in High-T c Superconductors: Implications for Magnetic Suspension and Shielding" Applied Physics, Vol. A48, pages 87-91 (January, 1989) D. Marshall et al. describe two phenomena which result from flux penetration and pinning in a superconductor. These phenomena include magnetic suspension, wherein a magnet is suspended stably beneath another magnet with a superconductor interposed between the two magnets, and the intensification of magnetic flux upon passing through a superconductor.
What is not taught by this prior art, and what is thus an object of the invention to provide, is the active control of the levitation of a magnetic body relative to a superconductor.
A further object of the invention is to provide a superconducting structure comprised of Josephson junction devices that enable the controlled levitation and positioning of a magnetic body relative to the superconducting plane.
Another object of the invention is to provide a superconducting plane that includes a plurality of electrically addressable devices to enable the precise control of levitation height and a position of a magnetic body above a superconductor.
SUMMARY OF THE INVENTION
The foregoing and other problems are overcome and the objects of the invention are realized by an electrically addressable device which provides precise control of the levitation of a magnet above a superconductor.
More particularly, the invention pertains to apparatus for levitating a magnetic body. The apparatus includes a structure having a planar or a curved surface comprised of a material that is superconductive below a critical temperature. The structure includes at least one device, preferably a Josephson junction device, for passing a variable current therethrough for controlling an amount of magnetic flux penetration into the structure. At a first current value magnetic flux generated by the magnetic body is excluded from the structure and the magnetic body is levitated above a surface of the structure. At a second current value the magnetic flux penetrates the structure such that the levitating magnetic body approaches a surface of the structure.
An embodiment of the invention includes a structure that is differentiated into an array of regions comprised of superconductive material, each of the regions being separated from immediately adjacent regions by a gap having a width equal to a tunnelling distance. This arrangement defines a Josephson tunnel junction device between each region and each of the immediately adjacent regions. In an illustrated embodiment each of the regions has an approximately square surface area having semi-circular concave corners for forming, at each corner, a substantially circular aperture with the corner of each of three adjacent regions. Other shapes may be employed for tiling the surface such as, by example, triangular and hexagonally shaped regions.
The magnetic body is selected to have a dimension that is equal to or exceeds a spacing between adjacent apertures. Magnetic flux lines passing in opposite directions through two adjacent apertures stabilize the levitating magnetic body against lateral motion. A source of electrical current that is coupled individually to each of the regions selectively changes the direction of flux lines passing through one or more apertures for causing a lateral movement of, or a rotation of, the levitating magnetic body relative to the surface of the structure.
Embodiments of the invention are disclosed for transporting a material that is supported by the magnetic body and for operating a display device.
BRIEF DESCRIPTION OF THE DRAWING
The above set forth and other features of the invention are made more apparent in the ensuing Detailed Description of the Invention when read in conjunction with the attached Drawing, wherein:
FIG. 1 is an elevational view showing, in accordance with the prior art, a magnet levitating above a superconducting plane;
FIG. 2 is an elevational view showing a magnet being controllably levitated above a Josephson junction device;
FIG. 3 a graphically illustrates a current-voltage characteristic of the Josephson junction device of FIG. 2;
FIG. 4 is a side view showing a magnet being controllably levitated within a closed-loop vertical positioning system;
FIG. 5A is an elevational view of an electrically addressable superconducting planar array of Josephson junction devices that enable the precise control of levitation height and position of a magnet;
FIG. 5B is a cross-sectional view taken along the section line B--B of FIG. 5A;
FIGS. 6A-6D illustrate the rotation of a levitating magnet about an edge thereof; and
FIG. 7 illustrates, in cross-section, a display device that incorporates the superconducting array of FIG. 5A.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the embodiment of the invention illustrated in FIG. 2 there is now disclosed a structure for controlling the position of a levitated magnetic body 12 over a surface 10a of a superconductor 10, the position being controlled by controlling the magnitude of a current in the superconductor 10.
In FIG. 2 this structure includes a two terminal Josephson junction device 14 formed across a plane of the superconductor 10. A current-voltage characteristic of a typical Josephson tunnel junction device is shown in FIG. 3. In the zero voltage regime (A) of the Josephson tunnel junction 14 a supercurrent flows which is controlled by an external power supply 18. For this condition the total supercurrent is a combination of the currents induced by the magnet 12 and the current (I EXT ) that results from the external power supply 18. To achieve control over the power supply current a simple rheostat 18a may be employed. By increasing the magnitude of the external current provided by the power supply 18, so that the total current exceeds the critical current of the superconductor 10, the superconductor 10 becomes normal and levitation of the magnet 12 ceases. Between the zero voltage supercurrent (regime A) and a point where the increased current causes the superconductor 10 to go normal (point B) there exist a plurality of different levitation heights that the magnet 12 may assume. The external current supplied by the power supply 18 may have either polarity for adding to or subtracting from the total current. Alternating currents (ac) currents may also be employed. The Josephson junction device is preferably operated at a current that is less than the maximum Josephson current (I J (MAX)) so as to remain on the y-axis of the curve of FIG. 3.
The use of a Josephson junction device is important in that this type of device is operable to conduct both a normal current and a supercurrent. In contradistinction, an insulating gap would allow no current to pass, while a resistive link would result in power dissipation. The Josephson junction device has a maximum current density of approximately 10 5 Amp/cm 2 . It should be noted that the term "Josephson junction device" as employed herein is intended to include tunnel junction devices, as illustrated, and also weak link devices such as microbridges. For this latter embodiment small constrictions of an appropriate width are disposed between adjacent tiles, as opposed to a tunnel barrier.
In accordance with the invention the height of the magnet 12 above the Josephson junction device 14 is controlled by controlling the magnitude of I EXT . This control of magnet 12 height may be employed in a number of novel and useful applications. As an example, and in the closed-loop vertical positioning system depicted in FIG. 4, as the magnet 12 rises above the underlying superconductor 10 it makes electrical contact with and closes a circuit, shown schematically as a normally-open switch 20, causing I EXT to flow. All or a portion of this current flows in the Josephson junction device 14, thereby increasing the total current and causing the magnet 12 to descend, thus breaking the established electrical contact through switch 20. As a result, the height of the magnet 12 above the superconductor 10 oscillates between the switch-open position and the switch-closed position. The levitating magnet 12 may also be employed with a non-contact type of switch, such as a Hall-effect device, or an optical beam that is interrupted at a predetermined height above the superconductor 10. It should be noted that this technique may be employed to open or close any external circuit, and not just the circuit that provides current to the Josephson junction device. One application for the controlled levitation of the magnet 12 is to transport an object that is supported by or coupled to the magnet 12. This technique is useful in, for example, a harmful or poisonous environment and/or for transporting quantities of toxic or radioactive substances. As the current I EXT may be quite precisely controlled, precise magnet positioning is achieved resulting in the execution of precise positioning of the object.
In this regard reference is made to FIGS. 5A and 5B as showing one embodiment of a precise magnet positioning and levitation system suitable for transporting an object attached to or supported by the magnet. This configuration of a superconductor array 30 enables a magnet 32 to be moved to a desired x-y position relative to an array 30 x-y coordinate system. The superconductor array 30 is formed of a mosaic of, by example, approximately square-shaped tiles 34 of length L on a side and of thickness T. The corners of each tile 34 are formed to define apertures 36 of radius R. The vertical facets 34a of the tiles 34 are separated by a distance selected so as to form a rectangular Josephson junction 38 of size LxT between each side of a tile 34 and its four nearest neighbor tiles. Thus, in this embodiment, each tile 34 is surrounded by four Josephson junction devices 38.
It should be noted that the square tiles are but one suitable tile shape. Other shapes for tiling the surface of the plane include, but are not limited to, triangles, hexagons, and, in general, any polygonal shape. For a triangularly shaped tile each tile is surrounded by three Josephson junction devices, for a hexagonally shaped tile each tile is surrounded by six Josephson junction devices, etc. For these alternate shapes the apertures are formed at the vertices of each tile. It should further be noted that teaching of the invention is not limited only to planar surfaces and that curved surfaces may also be tiled as described above. Also, tiles of differing shapes and sizes may be employed together.
In a quiescent state, with no currents passing through the Josephson junctions 38, a magnetic flux (F) consisting of an integral number of fluxoids threads or passes each of the apertures 36. Referring to FIG. 5B it is assumed, by way of example, that only two nearest neighbor apertures contain flux. Each aperture 36 passes the same amount of flux but in opposite directions. The permanent magnet 32, having opposed North (N) and South (S) poles as shown and dimensions of approximately TxTxL, is attracted to the flux-passing pair of apertures. If the threaded flux is initially large, the magnet 32 is held at the surface of the array 30. If the flux is changed so that the amount of flux threading the two apertures 36 approaches zero, the attraction to the magnet 32 decreases and the magnet 32 levitates at some height above the surface of the array 30. However, the magnet 32 tends to remain in the neighborhood of the two apertures. When the Josephson junctions 38 are activated by the application of a current (1) thereto, such that the flux threads an adjacent pair of apertures 36, the magnet 32 will be attracted to the new pair of apertures, thereby changing its lateral position relative to the array 30 x-y coordinate system. If the flux is once more increased at the new pair of apertures 36 the magnet 32 will be attracted to the surface of the array 30 and held, or "clamped, at the new x-y position. As will be described, a similar sequence of control currents are employed to rotate the magnet 32.
The controlled activation of the Josephson junction devices 38 is achieved through the use of a plurality of electrodes 40, individual ones of which are coupled to one of the tiles 34 in a manner depicted in FIGS. 5A and 5B. Each of the electrodes is connected to a controller 42 that applies a current to one or more pairs of adjacent electrodes 40 for establishing the flow of current (I) through the Josephson junction device 38 that is interposed between two adjacent tiles 34. As was previously described, as the current flow is increased through the appropriate Josephson junctions the levitating magnet 32 approaches the surface of the array 30. The magnitude of I may vary within a range of several milliamps to several hundred milliamps, the magnitude being a function of the tunnel junction area between adjacent tiles
By selectively applying current to pairs of tiles 34 the magnet 32 is translated across or rotated about the surface of the array 30 in a controlled manner.
In regard to the embodiments described thus far the superconductor material may be a low temperature superconductor or a high temperature superconductor. By example, Niobium is one suitable low temperature superconductor material and YBa 2 Cu 3 O x or Tl 2 Ca 2 Ba 2 Cu 3 O 10 are two suitable high temperature superconducting materials. The use of YBa 2 Cu 3 O x is advantageous in that it enables operation of the array 30 at a temperature corresponding to that of liquid nitrogen (LN 2 ), or 77K. The magnet 32 is preferably comprised of rare earth material such as SmCo. The dimension L is typically within a range of approximately two micrometers to approximately 100 micrometers, or greater, with 20 micrometers being a typical value. The thickness T is typically in the range of approximately 100 nanometers to approximately one micrometer. A typical radius (R) of each of the apertures 36 is approximately two micrometers for L equal to approximately 20 micrometers. The vertical facets 34a of the tiles 34 are spaced apart from one another by a distance of approximately 20 Angstroms to approximately 30 Angstroms. Interposed between vertical facets 34a of adjacent tiles 34 is a Josephson tunnel barrier 34b. The material of Josephson tunnel barriers 34b is selected to be compatible with the selected superconductor material. By example, for the low temperature superconductor material Niobium the barrier material 34b may be comprised of niobium oxide or aluminum oxide. For the high temperature superconducting material the insulating material may be comprised of barium fluoride, magnesium oxide, strontium titanate, or the non-superconducting oxide material PrBa 2 Cu 3 O x . It is also within the scope of the invention to provide a semiconductor barrier material 34b such as one comprised of silicon-germanium, germaniumtellurium, or cadmium sulfide. The use of a semiconductor barrier material is advantageous in that it permits the distance between the vertical facets 34a to be wider due to the lower tunnel barrier potential present within the semiconductor material. It is also within the scope of the invention to provide a vacuum between the vertical facets 34a in place of an insulating film barrier.
The fabrication of the array 30 may be achieved by conventional semiconductor photolithographic techniques. As an example, for a superconducting array comprised of a high temperature superconductor, processing begins with a substrate, such as MgO, through which a plurality of via holes are made. Each of the via holes is formed at a position where an electrode 40 is required. The via holes are metalized and the substrate is planarized. A layer of a high temperature superconductor is applied to the surface of the substrate to the desired thickness T. A layer of photoresist is applied over the superconductor layer, followed by the photolithographic definition of the gaps 34a, between the tiles 34, and the apertures 36 at the tile corners. The structure is next processed to remove the exposed photoresist and portions of the superconductor material to form the desired mosaic pattern. The selected insulating film material 34b is then evaporated or otherwise deposited or grown so as to fill the gaps 34a and, if desired, the apertures 36. The photoresist layer is then removed.
One application for the array 30 is in the manufacture of integrated circuits. One example is the customization of logic chips. In that the design of a new chip is a lengthy and expensive process, it is often desirable to employ a "generic" design which is customized at a late stage of manufacture into a desired configuration. Such generic chips often are provided with open circuits which are required to be closed to make the desired circuit connections. In this regard, the magnet 32 supports and transports a quantity of electrically conductive material, such as a solder ball 44. The integrated circuit chip is disposed such that an active circuit surface area 46 is supported above the array 30 at a height that is within reach of the levitating magnet 32. The controller 42 is employed to sequentially activate the Josephson junctions 38 so as to transport the magnet 32, and the ball of solder 44, to a desired location upon the active circuit surface 46. Once positioned, the ball of solder 44 is melted with a laser (not shown) or some other suitable means so as to make an electrical connection between two points upon the active circuit surface 46. It should be noted that a significant number of magnets may be simultaneously controlled in this manner for moving over a single array 30.
Another similar application of the invention is in conveying material so as to repair a mask of the type used to control the exposure of a photoresist material.
FIGS. 6A-6D illustrate a further embodiment of the invention wherein the superconducting array 30 is employed as an element of a display device. The display device incorporates the array 30 and the electrodes 40 and is constructed as previously described. The electrodes 40 are controlled such that a sequence of currents causes a suspended magnetized body to rotate about an axis while the body is levitated above the surface of the array 30.
The magnetized body is provided as a flat, approximately square magnet 48 that is polarized in a direction parallel to one of its sides. The magnet 48 has a length and a width that is approximately equal to the dimensions of an underlying tile 34. In FIG. 6A the magnet 48 is initially held in place above one particular tile 34 by lines of magnetic flux (F) which rise through two adjacent apertures 36 at corners of the tile 34 and which descend through two other adjacent apertures 36. In FIG. 6B the polarity of the flux through two apertures is reversed by passing a current through the associated Josephson junction 38. As a result, that side of the magnet 48 is repelled and will tend to move up away from the plane of the array 30. However, the opposite side of the magnet 48 remains attracted by the descending lines of flux. As a result, the magnet 48 rotates about an axis parallel to the side of the magnet 48 that is held in place. That is, the magnet 48 appears to operate in a manner similar to a hinged door. Referring to FIG. 6C, as the magnet 48 approaches a position that is perpendicular to the array 30 another current is provided to generate flux through the two apertures on the opposite side of the adjacent tile 34. This flux attracts the rotating edge of the magnet 48, thus causing the magnet 48 to swing through the perpendicular position and come to rest above the adjacent tile (FIG. 6D). As can be seen, the magnet 48 has been rotated into a new position and a new orientation. An alternative method is to reverse the flux from the "hinge" side of the tile to the opposite side of the tile while the magnet is in the perpendicular position. This causes the magnet to return to rest on the same tile after it is rotated.
In accordance with this embodiment of the invention the magnet 48 is provided with a dark surface 48a on one side and a lighter surface 48b on the opposite side. Thus, any desired light and dark pattern can be formed by controllably rotating a plurality of the magnets 48.
It is also within the scope of the invention to provide cubic magnets having sides of different colors. The cubic magnets are rotated in a manner described above so as to provide on a visible surface of each cubic magnet a desired one of six colors.
The display device may be operated with the array 30 of tiles 34 completely covered with the magnets 48, or with only a partial covering of magnets.
Referring to FIG. 7 there is shown a further embodiment of a display device 50 that includes means for enclosing each magnet 52 within a cavity or chamber 54. The walls of the chamber 54 tend to constrain the lateral motion of the enclosed magnet 52 and thus reduce the precision required of the controlling currents while preventing the loss of any magnets. A fly eye-type transparent lens 56 is provided at the top of each chamber 54 so as to form an image with high contrast for the case where the magnets 52 do not cover the entire superconducting plane 30. Beneath each lens 56 is a layer of material into which the chambers 54 are formed, each chamber containing a single one of the magnets 52. Preferably, each magnet 52 and its associated chamber 54 are rectangular in shape, as viewed from above, and have a long direction perpendicular to an axis about which the magnets are rotated. In this embodiment the magnets 52 are constrained from completely rotating through a vertical axis (VA) and the controller 42 need not be responsible for controlling this degree of freedom. For this embodiment an upper surface of each of the magnets 52 may be made dark and the underlying surface of the array 30 is made lighter, or vice versa. A partial rotation of the magnet 52 thus provides a visible contrast by exposing to view the underlying lighter surface of the array 30.
It should be realized that the display device may be made very thin. Also, the addition of small areas of magnetic films to the array 30 can be employed to preserve the image in the absence of input power. Of course, for all of these various embodiments of the invention it is required to operate the superconducting array 30 below its associated critical transition temperature in order to obtain the benefit of the operation of the Josephson junction devices 38 that are integrally formed within the array.
It should also be realized that the controller 42 may be embodied in any apparatus suitable for controllably applying the required currents to the Josephson junction devices. Controller 42 may include a data processor coupled to a plurality of current switches or a display controller device having outputs that control the application of the currents.
Thus, while the invention has been particularly shown and described with respect to a preferred embodiment thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the scope and spirit of the invention.
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Apparatus for levitating a magnetic body. The apparatus includes a structure (10) comprised of a material that is superconductive below a critical temperature. The structure includes at least one Josephson junction device (14) for passing a variable current therethrough for controlling an amount of magnetic flux penetration into the structure. At a first current flow magnetic flux generated by a magnetic body (12) is excluded from the structure and the magnetic body is levitated above a surface of the structure. At a second current flow the magnetic flux penetrates the structure, causing he levitating magnetic body to approach a surface of the structure. Controllably applying a current to an array (30) of superconductive tiles (34), forming Josephson tunnel junctions (38), is shown to provide a lateral motion of, or a rotation of, the magnetic body relative to the surface.
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This application is a division of application Ser. No. 09/617,676, filed Jul. 14, 2000, now U.S. Pat. No. 6,528,105.
TECHNICAL FIELD
The present invention relates to a portable food container, and more specifically, a single handed container which consists of two separate containers holding two different food types which are mixed while eating.
BACKGROUND
Research shows that breakfast is the most important meal of the day. One of the most common breakfast foods is cereal. Cereal is typically placed in a container, milk is poured over the cereal, and the consumer consumes the mixture with a spoon. Cereal consumption normally requires two hands, and is not an activity which can be safely performed while the consumer is engaged in various other activities such as driving a vehicle.
In a move to make breakfast consumption more convenient, many manufacturers have offered breakfast bars, breakfast sandwiches and other breakfast foods which can be consumed with a single hand. There have also been several attempts to construct a container which stores cereal and milk separately, allows the two to be mixed when consumed and allows the consumer to eat the mixture with a single hand.
U.S. Pat. Nos. 5,588,561 and 5,753,289, issued to Ness, describe a container for holding cereal and milk in a separate compartments. Cereal is placed in the inner, inflexible container, while milk is placed in the outer flexible table. Cereal is shaken from the inner, inflexible, container into the consumer's mouth, and the consumer then squeezes the outer flexible container to squirt milk into the consumer's mouth. In this manner, the cereal and the milk are mixed inside the consumer's mouth. The Ness patents also require rotation of the portable food container to a dispensing position before the consumer can use the product. A need exists for a simplified single handed container, which will allow an individual to consume cereal and milk with a single hand while hiking, camping, driving, or while involved in other activities.
SUMMARY OF THE INVENTION
Accordingly, a need exists for a simplified, one handed container, which stores a dry particular food separately from a liquid food, and which allows the consumer to easily mix the two foods types without the need for rotation or squeezing.
These and other objects, features and technical advantages are achieved by a system which includes a food container which is comprised of an inner cup, for holding a particulate food, and an outer cup which is adapted to receive the inner cup within it in a manner in which a space is left between the two cups for holding a liquid food. The inner cup includes a flange that interlocks with the open end of the outer cup in a liquid tight manner. The flange has at least one aperture for discharging the liquid food. The particulate food and the liquid food are consumed simultaneously by tilting the container towards the mouth of the user to discharge the particulate food from the inner cup and the liquid food from the outer cup through the aperture. The particulate food can be a ready to eat cereal and may be of the non-flake type. The flange has a horizontal surface containing the aperture. The aperture may allow the liquid food to flow through it by gravity, or it may prevent the liquid food to flow through it unless a sucking force is applied to the aperture. An additional member may be included with the container which partially covers the opening of the inner cup and is used to regulate the discharge of the particulate food. The flange can also have a vent aperture. The outer cup is composed of a moisture resistant paper and the inner cup is made of plastic.
The objects, features and technical advantages are also achieved by a method of dispensing particulate food and a liquid food comprising providing an inner cup containing a particulate food and an outer cup adapted to receive the inner cup with a space there between, and where the space contains a liquid food. The inner cup has a flange which interlocks with the open end of the outer cup in a liquid tight manner and this flange has an aperture for discharging the liquid food. By tilting the container, both the particulate and the liquid food are simultaneously discharged into the mouth of the user. The particulate food is a ready to eat cereal and can be of the non-flake cereal type. The liquid food can be discharged through the aperture through gravity flow or may be sized to require the liquid food to be sucked from the aperture. The method can further include a mechanism to regulate the discharge of the particulate food from the inner cup.
Another embodiment of the present invention can include a food container which is comprised of an inner bottle for holding a particulate food and an outer bottle which is adapted to receive the inner bottle with a space there between the two bottles for holding a liquid food. The inner bottle can have a tripod member that interlocks with the closed end of the outer bottle. The outer bottle has at least one aperture for discharging the liquid food and the particulate food and the liquid food can be consumed simultaneously by tilting the container towards the mouth of the user to discharge the particulate food from the inner container and the liquid food from the outer bottle through the aperture. The particulate food is a ready to eat cereal and can be of the non-flake cereal type. The liquid food can be discharged through the aperture through gravity flow or may be sized to require the liquid food to be sucked from the aperture. The method can further include a mechanism to regulate the discharge of the particulate food from the inner cup. The tripod member can be comprised of a series of convex and concave portions in which the convex portion interlocks into a corresponding rim of the outer bottle and the concave portion provides additional space for holding the liquid food.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
FIG. 1 is a diagram of an outer container of the cup-in-cup design of the current invention;
FIG. 2 is a diagram of an inner container of the cup-in-cup design of the current invention;
FIG. 3 is a diagram of the mating of the outer cup of FIG. 1 with the inner cup of FIG. 2;
FIG. 4 is a drawing of the mated combination of FIG. 3 with an orifice reducer;
FIG. 5 is an exploded view of the cup-in-cup combination with the peel seal;
FIG. 6 is a drawing of the cup-in-cup design as sold;
FIG. 7 is a diagram of the bottle-in-bottle embodiment of the current invention;
FIG. 8 is an exploded view of the bottle-in-bottle embodiment;
FIG. 9 is a cutaway view of the bottle-in-bottle embodiment;
FIG. 10 is a diagram of the tripod shape of the base of FIG. 7 's bottle-in-bottle embodiment; and
FIG. 11 is a drawing of the orifices used to pass milk from inside the outer bottle of the bottle-in-bottle embodiment.
DETAILED DESCRIPTION
FIG. 1 shows an outer cup of a cup-in-cup design while FIG. 2 shows the inner cup of the same embodiment. Outer container 100 of FIG. 1 is composed of an upper lip 105 , the sidewall 110 , the bottom 115 , and the inside 120 . In a preferred embodiment, upper lip 105 is constructed of a rigid material, such as moisture proof cardboard. Similarly, sidewall 110 is constructed of a rigid material such as moisture proof cardboard or heavy paper. This rigid sidewall is not intended to be squeezed to force liquid from the aperture of the inner container ( 200 of FIG. 2 ). The bottom 115 is also constructed of a similar material. In normal operation, milk or a similar liquid food is placed inside 120 , the container 100 .
Inner container 200 of FIG. 2 is composed of a sidewall 205 , a bottom 210 , and attaching lip 215 , a lip sidewall 220 , an eating surface 225 , and one or more vents 230 . The sidewall 205 and the bottom 210 may be constructed of a rigid or a flexible moisture proof material. The attaching lip 215 must contain enough rigidity and flexibility to meet with and attach to lip 105 of the outer container of FIG. 1 . The lip sidewall 220 connects the attaching lip 215 to the eating surface 225 . The eating surface 225 is the portion of the inner cup 200 which makes contact with the consumer's lip. Vent 230 allows the milk or similar liquid contained within the inside 120 of outer cup 100 of FIG. 1 to pass into the consumer's mouth. Opening 235 of inner container holds particulate food, cereal or similar food substance.
Referring to FIG. 3, the interrelationship between the outer cup 100 of FIG. 1 and the inner cup 200 of FIG. 2 is shown. The inner cup 200 fits within the interior 120 of the outer cup 100 . When the inner cup 200 is mated with the outer cup 100 , the attaching lip 215 fits securely over lip 105 of the outer cup. When mated, the sidewall 205 and the bottom 210 of the inner cup 200 are contained within the inside 120 of the outer cup. The smaller diameter of the sidewall 205 of the inner cup, as compared to the larger diameter of the sidewall 110 of the outer cup, ensures that the inner cup 200 does not fill the entire opening 120 of the outer cup 100 . This difference in diameters between the inner cup and the outer cup's sidewalls creates a space between the two containers and ensures that there is sufficient room inside the outer cup for a liquid such as milk. This liquid, contained within opening 120 , of the outer container 100 can pass through the vent 230 of the inner cup into the consumer's mouth.
Referring now to FIG. 4, an orifice reducer 400 can be used to regulate the flow of the dry material, or particulate food, from opening 235 of the inner cup into the consumer's mouth. This orifice reducer 400 fits within a groove on the eating surface 225 of the inner container between point 405 and 410 . Preferably, this groove 415 , which the orifice reducer fits into, traverses around approximately three-quarters of the circumference of the eating surface 225 . As depicted in FIGS. 2, 3 and 4 , the vent 230 can be a single opening. Alternatively, the vent 230 can consist of several smaller openings. Preferably, a venting hole is also included around the circumference of the eating surface 225 to ensure that a vacuum is not created when liquid passes outside of the vent 230 .
FIG. 5 shows an exploded view of the single handed container which consists of the outside cup 100 , the inside cup 200 , the orifice reducer 400 and the peel seal 500 . The peel seal 500 is used to ensure sanitary conditions of the single handed container when shipped. FIG. 6 illustrates the single handed container when it is ready for shipment.
In one embodiment of the single handed container, the volume of the outer container 100 is 14 fluid ounces, the volume of the inner container 200 is 9.5 fluid ounces, the diameter of bottom 115 of FIG. 1 is 2.5 inches, the top diameter along the lip 105 of FIG. 1 is 3.625 inches and the height of the outer container is 5 inches.
An alternative embodiment, the bottle-in-bottle configuration, of the present invention is shown in FIG. 7 . In this embodiment, the invention consists of two separate bottles which snap together in the base at 705 . This bottle-in-bottle embodiment includes the outer bottle 710 , the inner bottle 715 , and a snap cap 120 . A peel seal, (not show in figure) can also be included to ensure non-contamination. This peel seal is shown in FIG. 8 as item 805 . In a preferred embodiment of the bottle-in-bottle embodiment, the capacity of the outer bottle 710 is 14.5 fluid ounces, while the capacity of the inner bottle 715 is 9.5 fluid ounces. In a preferred embodiment of the bottle in bottle combination, the bottom diameter 810 of FIG. 8 is 2.5 inches while the top diameter 815 is 3.625 inches. The height of the overall container is 5 inches. In this bottle-in-bottle embodiment, the liquid contained in the outer bottle 710 is passed into the consumer's mouth through an orifice located on the inside diameter of the upper portion of the outside bottle 820 . This orifice allows milk, or similar liquids to flow from the inside of the outer bottle into the consumer's mouth. The inner bottle holds the particulate food or similar food substance.
Referring to the cutaway FIG. 9, the outer bottle 710 is shown with the inner bottle 715 in place. The snap fit between the outer bottle 710 and the inner bottle 715 is shown at 720 . Additionally, the tripod shape 725 of the base of the inner bottle 715 facilitates milk flow from the space between outer bottle 710 and inner bottle 715 into the consumer's mouth. The tripod shape also provides additional space for the liquid food. FIG. 10 further shows the tripod shape 725 .
As previously mentioned, orifice 1105 allows milk to flow from the inside of the outer bottle 710 along the outside of the inner bottle 715 and into the consumer's mouth. The size and the number of these orifices can be varied to regulate milk flow.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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The invention discloses a method and an apparatus for a food container which includes an inner member (which can be a cup or a bottle) for holding a particulate food; an outer member (which can be a second cup or a second bottle) adapted to receive the inner member, with a space between the inner and the outer members, for a liquid food; where the inner member interlocks with the outer member and openings are provided for the discharge of the liquid food; and the particulate food and the liquid food can be consumed simultaneously by tilting the container towards the mouth of the user to discharge or withdraw particulate food from the inner member and liquid food from the outer member through the aperture.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electronic control device for an internal combustion engine which detects a first crank angle position SGTT and a second crank angle position SGTL on the side of advance ignition angle of SGTT, calculates a target ignition timing at every SGTL, and sets the target ignition timing at every SGTL or at every SGTT depending on a condition of the setting.
2. Discussion of Background
Conventionally, the electronic control device of this kind, obtains a crank angle signal from a crank angle sensor provided in an internal combustion engine (hereinafter, simply engine) as shown in FIG. 4 taking an example of a four cylinder engines. A pulse-like electric signal as shown in FIG. 4 is obtained from the crank angle sensor at every half revolution (180°) of a crankshaft. P1 shown in FIG. 4 is a detection point of the first crank angle position SGTT, and P2 provided on the side of advance ignition angle of P1, a detection point of the second crank angle position SGTL. In FIG. 4, P3 designates a top dead center of the engine, and in this example, SGTT is set at 6° before the top dead center, and SGTL, 76° before the top dead center.
Furthermore, the above mentioned electronic control device measures a detection period T1 of SGTL from the crank angle signal, and calculates and sets the target ignition timing at every SGTL by determining an ignition timing optimum in running condition of the engine, based on an intake air quantity obtained from signals of revolution number of the engine calculated by the period T1, and an air-flow sensor.
When the target ignition timing is set on the side of retarded ignition angle of SGTT, abnormal retarded ignition angle or abnormal advance ignition angle may be generated by rapid acceleration or by rapid deceleration of the engine, respectively. To prevent this abnormality, when the target ignition timing is set on the side of retarded ignition angle of SGTT, the target ignition angle may be set by SGTT, and not by SGTL.
FIG. 9A signifies the above-mentioned crank angle signal, and FIG. 9B, an ignition signal. In this example, the target ignition timing is set on the side of advance ignition angle of SGTT, and the ignition is performed when time elapsed from SGTL reaches a setting timing P1 which corresponds with the target ignition timing.
At this occasion, when a detection timing t2 of SGTT is abruptly changed to t2' as shown in FIG. 9C by rapid acceleration, since the successive ignition is performed at the timing of t1, the ignition timing is abnormally retarded, and misfire of the engine may be caused. Accordingly, in the conventional case, when the target ignition timing is set on the side of advance ignition angle of SGTT, and when the rapid acceleration takes place, the ignition is performed at the detection timing t2' detecting SGTT as shown in FIG. 9D, so that the ignition timing is not retarded abnormally.
As the electronic control device of this kind, for instance, "an electronic ignition control device for an internal combustion engine" shown in Japanese Examined Patent Publication No. 51155/1983, or the like is pointed out.
However, when the target ignition timing is set at every SGTL or at every SGTT depending on the setting condition as mentioned above, if a detection error is generated between SGTL and SGTT which are detected by the crank angle sensor, the target ignition timing is deviated.
Accordingly, when adjustment is made by SGTT as a reference, the detection point of SGTL is deviated by an error portion. Therefore when the target ignition timing is set from SGTL, that is, when a timer is set for generating the ignition signal from the detection point of SGTL, the target ignition timing is deviated. Furthermore, when adjustment is made by SGTL as a reference, the detection point of SGTT is deviated by an error portion. Therefore, when the target ignition timing is set from SGTT, that is, when a timer for generating the ignition signal is set from the detection point of SGTT, the target ignition timing is deviated.
Furthermore, if the crank angle sensor is finely worked so that it detects accurately, measurement error between SGTL and SGTT can be dispensed with. However, it becomes an very expensive one.
Furthermore, in the conventional electronic control device of the engine, it is possible to prevent the abnormal retarded ignition angle by rapid acceleration in the case when the target ignition timing is set on the side of advance ignition angle of SGTT. However, as for the abnormal retarded ignition angle by rapid acceleration in the case when the target ignition timing is set on the side of retarded ignition angle of SGTT, no counter measure is provided to prevent the abnormality.
When the ignition is performed at a timing t4 on the side of retarded ignition angle of SGTT, as shown in the crank angle signal and the ignition signal of FIGS. 10A and 10B, respectively, and when the detection timing t3 of SGTT is abruptly changed to t3' by rapid acceleration as shown in FIG. 10C, the successive ignition is performed at the timing of t4 as shown in FIG. 10D, the ignition timing is abnormally retarded and misfire of the engine may be caused.
SUMMARY OF THE INVENTION
It is an object of the present invention to solve of the above problems. The target ignition timing is corrected in the above-mentioned electronic control device, based on a detected time interval between SGTL and SGTT.
Furthermore, a restriction time is determined in the electronic control device, corresponding with a time interval (TM in FIGS. 10A to 10D) between SGTL and the target ignition timing, the electronic control device determines whether the ignition signal is generated after the restriction time elapses from the actual detection of SGTT, and forcibly generates the ignition signal when the ignition signal is not generated in the restriction time.
Therefore, according to the present invention, when a detection error is generated between SGTL and SGTT, the target ignition timing which is set at every SGTL or at every SGTT, is corrected based on a time interval between detection timings of SGTL and SGTT.
Furthermore, according to the present invention, when the target ignition timing is set on the side of retarded ignition angle of SGTT, the ignition signal is forcibly generated when the ignition signal is not generated after the restriction time elapses from when SGTT is actually detected.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a block diagram showing an Example of an electronic control device for an internal combustion engine according to the present invention;
FIG. 2 is a flow chart showing a treatment performed in synchronism with SGTL in the electronic control device;
FIG. 3 is a flow chart showing a treatment performed in synchronism with SGTT in the electronic control device;
FIG. 4 is a diagram showing a crank angle signal;
FIGS. 5A, 5B and 5C are timing charts showing a characteristic operation of the electronic control device of FIG. 1;
FIG. 6 is a flow chart showing a treatment performed in synchronism with SGTL in the electronic control device;
FIG. 7 is a flow chart showing a treatment performed in synchronism with SGTT of the electronic control device;
FIG. 8 is a flow chart showing a timer interruption treatment;
FIGS. 9A, 9B, 9C and 9D are timing charts for explaining an operation for preventing of abnormal retardation of ignition angle by rapid acceleration when the target ignition timing is set on the side of advance ignition angle of the conventional electronic control device; and
FIG. 10A, 10B, 10C and 10D are timing charts for explaining an abnormal retarded ignition angle which caused by rapid acceleration, when the target ignition timing is set on the side of retarded ignition angle of SGTT.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A detailed explanation will be given to an electronic control device for an internal combustion engine according to the present invention as follows.
FIG. 1 is a block diagram showing an Example of the electronic control device. In FIG. 1, a reference numeral 1 designates a control device, 2, a crank angle sensor, and 3, an ignition device. The control device 1 is composed of an input interface 11, an output interface 12 and a microcomputer 13. The input interface 11 shapes a signal from the crank angle sensor 2, and outputs it to the microcomputer 13 as the crank angle signal as shown in FIG. 4. The output interface 12 receives an ignition signal from the microcomputer 13, and drives the ignition device 3. The microcomputer 13 is a will-known one, which includes a timer 131, a ROM 132 and a RAM 133.
FIGS. 2 and 3 are flow charts showing function of the microcomputer 13.
The microcomputer 13 performs steps shown in FIG. 2 in synchronism with the crank angle signal SGTL. First, in step 201, the operation measures a period T1 of SGTL. The operation goes to step 202, looks up maps by revolution number obtained from the period T1 and the intake air quantity obtained by a signal from an air-flow sensor (not shown), and obtains an ignition timing which is optimum in running condition of the engine, as the target ignition timing. Furthermore, the operation goes to step 203, and calculates a set value of timer for ignition T2. T2 which is a time interval from SGTL to the target ignition timing, is calculated by the following equation (1) in case that adjustment is performed with respect to the crank angle by SGTL as a reference, and the following equation (2) in case that adjustment is performed with respect to the crank angle by SGTT as a reference.
T2=T1×(76°-θ)/180° (1)
T2=T1×(76°+α-θ)/180° (2)
where θ is angle from the top dead center to the target ignition timing, which is positive (+) on the side of the advance ignition angle, and negative (-) on the side of retarded ignition angle. Furthermore, in the above equations, α denotes an detection error (crank angle error) between SGTL and SGTT, which is a value obtained by a treatment performed in synchronism with SGTT, mentioned later. When the adjustment with respect to the crank angle is performed by SGTL as a reference, the detection error α is not in the equation (equation (1)). When the adjustment is performed with respect to the crank angle by SGTT as a reference, the detection error α is included in the equation (equation (2)).
Next, the operation goes to step 204 and calculates a timer setting value T0 which is set at the detection point of SGTT when the target ignition timing is set on the side of retarded ignition angle of SGTT, by the following equation (3) in case that adjustment is performed with respect to the crank angle by SGTL as a reference, and by the equation (4) in case that the adjustment is performed with respect to the crank angle by SGTT as a reference.
T0=T1×θ1/180° (3)
T0=T1×θ1/180° (4)
where θ1 in equation (3) is 6°-α-θ when 6°-α-θ>0, and 0° when 6°-α-θ≦0, and θ1 in equation (4), is 6°-θ when 6°-θ>0, and 0° when 6°-θ≦0.
In this case, when the adjustment is performed with respect to the crank angle by SGTL as a reference, the error α is included in the equation (equation (3)), and the error α is not included in the equation (equation (4)) when the adjustment is performed with respect to the crank angle by SGTT as a reference.
Furthermore, the operation goes to step 205, and determines whether the operation is in a zone wherein the setting of the target ignition timing is performed based on SGTT, or whether the operation is in a zone wherein the set value of the timer T0 is to be set to the timer 131 at the detection point of SGTT. That is to say, the operation determines whether the target ignition timing is on the side of retarded ignition angle (θ1>0) of SGTT, and whether the operation is in a zone of running condition of the engine wherein a variation of period of the crank angle signal is considerable, and the actual ignition timing is considerably deviated from the target ignition timing in case that the timer is set from STGL.
When the operation in the zone, the treatment is finished. When the operation is out of the zone, the operation goes to step 206, and sets the setting value of the timer T2 to the timer 131, by which the timer 131 outputs the ignition signal after the time T2 elapses from the detection point of SGTL.
By the way, the period T1 utilized in equations (1) to (4), may be a period added with a correction considering the variation of period.
Next, the microcomputer 13 performs steps shown in FIG. 3 in synchronism with the crank angle signal SGTT. First, in step 301, the operation determines whether the operation is in a "SGTT timer setting zone". The SGTT timer setting zone mentioned here is the same with the zone explained in step 205 of FIG. 2. If the operation is not in this zone, the operation goes to step 303. When the operation is in the zone, the operation goes to step 302. In step 302, the operation sets the setting value of timer T0 which is obtained by the equation (3) or equation (4), to the timer 131, by which the timer 131 outputs the ignition signal after the time T0 elapses from the detection point of SGTT.
In step 303, the operation determines whether there is a variation of period. That is to say, the operation calculates a variation of the period between SGTLs, between the preceding time and the current time, and determines that the variation of period does not take place when the variation is a predetermined value or below. When there is a variation of period, the treatment is finished, and if not, the operation goes to step 304. In step 304, the operation calculates a detection timing interval TH between SGTL and SGTT. Furthermore, the operation goes to step 305 and calculates a detection error between SGTL and SGTT that is, a crank angle error α by the following equation (5). This crank angle error α is utilized in the STGL synchronization treatment.
α=(TH/T1)×180°-70° (5)
Next, explanation will given to another embodiment of the present invention as follows.
FIGS. 6 to 8 are flow charts for explaining function of the microcomputer 13.
The microcomputer 13 performs steps shown in FIG. 3 in synchronism with the crank angle signal SGTL. First, in step 401, the operation calculates a period T1 of SGTL. The operation goes to 402, and looks up maps by a revolution number obtained from the period T1, and the intake air quantity obtained by a signal from an air-flow sensor (not illustrated), and obtains an ignition timing which is optimum in running condition of the engine, as a target ignition timing. The operation goes to 403, and calculates a setting value of the timer for ignition T2. The operation calculates the time from SGTL to the target ignition timing T2 by the following equation (6).
T2=T1×(76°-θ)/180° (6)
where θ is an angle from the top dead center to the target ignition timing, which is positive (+) on the side of advance ignition angle, and negative (-) on the side of retarded ignition angle.
Next, the operation goes to step 404, and set the time T2 obtained in the preceding step 403, to the timer 131, by which the timer 131 outputs the ignition signal after the time T2 elapses from the detection point T2 of SGTL.
Furthermore, the operation goes to step 405, and calculates the setting value of the timer (restriction timer) T0' by the following equation (7), to restrict the ignition timing from being retarded. This restriction time T0' is set to the timer 131 in synchronism with the crank angle signal SGTT.
T0'=T1×A/180°+α' (7)
where A is 6°-θ when 6°-θ>0 and 0° when 6°-θ≦0. Furthermore, in equation (7), α' denotes a very little time which is pertinently determined.
The period T1 which is utilized in equations (6) and (7), is a period corrected considering a variation of the period.
Next, the microcomputer 13 performs steps shown in FIG. 7 in synchronism with the crank angle signal SGTT. The operation sets the restriction time obtained in step 405 to the timer 131 (step 501), by which the timer 131 generates an interruption signal after a time interval T0' elapses from the detection point T1 of SGTT.
When the timer 131 generates the interruption signal, the microcomputer 13 determines in synchronism with the interruption signal, firstly whether the ignition is finished, following the flow chart shown in FIG. 8 (step 601). That is to say, the operation confirms whether the ignition signal is generated, and finishes the treatment if the ignition signal is generated. If the ignition signal is not generated, the operation determines that the crank angle signal changes rapidly (rapid acceleration), and forcibly generates the ignition signal in step 602, by which the operation prevents an abnormal retarding of the ignition angle.
When the ignition is performed at the timing t6 on the side of the retarded ignition angle of SGTT, as shown in the crank angle signal and the ignition signal of FIGS. 5A and 5B, respectively, when a detection timing t5 of SGTT is rapidly changed to t5' by rapid acceleration, as shown in FIG. 5C, the ignition is performed forcibly at t7 after the time T0' elapses from t5', thereby preventing an abnormal retardation of ignition angle.
As is the apparent in the above explanation, according to the present invention, when the detection error is caused between SGTL and SGTT, the target ignition timing which is set at every SGTL or at every SGTT, is corrected based on the detection time interval between SGTL and SGTT, and the ignition timing is accurately controlled without requiring a severe accuracy in the crank angle sensor.
As apparent in the above explanation, according to the present invention, when the target ignition timing is set on the side of retarded ignition angle of SGTT, and when ignition signal is not generated after a restriction time elapses from when SGTT is actually detected, the ignition signal is forcibly generated, by which an abnormal retardation of ignition angle due to a rapid acceleration is prevented when the target ignition timing is set on the side of the retarded ignition angle of SGTT.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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An electronic control device for an internal combustion engine which comprises: means of detecting a first crank angle position, SGTT and a second crank angle position, SGTL provided at a position on advance ignition angle side of the first crank angle position; means of calculating and setting the target ignition timing at every SGTL; means of determining a restriction time corresponding with a time interval between the SGTT and a target ignition timing when the target ignition timing is set at a timing on retarded ignition angle side of the SGTT; means of determining whether an ignition is generated after the restriction time elapses; and means of forcibly generating the ignition signal when the ignition is determined not to be generated.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of International application No. PCT/EP2011/068011, filed on October 14, 2011, published as WO-A1-2013053402, and incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to hearing aids. The invention, more specifically, relates to a soft custom ear mold for hearing aids. The invention further relates to a method of manufacturing a soft custom ear mold. The invention, in particular, relates to a tool for use in the method.
[0004] In the context of the present disclosure, a hearing aid should be understood as a small, battery-powered, microelectronic device designed to be worn behind or in the human ear by a hearing-impaired user. Prior to use, the hearing aid is adjusted by a hearing aid fitter according to a prescription. The prescription is based on a hearing test, resulting in a so-called audiogram, of the performance of the hearing-impaired user's unaided hearing. The prescription is developed to reach a setting where the hearing aid will alleviate a hearing loss by amplifying sound at frequencies in those parts of the audible frequency range where the user suffers a hearing deficit. A hearing aid comprises one or more microphones, a battery, a microelectronic circuit comprising a signal processor, and an acoustic output transducer. The signal processor is preferably a digital signal processor. The hearing aid is enclosed in a casing suitable for fitting behind or in a human ear.
[0005] As the name suggests, Behind-The-Ear (BTE) hearing aids are worn behind the ear. To be more precise an electronics unit comprising a housing containing the major electronics parts thereof is worn behind the ear. An ear mold for emitting sound to the hearing aid user is worn in the ear, e.g. in the concha or the ear canal. In a traditional BTE hearing aid, a sound tube is used because the output transducer, which in hearing aid terminology is normally referred to as the receiver, is located in the housing of the electronics unit. In some modern types of hearing aids a conducting member comprising electrical conductors is used, because the receiver is placed in the earpiece in the ear. Such hearing aids are commonly referred to as Receiver-In-The-Ear (RITE) hearing aids. In a specific type of RITE hearing aids the receiver is placed inside the ear canal. This is known as Receiver-In-Canal (RIC) hearing aids.
[0006] 2. Prior Art
[0007] Basically two different types of ear molds are offered today. The first type may be denoted custom ear molds and are characterized in that the shape of a specific ear canal is obtained and that the ear mold is subsequently manufactured such that it corresponds to the specific ear canal. At present the shape of the ear canal is typically obtained using an ear impression but this need not be the case since e.g. various digital scanning methods can also provide the shape of a specific ear canal. The second type may be denoted instant fit ear molds and are characterized in that they have not been adapted to the shape of a specific ear canal. Instead this type of ear molds has been adapted to cover a wide range of ear canals. Generally the custom ear molds are advantageous compared to the instant fit type in that they provide a secure and precise fit in the ear canal, whereby the ear molds will not tend to fall out of the ear, and the leakage of sound around the ear mold will be small whereby the risk of acoustic feedback is reduced.
[0008] The respective custom and instant-fit ear molds may further be sub-divided into soft and hard ear molds. The hard custom ear molds may e.g. be manufactured using rapid prototyping techniques. Further details concerning such a method can be found e.g. in U.S. Pat. No. 5,487,012.
[0009] Generally the hard ear molds are advantageous in that the hard materials provide high acoustic attenuation. This is important in order to control sound leakage, and hereby acoustical feedback, from an interior sound channel in the ear mold and towards the surroundings outside the ear mold. The hard ear molds may be disadvantageous in that the hearing aid fitter will typically have to send the ear canal impressions to a remote ear mold manufacturing site, which has the consequence that the hearing aid user has to wait a few days before he can obtain his new hearing aid with hard custom ear molds.
[0010] The soft custom ear molds are typically manufactured by a hearing fitter, who obtains an impression of a specific ear canal and uses a negative of the impression to mold a soft ear mold in e.g. silicone. The soft custom ear molds are advantageous in that they may provide an improved comfort relative to hard ear molds, in that they may reduce sound leakage—even compared to hard custom ear molds, and in that local hearing aid fitters can manufacture this type of ear mold in-house. The soft ear molds may be disadvantageous in that the acoustic attenuation of the available soft ear mold materials is low compared to the available hard ear mold materials.
[0011] As already disclosed the soft ear mold is preferably manufactured in silicone. A preferred silicone is the Biopor, which is biocompatible. However, other resilient materials, such as soft acrylic may also be applied. Generally, the soft ear mold should preferably be manufactured from a material having a hardness which is below 80 measured on the Shore durometer type A scale (see the standard ASTM D2240 for description of the test). This is often written as Shore 80A. Preferably, the hardness is below Shore 60A, and more preferably the hardness is in the range from Shore 20A to Shore 45A.
[0012] In order to solve the problem of the limited acoustic attenuation of the soft ear mold materials it has been proposed in the art to insert a sound tube of a highly acoustic attenuating material into the sound conduit of the soft ear mold. It has been proposed to use e.g. Polyvinyl Chloride (PVC) and Polyurethane (PUR) as sound tube material. These materials are relatively soft and it has therefore been suggested to insert the sound tube into the soft ear mold by:
putting a hard mounting tool through the sound conduit of the ear mold such that the first end of the mounting tool is on the first side of the ear mold and the other end of the mounting tool is on the other side of the ear mold, fixing the sound tube onto a hard mounting tool, pulling the mounting tool, and hereby the sound tube, back through the sound conduit of the ear mold, removing the hard mounting tool from the sound tube, and trimming the ends of the sound tube to make them flush with the ear mold.
[0018] In order to keep the sound tube at the correct position inside the soft ear mold it has been suggested to achieve this by:
providing a soft ear mold wherein the sound conduit is adapted to accommodate a bushing, putting a hard mounting tool through the sound conduit of the ear mold such that the first end of the mounting tool is on the first side of the ear mold (the side adapted to face outwards when inserted in an ear canal) and the other end of the mounting tool is on the other side of the ear mold, fixing a hard bushing to a first end of the sound tube, engaging the first end of the mounting tool with the second end of the sound tube, pulling the mounting tool, and hereby the sound tube and the bushing, back through the sound conduit of the ear mold until the bushing is seated correctly inside the ear mold, removing the hard mounting tool from the sound tube, and trimming the second end of the sound tube flush with the ear mold.
[0026] The soft ear molds may be further be disadvantageous in that traditional ear wax guards, such as disclosed in e.g. U.S. Pat. No. 9,795,562, cannot be used. The main reason for this is that the soft ear molds are not capable of accommodating an ear wax guard or an ear wax guard bushing in the same manner as a hard ear mold. It has therefore become common practice to use the soft ear molds without an ear wax guard. A consequence of this is that the sound tube has to be cleaned regularly which is more cumbersome than simply replacing an ear wax guard.
[0027] It is therefore a feature of the present invention to overcome at least these drawbacks and provide a soft custom ear mold that permits the use of an ear wax guard.
[0028] It is another feature of the current invention to provide a method for manufacturing a soft custom ear mold.
SUMMARY OF THE INVENTION
[0029] The invention, in a first aspect, provides a method for manufacturing a soft custom ear mold having an ear wax guard bushing, comprising the steps of providing an outer part of a soft custom ear mold with a through going conduit having holding means, providing an inner part of a soft custom ear mold comprising a first bushing, a sound tube and an ear wax guard bushing arranged such that the first bushing is fixed to the sound tube and a first end of the ear wax guard bushing is fixed to a first end of the sound tube, providing an elongated tool with an end adapted for engaging a second end of the ear wax guard bushing, putting the elongated tool through the soft custom ear mold conduit, fixing the elongated tool to the second end of the ear wax guard bushing; inserting the inner part into the ear mold conduit by pulling the elongated tool having said inner part attached, through the ear mold conduit until said first bushing is properly positioned in said holding means, and disengaging the elongated tool from the ear wax guard bushing.
[0030] This provides a manufacturing method that is simple to carry out and only requires the use of inexpensive tools.
[0031] The invention, in a second aspect, provides a soft custom ear mold comprising: an inner ear mold part that comprises a first bushing, a sound tube and an ear wax guard bushing, an outer ear mold part that is adapted to fit an individual ear canal and comprises a sound conduit having holding means adapted to engage the first bushing of said inner part, wherein said holding means defines the correct positioning of said inner part in the sound conduit of said outer part whereby a precise and stable positioning of the ear wax guard bushing in the soft custom ear mold is provided.
[0032] This provides a soft custom ear mold that permits the use of an ear wax guard that can be replaced by the hearing aid user in a simple manner.
[0033] Further advantageous features appear from the dependent claims.
[0034] Still other features of the present invention will become apparent to those skilled in the art from the following description wherein the invention will be explained in greater detail.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] By way of example, there is shown and described a preferred embodiment of this invention. As will be realized, the invention is capable of other different embodiments, and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive. In the drawings:
[0036] FIG. 1 illustrates a sound tube, a first bushing and a wax guard bushing in assembled form according to an embodiment of the invention;
[0037] FIG. 2 illustrates the sound tube, the first bushing and the wax guard bushing of FIG. 1 in unassembled form;
[0038] FIG. 3 illustrates an outer part of a soft custom ear mold according to an embodiment of the invention;
[0039] FIG. 4 illustrates an elongated tool adapted for engaging a wax guard bushing according to an embodiment of the invention;
[0040] FIG. 5 illustrates a first stage in a method for manufacturing a soft custom ear mold according to an embodiment of the invention;
[0041] FIG. 6 illustrates a second stage in a method for manufacturing a soft custom ear mold according to an embodiment of the invention;
[0042] FIG. 7 illustrates a third stage in a method for manufacturing a soft custom ear mold according to an embodiment of the invention;
[0043] FIG. 8 illustrates a wax guard and a wax guard insertion and extraction tool according to an embodiment of the invention;
[0044] FIG. 9 illustrates a receiver module adapted for insertion in a soft custom ear mold according to an embodiment of the invention;
[0045] FIG. 10 illustrates the soft custom ear mold according to an embodiment of the invention with the receiver module of FIG. 9 inserted;
[0046] FIG. 11 illustrates a first stage in a method for manufacturing a soft custom ear mold according to an embodiment of the invention;
[0047] FIG. 12 illustrates a second stage in a method for manufacturing a soft custom ear mold according to an embodiment of the invention; and
[0048] FIG. 13 illustrates a third stage in a method for manufacturing a soft custom ear mold according to an embodiment of the invention.
DETAILED DESCRIPTION
[0049] Reference is now made to FIG. 1 , which illustrates an inner part 100 of a soft custom ear mold. The inner part 100 comprises a first bushing 101 , a sound tube 102 and a wax guard bushing 103 . The first bushing 101 is fixed onto a first end of the sound tube 102 , and the wax guard bushing 103 is fixed onto the second end of the sound tube 102 . Both bushings are fixed onto the sound tube using a press-fit between the relatively hard bushings 101 and 103 and the comparatively soft sound tube 102 .
[0050] The first bushing 101 is adapted such that it comprises a bend. This feature makes the first bushing 101 especially advantageous when inserted in the outer part of a soft ear mold since the sound conduit of the outer part of the soft custom ear mold may otherwise tend to collapse, in or around the bend, as may otherwise be imparted on insertion into an ear canal.
[0051] The sound conduit may comprise such a bend simply due to the shape of the ear canal or due to the placement of a receiver in the concha, in which case it may be required that the sound conduit bends from the plane of the concha and into the ear canal, e.g. as shown in WO-A1-2010040351.
[0052] The first bushing 101 is adapted such that it can be accommodated in a corresponding structure in the outer part 200 of the soft custom ear mold whereby the inner part 100 of the soft custom ear mold is fixed at the desired position inside the outer part 200 of the soft custom ear mold. Additionally the first bushing 101 comprises holding means adapted to detachably fix a receiver or a sound tube to that end of the first bushing 101 that is not fixed to the sound tube 102 . Thus in the first case the first bushing is adapted for a receiver-in-the-ear (RITE) type hearing aid and in the latter case the first bushing is adapted for a traditional behind-the-ear (BTE) type hearing aid. The first case is further described below with reference to FIGS. 9-10 and the latter case is further described with reference to FIGS. 11-13 .
[0053] As already discussed the sound tube 102 is preferably manufactured in materials such as Polyvinyl Chloride (PVC) or Polyurethane (PUR) that provide a suitable flexibility for insertion in the sound conduit of the outer part 200 of an ear mold while decreasing the acoustic leakage from the sound conduit.
[0054] The wax guard bushing 103 is adapted such that it can receive a replaceable ear wax guard 104 . Such replaceable ear wax guards are well known within the art of hearing aids and are disclosed in e.g. U.S. Pat. No. 6,795,562 as already discussed above.
[0055] Thus it has to appreciated that the inner part 100 of the ear mold comprising the two bushings 101 and 103 and the sound tube 102 when inserted in the corresponding outer part 200 of the ear mold provide a soft custom ear mold 300 (see e.g. FIG. 10 ) that can accommodate the use of traditional replaceable ear wax guards 104 , whereby the cleaning and maintenance of the soft custom ear mold 300 will become easier and the performance of the ear mold generally improve because the sound output opening of an ear mold having an ear wax guard will be less prone to clogging with ear wax.
[0056] Further it has to be appreciated that it is considerably easier to adapt the outer part 200 of the ear mold such that it can accommodate the first bushing 101 as opposed to adapting the outer part 200 of the ear mold to accommodate the wax guard bushing 103 because the first bushing 101 is larger and because the first bushing 101 is accommodated fully in the interior of the outer part 200 of the ear mold (as opposed to in an opening of the outer part 200 of the ear mold) which makes positioning and fixation of the inner part 100 in the outer part 200 of the soft custom ear mold less difficult to achieve. In the present context this presents a significant advantage because the soft custom ear molds are generally manufactured in-house by a hearing aid fitter using only simple manufacturing equipment. Furthermore the ear wax guard bushing 103 will be securely fixed to the inner part 100 of the soft custom ear mold and will therefore not tend to drop out from the soft custom ear mold.
[0057] In another embodiment the outer part 200 of the soft custom ear mold is manufactured using a negative of an ear canal impression as outer surface of the mold form and wherein the inner structure of the sound conduit is formed by using a mold insert to mold around. In a further embodiment the mold insert comprises a hard cylindrical mold insert part that may be inserted into a softer hollow sleeve having an outer structure corresponding to the desired inner structure of the sound conduit of the outer part of the soft custom ear mold. This type of mold insert allows the manufacture of a less pliable inner structure of the sound conduit, e.g. an inner structure adapted for snap fitting onto the first bushing whereby a more secure positioning and fixation of the inner part of the soft custom ear mold is provided. This can be achieved since the hard cylindrical insert part can be conveniently removed after molding independent of the inner structure of the sound conduit and after removal of this part the remaining hollow sleeve becomes very pliable and therefore easy to remove after molding even in case of a sound conduit with an inner structure having only limited pliability.
[0058] In variations according to the embodiment of FIG. 1 the bushings 101 and 103 may be fixed onto the sound tube 102 using at least one of the methods selected from a group comprising press-fitting, snap-fitting, gluing, welding and two-component molding. Especially press-fitting and gluing can be combined.
[0059] Reference is now made to FIG. 2 , which illustrates the first bushing 101 , the wax guard bushing 103 and the sound tube 102 as separated components prior to being assembled into the inner part 100 of the soft custom ear mold.
[0060] Reference is also made to FIG. 3 , which illustrates the outer part 200 of a soft custom ear mold.
[0061] Reference is now made to the FIGS. 4-8 , which illustrate a tool for mounting the inner part 100 of the soft custom ear mold in the outer part 200 of the soft custom ear mold 300 and corresponding steps of a method for mounting said inner part 100 in said outer part 200 .
[0062] Reference is first made to FIG. 4 , which illustrates an elongated tool 400 with a pointed thread 401 adapted such that the tool 400 when engaging the inner surface of the wax guard bushing 103 enables the wax guard bushing 103 to be pulled through the outer part of the soft custom ear mold 200 . The tool comprises a forward part 402 with a narrow diameter adapted to fit inside a conduit and with a length sufficient to extend through the conduit to protrude at the other end. Further the tool comprises a rearward part 403 which is thicker and is adapted to provide a grip for manipulation.
[0063] Reference is now made to FIG. 5 , which illustrates a first step in said method wherein said pointed thread 401 and forward part 402 of the tool 400 has been put through said outer part 200 .
[0064] Reference is then made to FIG. 6 wherein said tool 400 has engaged said inner part 100 .
[0065] Reference is then made to FIG. 7 wherein said elongated tool 400 with said inner part 100 attached has been pulled back through said outer part 200 until the first bushing 101 is seated in the corresponding structure (not visible in the drawing) in said outer part, whereby the soft custom ear mold 300 is completed. Subsequently the elongated tool 400 is disengaged from the wax guard bushing 103 by twisting the elongated tool 400 in the opposite direction of the rotation used for the initial engagement. The soft custom ear mold 300 is hereby provided with a wax guard bushing 103 that allows traditional replaceable wax guards to be used.
[0066] Finally reference is made to FIG. 8 , which illustrates a traditional wax guard insertion and extraction tool 500 and a corresponding wax guard 104 . Further details may be found in U.S. Pat. No. 6,795,562.
[0067] Reference is now made to FIGS. 9-10 , which illustrate insertion of a receiver module 600 in a soft custom ear mold 300 according to an embodiment of the invention.
[0068] Reference is first made to FIG. 9 , which illustrates the receiver module 600 that comprises the receiver housing 601 and a corresponding electrical conductor 602 for connection to the external part of the RITE hearing aid. The receiver housing 601 comprises holding means adapted for engagement with a first bushing 101 of the inner part 100 of the soft custom ear mold 300 .
[0069] Reference is finally made to FIG. 10 , which illustrates the soft custom ear mold 300 with the receiver module 600 inserted.
[0070] Reference is now made to FIGS. 11-13 , which illustrate insertion of an inner part 700 in an outer part 800 of a soft custom ear mold according to an embodiment of the invention.
[0071] Reference is first made to FIG. 11 , which illustrates the inner part 700 of the soft custom ear mold, the outer part 800 of the soft custom ear mold and an elongated tool 400 .
[0072] The inner part 700 comprises an external sound tube part 701 , a first bushing 702 , an internal sound tube part 703 and a wax guard bushing 103 , 704 , wherein the first bushing 702 is adapted such that a precise and firm positioning of the sound tube assembly 700 inside the outer part 800 is obtained when the first bushing 702 engages corresponding holding means formed at the inner surface of the sound conduit of the outer part 800 of the soft custom ear mold. Further FIG. 11 illustrates a first step in the method for mounting the inner part 700 in the outer part 800 of the custom ear mold, wherein said elongated tool 400 has been put through said outer part 800 .
[0073] Reference is then made to FIG. 12 wherein said elongated tool 400 has engaged the wax guard bushing 103 , 704 of said inner part 700 .
[0074] Reference is then made to FIG. 13 wherein said elongated tool 400 with said inner part 700 attached has been pulled back through said outer part 800 until the first bushing 702 is accommodated in the corresponding structure (not visible in the drawing) in said outer part 800 , whereby the soft custom ear mold 900 is completed. Subsequently the elongated tool 400 will be disengaged from the wax guard bushing 103 , 704 by twisting the elongated tool 400 in the opposite direction of the rotation used for the initial engagement. The soft custom ear mold 900 is hereby provided with a wax guard bushing 103 that allows traditional replaceable wax guards to be used.
[0075] According to the embodiment of FIG. 11 , the internal 703 and external 701 parts of the sound tube is one single tube and the first bushing 702 is fixed to an intermediate part of the sound tube. In variations of the sound tube according to FIG. 11 , the internal 703 and external 701 parts of the sound tube are two separate parts and the two ends of the first bushing are connected to the corresponding ends of the two sound tubes.
[0076] Other modifications and variations of the structures and procedures will be evident to those skilled in the art.
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A soft custom ear mold ( 300 ) comprising: an inner ear mold part ( 100 ) consisting of a first bushing ( 101 ), a sound tube ( 102 ) and an ear wax guard bushing ( 103 ), and an outer ear mold part ( 200 ) that is adapted to fit an individual ear canal and comprises a sound conduit having holding means adapted to engage said inner part ( 100 ). The holding means defines the correct positioning of said inner part ( 100 ) in the sound conduit of said outer part ( 200 ) whereby a precise and stable positioning of the ear wax guard bushing ( 103 ) in the soft custom ear mold ( 300 ) is provided. The invention also relates to a hearing aid comprising such an ear mold ( 300, 900 ), a method for manufacturing such an ear mold and a tool for carrying out a part of said manufacturing method.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 13/016,374, filed Jan. 28, 2011, which is a continuation of application Ser. No. 11/031,514, filed Jan. 7, 2005, which claims priority to and the benefit, under 35 U.S.C. 119(e), of the filing date of U.S. Provisional Application 60/535,615, filed Jan. 8, 2004 and titled “Apparatus and Methods for Processing Biological Samples”, all of which applications are incorporated by reference in their entirety.
FIELD OF THE INVENTION
This invention pertains to the fields of cytology and histology, molecular biology, biochemistry, immunology, microbiology and cell biology. In particular, the invention is related to the fields of molecular cytogenetics and immunohistochemistry and, even more particularly, to a method and an apparatus for processing, treatment, or even staining of at least one biological sample accommodated on a carrier member, such as a microscopic slide as well as to the control of the humidity and temperature during processing. Applications to which the present invention may relate especially include in-situ hybridization, fluorescent in-situ hybridization, cytology, immunohistochemistry, special staining, and microarrays, as well as potentially other chemical and biological applications.
BACKGROUND OF THE INVENTION
Histological and cytological techniques have been used to analyse biopsies and other tissue samples, as an aid to medical diagnosis and research. Cytology is the study of the structure of all normal and abnormal components of cells and the changes, movements, and transformations of such components. Cells are studied directly in the living state or are killed (fixed) and prepared by for example thin layer preparation systems, embedding, sectioning, and/or staining for investigation in bright field, fluorescent or electron microscopes. Histology is the study of groups of specialised cells called tissues that are found in most multi-cellular plants and animals. Histological investigation includes study of tissue and cell death and regeneration and the reaction of tissue and cells to injury, a disease state such as cancer or invading organisms such as HPV (Human Papilloma Virus). Because normal tissue has a characteristic appearance, histological examination is often utilised to identify diseased tissue.
In situ hybridisation (ISH), and Immunohistochemistry (INC) analyses are useful tools in histological diagnosis and the study of tissue morphology. In situ hybridisation (ISH), immunocytochemistry and immunohistochemistry (INC) seek to identify a detectable entity in a sample by using specific binding agents capable of binding to the detectable entity.
A biological sample is in this application to be understood as a biological sample such as histological samples, e.g. tissue and cell specimens, including cell lines, proteins and synthetic peptides, tissues, cell preparations, blood, bodily fluids, blood smears, metaphase spreads, bone marrow, cytology specimens, thin-layer preparations, and specifically biological samples on microscope slides. The biological sample may further suitably be selected from histological material, including formalin fixed and paraffin embedded material, cytological material, fine needle aspirates, cell smears, exfoliative cytological specimens, touch preparations, bone marrow specimens, sputum samples, expectorates, oral swabs, laryngeal swabs, vaginal swabs, bronchial aspirates, bronchial lavage, gastric lavage, blood, urine, and body fluids. Such biological samples may be subjected to various treatments. Further, the biological sample may be suitably selected from non human sources, including virus and fungus swabs, samples taken from medical equipment, veterinary samples and food. Also, samples may be taken from hair, organs, sperm and egg cells as well as cell grown in vitro. The biological samples are preferably from living or post-mortem tissues of Homo sapiens , but not limited to eukaroytic cells. Examples include detection of prokaryotic organisms, such as Escherichia coli 0157 in drinking water.
Slides can be any suitable solid or semi solid support for the biological sample. In particular, the support may be a microscope slide, a micro array, a membrane, a filter, a polymer slide, a chamber slide, a dish, or a Petri dish.
The current invention relates especially—but not exclusively—to in situ hybridisation (ISH). In situ hybridisation is a diagnostic method for characterization and evaluation of genes, chromosomes, cells, cell aggregates, tissues and other biological samples. In situ hybridisation can be used to evaluate and characterize the status, genetic abnormalities and other disease states, such as cancer or disease, caused by infectious organisms. Further, it can be used to characterize cells with respect to infectious agents such as, but not limited to, HPV, HIV (Human Immunodefiency Virus) and HCV (Hepatitis C Virus). Molecular genetic events, such as aneuploidy, gene amplification, gene deletion, RNA expression, RNA transportation, RNA location and chromosome translocations, duplications, insertions, or inversions that are difficult to detect with karyotype analysis, PCR (Polymerase Chain Reaction), or LCR (Ligase Chain Reaction) can be characterized by ISH.
The ISH techniques can have the potential to increase the survival chances of cancer patients by making possible earlier detection of malignancy and more accurate prognostic assessments following tumour surgery. The technique can also be applied to prenatal and postnatal genetic analysis. Furthermore, the technology can be used for simultaneous detection of multiple genetic anomalies in an individual cell, and thereby save assay time and limit specimen requirements.
Non limiting examples of diagnostically important ISH assays include detection of HER-2 (also known as HER-2/neu or c-erbB2), Topo II (breast carcinoma), telomers, EGFr, C-Myc (breast carcinoma), N-Myc (neuroblastoma); translocation probe pairs for BCR/ABL (chronic myelogenous leukemia), EWS (Ewing's sarcoma), C-Myc (Burkitt's lymphoma, T cell ALL), acute myeloid leukemia (AML), myeloproliferative disorders (MPD), Myelodysplastic Syndrome (MDS) and centromeric probes for chromosomes 17, 7, 8, 9, 18, X, and Y. Other examples include the analysis of Epstein-Barr virus, Herpes simplex virus and Human cytomegalo virus, Human papilloma virus, Varizella zoster virus and Kappa and Lambda light chain mRNAs. Yet other examples include the detection and analysis of samples of non-human origin, for example, food borne parasites and disease causing microbes and viruses. More specific examples include:
i) the analysis of HER-2/neu, also known as c-erbB2 or HER-2, which is a gene that has been shown to play a role in the regulation of cell growth. The gene codes for a transmembrane cell surface receptor that is a member of the tyrosine kinase family. HER-2 has been shown to be amplified in human breast, ovarian and other cancers;
ii) the analysis of aneuploidy for chromosomes 3, 7, 17 and loss of the 9p21 locus in urine specimens from patients with transitional cell carcinoma of the bladder;
iii) the detection and quantification of the lipoprotein lipase (LPL) gene located at 8p22 and the C-MYC gene located at the 8q24 region (Two genetic alterations observed in abnormal cells, such as Prostate cancer samples, are gain of 8q24 and 8p21-22 (LPL) loss of heterozygosity.);
iv) the identification and enumeration of chromosome 8 in cells obtained from bone marrow. An association has been made between trisomy 8 and both myeloid blast crisis and basophilia (Trisomy 8 is a prevalent genetic aberration in several specific diseases like Chronic Myelogenous Leukemia (CML), acute myeloid leukemia (AML), and myeloproliferative disorders (MPD).);
v) the analysis of chromosome aneuploidy like translocations of the immunoglobulin heavy chain locus (IGH) located at 14q32 and frequently observed in patients with various hematological disorders (These IGH translocations result in the upregulation of oncogenes due to the juxtaposition of IGH enhancers with these oncogenes.);
vi) the identification of inv(16)(p13q22) where the CBFB gene located in 16q22 is fused to the MYH11 gene located in 16p13, resulting in a chimeric protein product detected in acute myeloid leukemia (AML);
vii) the detection of Human Papilloma Viruses (HPV), which are a group of small DNA viruses (There are more than 90 HPV types. Persistent HPV infection may result in cervical cancer, and has also been associated with other types of cancer, e.g. colon cancer. HPV types are classified according to the risk associated with the development of cervical cancer. Fifteen types are classified as high-risk, and these are detected in more than 99% of all cervical cancers.).
In summary, the in situ Hybridization (ISH) technique is a useful method for the analysis of cells for the occurrence of chromosomes, chromosome fragments, genes and chromosome aberrations like translocations, deletions, amplifications, insertions or inversions associated with a normal condition or a disease. Further, ISH is useful for detection of infectious agents as well as change in levels of expression of RNA.
The ISH techniques should be understood to include, for example, fluorescent in situ hybridization (FISH), chromogenic in situ hybridization (CISH), Fiber FISH, CGH, chromosome paints and arrays. In the following, the ISH technique and procedures are described in greater detail. ISH uses nucleic acid probes, designed to bind, or “hybridize,” with the target DNA or RNA of a specimen, usually fixed or adhered to a glass slide. DNA, RNA, PNA, LNA or other nucleic acid probes of synthetic or natural origin can be used for the ISH technique. The probes are labelled to make identification of the probe-target hybrid possible by use of a fluorescence or bright field microscope. The probe is typically a double or single stranded nucleic acid, such as a DNA or RNA. It is labelled using radioactive labels such as 31P, 33P or 32S, or non-radioactively, using labels such as digoxigenin, or fluorescent labels, a great many of which are known in the art. The hybrid is often further analysed with computer imaging equipment. Since hybridization occurs between two complementary strands of DNA, or DNA analogues, labelled probes can be used to detect genetic abnormalities, providing valuable information about prenatal disorders, cancer, and other genetic or infectious diseases.
Unlike other molecular DNA-based tests, which require cell lysis to free nucleic acids for analysis, ISH allows analysis of DNA in situ, that is, in its native, chromosomal form within the cell or even the nucleus. This feature permits the analysis of chromosomes, genes and other DNA/RNA molecules of individual cells. For direct-labelled probes, the results are detected by viewing the samples under a fluorescence microscope with appropriate filters. Indirect detection, like CISH, demands additional labelling steps, which typically require streptavidin or antibody-enzyme conjugates or fluorophore-labeled counterparts, and additional washing steps once the probe is bound to the target.
An exemplified general ISH procedure includes one or several of the following sequential procedural steps:
i) Mounting of the biological sample on slides
ii) Baking at elevated temperatures
iii) Dewaxing or deparaffination if necessary
v) Washing
v) Target retrieval at elevated temperature
vi) Denaturing at elevated temperature
vii) Incubation with blocking reagents
viii) Addition of probe mixture to the sample on the slide.
ix) Placing a coverslip over the sample and the probe mix and sealing with rubber cement.
x) Hybridization at elevated temperatures.
xi) Washing at elevated temperatures and removal of coverslip
xii) Air drying and counterstaining
xiii) Visualization according to the instruction for FISH or CISH
xiv) Examination and evaluation in a microscope
In more detail, an exemplified FISH protocol for paraffin embedded tissue sections could include one or several of the following sequential procedural steps:
i) Cutting 2-4 micrometer tumour sections from a block
ii) Mounting on slides
iii) Baking at 60° C. for 30 minutes
iv) Deparaffination using xylene
v) Rehydration by immersing in ethanol/water mixtures
vi) Pre treating by washing with an aqueous buffer for 10 minutes at 95° C.
vii) Pepsin digesting for 10 minutes at ambient temperature
viii) Washing repeatedly
ix) Dehydration in a series of cold ethanol/water mixtures
x) Air drying
xi) Addition of 10 microliter fluorescent labelled DNA or PNA probe mixture per slide
xii) Sealing with a 22 by 22 mm glass coverslip and rubber cement at the edges
xiii) Denaturing at 82° C. for 5 minutes, directly followed by
xiv) Hybridization over night (18 hours) at 45° C.
xv) Removal of the coverslip
xvi) Stringent washing at 65° C. for 10 minutes
xvii) Washing repeatedly with wash buffer
xviii) Dehydration by immersing in a series of cold ethanol/water mixtures
xix) Air drying
xx) Mounting with 10 microliter anti fade solution with DAPI as counter stain
xxi) Sealing with a coverslide
xxii) Examination and evaluation in a fluorescence microscope
The hybridization mixture is typically a complex mixture of many components. Non-limiting examples of components include formamide, water, triton x-100, tween 20, Tris or Phosphate buffer, EDTA, EGTA, polyvinylpyrrolidine, dextran sulfate, Ficoll, or salmon sperm DNA.
Chromogenic in situ hybridization (CISH) uses labelled probes, which can be visualized by the use of immunological staining methods similar to the IHC staining procedures. CISH has some differences compared to FISH techniques: The genetic aberrations may be viewed within the context of tissue morphology—simultaneous examination of histopathology and ISH results. Also, the results may be visualized with a standard bright field microscope, and the chromogenic dye (for example DAB) generated on the slide is permanent with no or little fading of fluorescent signals.
In addition to ISH, the current invention also relates to immunohistochemistry and immunocytochemistry. The general exemplified formalin fixed paraffin embedded (FFPE) immunohisto chemical (IHC) chromogenic staining procedure may involve the steps of: cutting and trimming tissue, fixation, dehydration, paraffin infiltration, cutting in thin sections, mounting onto glass slides, baking, deparaffination, rehydration, antigen retrieval, blocking steps, applying primary antibody, washing, applying secondary antibody-enzyme conjugate, washing, applying enzyme chromogen substrate, washing, counter staining, cover slipping and microscope examination.
As described above, the sample treatment of the slides is complicated, laborious and uses many different reagents at various temperatures for prolonged periods. It should be understood that under normal conditions only small amount of reagents, 200 μl or even less, are applied to the sample. Thus, the reagent and sample are very easily dried out, especially under high temperatures and at low relative humidity. Many of the procedural steps in ISH, including the denaturing and the hybridization steps are typically done in a humidity chamber. The humidity chamber is a closed or semi closed container in which the slides can be processed and heated. It should be understood that the processing temperature as well as the temperature ramp time—that is, the change of temperature per time unit, is important for both the overall protocol length and the subsequent visualized result. Furthermore, it has been observed that the staining result depends strongly on the humidity during the sample treatment. Also, the morphology can suffer from drying out during the treatment. For example, chromosome spreads are easily ruined due to drying out conditions. During the changes of temperatures the air above the slides will expand or contract. The reduction in pressure during lowering of the temperature will draw in air from the outside, which may be less saturated with water compared to the air above the slide. During heating, air will be pressed out of the space between the slide and the lid. This air will contain moisture, which will escape from the system. Consequently, due to the plurality of fast and repeated changes in temperature, high temperatures for prolonged time and the small space between the slides and the lid, moisture can escape either quickly, or over time, from the system, resulting in a change in the concentration of the reagents applied to the biological sample and thus a change in the protocol, or even drying out of the biological sample.
The absolute humidity is defined as the amount of water in a given volume of gas. The relative humidity is the ratio between the amount of water and the maximum amount of water possible at the given temperature and pressure. The maximum amount of water per volume, and consequently the relative humidity, depends strongly on the temperature, as described by the Clausius-Clapeyron equation. For example, without addition of water in a closed system, 100% relative humidity at 25° C. will correspond to 16.3% at 60° C. and 3.7% at 95° C., indicating the strong dependence of temperature. Even a small change of temperature will change the relative humidity dramatically. For example, a relative humidity of 100% at 80° C. will correspond to only 66.7% at 90° C. in a closed system without addition of moisture.
From the discussion above, it should be clear that precise control of humidity, heating and cooling is essential for obtaining, for example, consistent ISH results. Therefore, without an efficient humidifying system, heating of the slides can result in fast drying out of the reagents or sample.
DESCRIPTION OF PRIOR ART
In order to prevent drying out or loss of “reagents” of the slides, several different closed humidifying systems are known to be used in the cytogenetic, pathology and research laboratories during for example the critical steps of denaturation and hybridization.
U.S. Pat. No. 6,555,361 discloses a hybridization chamber that contains a built-in mechanism for saturating the air within the chamber when sealed thereby preventing drying of the liquid sample. The hybridization chamber is defined by matching top and bottom clam-shell like halves that, when brought together, are sealed by an O-ring and clamping device. The chamber is equipped with a liquid reservoir, the liquid from which will serve to saturate the volume of air sealed within the hybridization chamber. A saturated atmosphere within the chamber prevents evaporation of the sample. This patent illustrates an interior chamber sized to receive a glass microscope slide and suggests positioning a well within the chamber to retain liquid separately from the region for holding a liquid sample. Further, it is suggested to dispose a microporous membrane material in the chamber and specifically in the well. The control of temperature and humidity inside the chamber during rapid warm-up or cool-down periods is not discussed in this patent document.
Humid boxes or humidified chambers are typically plastic containers with a lid. Water-soaked paper towels are placed in the bottom of the box and excess water decanted away. Slides in racks can be placed horizontally or vertically in the box during for example overnight hybridization. Typical “home-made” humid box laboratory equipment includes standard Tupperware™ or Rubbermaid™ boxes or standard cake pans with a tight closing lid. Wet paper tissue is placed in the bottom. A frame or grid is placed over the tissues and the slides placed on the frame or grid before the lid is closed. The humid box is placed in a conventional or microwave oven or on top of a heating plate during for example the denaturation or hybridization steps. To further control the humidity and temperature profile, the humid box can be isolated to limit heat loss and thereby hold the temperature for longer periods.
An insulated box like e.g. the HybBox™ (InSitus BioTechnologies, Albuquerque, N. Mex., USA) made of expanded polystyrene with a base and a lid is an attempt to further control the humidity and temperature during for example hybridization. After denaturation of the biological sample on slides in an oven, the slides are transferred to the HybBox™, which is tightly closed. After hybridization, the box is opened and the slides further treated.
To further control the temperature profile during general slide processing, several temperature-controlled chambers are commercially available. One example is the Boekel Slide Moat™ (Boekel Scientific, Feasterville, Pa., USA) consisting of a temperature controlled heating block. Up to 30 standard microscope slides can be placed horizontally on the heating block. A glass lid with seals closes over the heating block and the slides. Placing wet towels on the heating block together with the slides can give high humidity.
The HYBrite™ Denaturation/Hybridization System (Vysis, Abbott Laboratories, Downers Grove, Ill., USA) is another temperature controlled humid chamber widely used in, especially, ISH laboratories. It consists of a programmable heating plate on which up to 12 microscope slides can be placed. A lid comes down over the heating plate and slides and closes the system. On each side of the slide heating plate, wells or channels can hold water or wet tissues or towels. Humidity is thereby sought controlled by the use of wet tissues or towels. Once the slides are placed in the instrument and the lid is closed, sequential denaturation and hybridization steps can be performed automatically without the intervention of the user.
In an attempt to further control the temperature and avoid small temperature fluctuations, the TruTemp heating system (Matrix, Hudson, N.H., USA) uses a heated lid in addition to the heated slide block. The instrument consists of a programmable heating block on which the slides are placed. The lid is further heated. Humidification is provided by water added to wells integrated into the heating block on which the slides rest.
Typically, the user can program the various commercially available temperature controlled humid systems with many time-temperature protocols from 0 to more than 24 hours and from ambient temperature to 100° C.
In yet another attempt to automate the temperature and humidity during processing, automated instruments using so called liquid coverslip systems (Ventana Medical Systems, Tucson, Az) have been introduced. The limiting of drying out of slide-mounted specimens has been sought by covering the reagents and sample with an immiscible oil. The system only limits the evaporation, resulting in loss of a significant part of the reagent volume and is not practical for hybridization in more than 12 hours at elevated temperatures.
The instruments eliminate a number of steps and reduce hands-on time required during conventional ISH procedures performed by cytogenetic, pathology and research laboratories. Nonetheless, the manual systems using ovens and various plastic containers, in general, still give the best results with regard to both preserved morphology and staining efficiency. The semi or fully automated humid boxes or chambers have the advantage of e.g. less hands-on work and ease of use. However, none of the semi or fully automatic humid boxes or chambers has succeeded in providing a performance equivalent to or exceeding the manual methods, with respect to preserved morphology and staining efficiency. The humidity control is closely connected to the temperature, as discussed previously, but is not easily controlled. Also, no known system has truly addressed the problem of having both controllable uniform temperature and uniform and high humidity over the slides for prolonged time.
In light of the above discussion, there is a need in the art for an improved treatment device for treating biological samples. In summary, the improved sample treatment device should ideally include: programmable temperature control; precise control of heating and cooling; fast change of temperature; independence of the number of slides treated; high humidity at any relevant temperature; constant humidity for prolonged periods; and uniform temperature and humidity over the slides. The present invention addresses such a need.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for processing biological samples, the apparatus comprising means for processing at least one biological sample accommodated on at least one carrier member, characterised in that at least one reservoir able to accommodate a fluid is arranged on a surface adjacent to and/or facing a substantial part of the at least one biological sample. The proximity of the fluid reservoir and the sample is important in order to ensure that vapor from the reservoir can be generated at a rate able to maintain a constant high relative humidity in the chamber formed around the sample by the inner surfaces of the apparatus during a heating period with raising temperature.
In a preferred embodiment, the reservoir is arranged above the at least one sample on the at least one carrier member.
In a preferred embodiment, the apparatus comprises a bottom member arranged to support at least one carrier member carrying at least one biological sample and characterised by further comprising a lid including at least one fluid reservoir. The preferred position of the fluid reservoir is on the lower surface of the lid. This ensures the optimal proximity to the samples.
In a preferred embodiment, the lid member is provided with holding means, such as a grid, slots and/or fingers (not shown), supporting the at least one fluid reservoir, arranged to be located above the biological samples when the lid is closed, thereby covering the bottom member.
In a preferred embodiment, an apparatus according to the invention is characterized in that the reservoir is placed less than 5 cm from the carrier member, and, preferably, less than 1.0 cm from the carrier member, and, yet more preferably, less than 0.50 cm from the carrier member.
Preferably, an apparatus according to the invention is characterized in that the macroscopic surface area of the reservoir adjacent to and/or facing the sample on the carrier member is more than 10% of the total carrier member area, and, preferably, more than 30% of the total carrier member area and, even more preferably, more than 60%. The extension of the reservoir plays an important role in the same way as the proximity by improving the rate by which the relative humidity may be changed as well as the ability to maintain a prescribed high relative humidity during a rapid heating period with raising temperature.
Preferably, an apparatus according to the invention is characterized by comprising heating means for heating the sample on the carrier member. Preferably, the heating means are incorporated in the apparatus.
Preferably, the apparatus is characterized by comprising temperature controlling means controlling the temperature of the carrier member and, thereby, the temperature of the biological sample on the carrier member. Preferably, the apparatus includes temperature-controlling means enabling an automatic heating of the sample according to instructions prescribed in a protocol defining the desired processing of the sample.
Preferably, the apparatus is characterized by comprising at least one temperature sensor connected to the temperature controlling means.
In a preferred embodiment the heating means are heating wires. Alternatively, the heating means may be inductive heating.
Preferably, the temperature controlling means comprises cooling means for cooling the sample on the carrier member. The prescribed processing of a biological sample typically involves cooling after a period of heating. In a preferred embodiment the cooling means are Peltier elements and/or at least one fan.
In a preferred embodiment, the apparatus may comprise heating means for heating the reservoir, and the temperature controlling means may enable control of humidity in the chamber by changing the temperature of the reservoir and/or sample by activating the heating means or the cooling means in the bottom member of the apparatus and/or in the lid.
In a preferred embodiment of the apparatus, the heating means for heating the sample on the carrier member and the heating means for heating the reservoir are controlled separately, and may be heated to different temperatures, so that the reservoir may become warmer than the sample or vice versa. In this manner, the control of the relative humidity within the chamber around the sample may be highly improved as a high humidity may be generated fast by raising the temperature of the reservoir, thereby releasing vapor molecules into the atmosphere in the chamber and thereby around the sample. Dependent on the temperature of the sample and the reagents on the sample—and such temperature can be controlled by heating or cooling the support of the sample—the vapor may stay in a balance with the reagents and the sample or may concentrate on the sample and in the solution comprising the reagents.
Alternatively, if a lower humidity is desired, this may be obtained by lowering the temperature of the reservoir so vapor tends to concentrate on the reservoir and become absorbed by the reservoir so vapor can be extracted from the atmosphere around the sample in case a drying out of the sample should be desired.
It is an essential advantage of the new apparatus according to the invention that a complete control of temperature and humidity in the atmosphere around the biological sample is made possible.
In a preferred embodiment of the apparatus, the reservoir is shaped as a substantially flat sheet. Preferably, the thickness of the reservoir is less than 1/10 of the length, so that the external surface—also called the macroscopic surface—is large compared to the volume. It is essential that the reservoir can contain a sufficient volume of water, but it is even more essential that the surface enabling an exchange of vapor in and out of the reservoir is large enough to enable a rapid release or absorption of vapor.
In a preferred embodiment of the apparatus, the reservoir is attached to a lid, which, in a closed position, covers the at least one biological sample on the carrier member lying on a temperature-controlled plate. In another preferred embodiment of the apparatus, the reservoir is the lid, which, in a closed position, covers individual slides with individual temperature controlled plates. In yet another preferred embodiment of the apparatus, the reservoir is the lid, which, in a closed position covers several slides lying on a number of temperature-controlled plates.
Preferably, in the apparatus according to the invention, the reservoir may have a curved surface structure and uneven surfaces, such as a corrugated surface.
Preferably, the fluid in the reservoir is a liquid and the reservoir comprises a medium able to adsorb and/or absorb and desorb and/or release the liquid. Preferably, the fluid is substantially pure water. Alternatively, the fluid may be water including additives, such as an anti-microbial agent.
The fluid may comprise formamide, aqueous buffers, alcohols, dimethylformamide, dimethylsulfoxid, N-methyl-pyrolidone, non-aqueous buffers or complex mixtures containing inorganic salts, detergents, pH buffers, organic solvents, glycerol, oil and/or water, or mixtures thereof.
Preferably, the reservoir is a device made of a material having a very high internal surface area, such as artificial and natural sponges, comprising a plurality of cavities able to accommodate a fluid. Preferably at least a substantial portion of the surface(s) is hydrophilic.
Preferably, the reservoir is made of a material from the group comprising polymeric fiber composites and blends, glass fiber materials, expanded porous polymers, porous ceramics, Rockwool™, wood pulp, cardboard, leather or celluloses based materials.
Preferably, the reservoir is made of a material comprising any of the compositions from the group comprising polyethylene, polypropylene, polyurethanes, polysulfones, polyvinyl, polyamide, polyisobutylene, siloxane polymers, polyacrylic compositions, ethylene Vinyl Acetate, viscose rayon, polystyrene, macroreticular polystyrene, aliphatic, or phenol-formaldehyde condensate polymers, epoxy, cotton, polysaccharide, modified polysaccharides, wood pulp, calcium carbonate, silica gels, glass fiber, bentonite, perlite and zeolite.
Preferably, the reservoir is made of a material from the group comprising manmade or synthetic polymeric bonded, non-bonded, woven or knitted fibers, micro fibers, textiles and tufted textiles. Preferably, the reservoir is made of a material from the group comprising bonded polyamide, polyester, polyolefines and cellulose acetate fibers. Preferably, the material is made of non-woven and bonded blends of hydrophilic modified polypropylene and polyethylene micro fibers. Preferably, the material is made of bundles of fibers or other loose material retained by a thin wall of film.
Preferably, the reservoir material has a density from 0.050 to 1.5 gram/cm 3 and, more preferably, from 0.075 to 0.75 gram/cm 3 . Preferably, the reservoir material has the ability to hold at least a predefined minimum volume of liquid per carrier member. Preferably, the reservoir material has the ability to hold at least 10 micro-liters (μl) in total per carrier member, and, more preferably, more than 100 micro-liters (μl) in total per carrier member, such as more than 200 micro-liters (μl) in total per carrier member, and even more than 500 micro-liters (μl) in total per carrier member, and such as more than 1000 micro-liters (μl) in total per carrier member.
Preferably, a further reservoir is arranged on top of the lid for fluid communication with the absorbing and desorbing reservoir opposite to the biological sample. The further reservoir can easily be refilled with water without opening the hybridising chamber, and the further reservoir may be in fluid communication with the reservoir material though thin channels in the lid allowing the water to ooze or flow slowly towards the reservoir material.
The current invention has solved the problem of control of humidity from an ISH or IHC reaction by having a liquid reservoir very close to and adjacent to, preferably facing, the sample on the slide. Furthermore, the reservoir is designed for fast exchange of humidity between the liquid phase in the reservoir and the vapor phase in the space between the slide and the lid.
The invention also relates to a reservoir. The reservoir according to the invention is characterised in that the reservoir comprises a medium capable of adsorbing and/or absorbing and desorbing and/or releasing the liquid.
Preferably, the reservoir may be shaped as a substantially flat sheet or plate, so that the surface of the reservoir facing the sample is large, preferably larger than the surface of the sample. Preferably, the thickness of the reservoir is less than 1/10 of the length, in order to fit into the chamber surrounding the at least one sample. Typically, the sample support and the cover or lid forming the chamber around the sample can be designed to leave only a little free space between the sample and the cover or lid. By minimising the volume of the chamber, it is easier to limit the evaporation from the sample as well as to control the content of the atmosphere in the small chamber.
In one embodiment, the reservoir may have a curved surface structure and uneven surfaces, such as a corrugated surface, in order to increase the surface area.
Preferably, the macroscopic surface area (external surface area) of the reservoir adjacent to and/or facing the sample on the carrier member is more than 10% of the total carrier member area, and, more preferably, more than 30% of the total carrier member area and, even more preferably, more than 60%.
Preferably, the reservoir is a device made of a material having a very high internal surface area, e.g. comprising a plurality of cavities able to accommodate a fluid, or wherein the material is made of bundles of fibers or other loose material retained by a thin wall of film. Preferably, at least a substantial portion of the surface(s) is hydrophilic.
Preferably, the reservoir may be impregnated with an anti microbial agent or other protective agents. Preferably, the type, shape and size of the reservoir material are selected to optimise surface properties to match with the liquid surface tension.
The reservoir is a device that can contain liquids, e.g. water, located above or adjacent to the slides and the heating plate below the slides. The liquid can be contained in the reservoir over the slides despite the gravitational forces.
The reservoir has the ability to fast adsorb and/or absorb as well as desorb and/or release liquids. The reservoir is preferably made of a material with very high surface area.
The reservoir can be made of a number of different materials, non-limiting examples including polymeric fiber composites and blends, glass fiber materials, expanded porous polymers, porous ceramics, Rockwool™, wood pulp, cardboard, leather or celluloses based materials.
Further non-limiting examples of reservoir materials include materials containing polyethylene, polypropylene, polyurethanes, polysulfones, polyvinyl, polyacrylic, ethylene Vinyl Acetate, viscose rayon, polystyrene, macroreticular polystyrene, aliphatic, or phenol-formaldehyde condensate polymers, epoxy, cotton, polysaccharide, modified polysaccharides, wood pulp, calcium carbonate, silica gels, glass fiber, bentonite, perlite or zeolite. Even a grid of thin steel wires may provide a reservoir for a liquid.
Preferable materials include manmade or synthetic polymeric bonded, non-bonded, woven or knitted fibers, micro fibers, textiles or tufted textiles. More preferably, the materials are made of bonded polyamide, polyester, polyolefines or cellulose acetate fibers. Even more preferably, the material is made of non-woven and bonded blends of hydrophilic modified polypropylene and polyethylene micro fibers. Further, it should be understood that the reservoir material could be made of bundles of fibers or other loose material retained by a thin wall of film.
The material can be selected to optimise surface energy to match with the liquid surface tension. The surface properties of the material can be due to the bulk material or from specific chemical, plasma or irradiation surface treatments. Such treatments are well known to the person skilled in the art of polymer chemistry.
The high internal surface areas can adsorb and later desorb a wide variety of different liquids depending on the environment in which they are used. The relative humidity over the sample on the slide is a consequence of the absorption characteristics of the reservoir material and the temperature. Because of the variation options, such as the type, surface properties, shape and size of the reservoir material, the porosity, and the pore size, the broad spectrum of requirements of humidification action can be fulfilled.
The reservoir should be selected from materials having a density from 0.050 to 1.5 gram/cm 3 , and, preferably, from materials having a density from 0.075 to 0.75 gram/cm 3 . Experience has proven that such density of the preferred porous or fibrous materials provides the desired absorbing and desorbing features.
The reservoir should be selected from materials and geometrical shapes having the ability to hold at least a predefined minimum volume of liquid per carrier member or microscope slide. Preferably, the reservoir has the ability to hold at least 10 microliters in total per carrier member, and, more preferably, more than 100 microliters in total per carrier member, and, yet more preferably, more than 200 microliters in total per carrier member, and, even more preferably, more than 500 microliters in total per carrier member, and, most preferably, more than 1000 microliters in total per carrier member.
The ability to hold the water is essential, as any water drops on the sample would deteriorate the staining of the sample. Also, a high amount of water in the reservoir is important to obtain a high rate of exchange of humid air in order to maintain the desired humidity above and within the sample.
Preferably, the reservoirs are in the form of flat sheets or plates. Preferably, they may have a curved surface structure and uneven surfaces such as a corrugated surface to optimise the surface area.
Preferably, the reservoir is sufficiently rigid and stable and self-supporting, and does not creep or bend downward. Also, preferably, the reservoir does not markedly swell or change shape during desorption or adsorption of liquids or due to change in temperature.
Preferably, the reservoir is placed less than 5 cm over the slides. More preferably, the reservoir is placed less than 1.0 cm over the slides, and, yet more preferably, less than 0.50 cm over the slides.
It should be understood that the slides and reservoir could be in a tilted or vertical or horizontal position. It is the position of the reservoir adjacent to or facing the sample on the slide which is essential. Also, the arrangement of slides and reservoir could be turned upside down, so that the reservoir will be located below the slide.
The macroscopic surface area (the external surface) of the reservoirs facing towards the slides should preferably be more than 10% of the total slide area. More preferably, the area should be more than 30% of the total slide area. Even more preferably, the area should be more than 100% of the total slide area. The macroscopic surface area of the reservoirs should be understood as the external area of the reservoirs and not the internal surface area of the fibers or cavities.
In one preferred embodiment, the reservoir is attached to a lid, which comes down over the slides lying on a temperature-controlled plate. Thereby, the slides are enclosed in a closed controllable space, preferably provided with temperature sensors controlling the climate. In another embodiment, the reservoir is placed between slides and the lid, which comes down over the slides lying on a temperature-controlled plate. In yet another embodiment, the reservoir is the lid, which comes down over individual slides with individually temperature-controlled plates, or several slides lying on a temperature controlled plate or plates.
It should be understood that the cover or lid could cover one, two or several slides on the temperature-controlled plate or the individually temperature-controlled plates.
In yet further embodiments, the reservoir as described above may be further temperature controlled by a heating device above the reservoir. Preferably, one or more sensors are arranged for sensing temperature above the slide(s).
If the reservoirs are attached to the lid and are to be changed, it is preferred to have small handles or perforated taps in the material for easy manual manipulation.
Preferably, heating from beneath the slide controls the temperature of the slide and biological sample. However, it should be understood that the reservoir could also be heated. Preferably, this can be done by electrical heating wires embedded in the reservoir material or from a heating plate in the lid. This will further increase the efficiency of the reservoir's ability to humidify the air over the slides, as a pre-warmed reservoir will more easily humidify the space over the slides.
It should further be understood that the reservoir could be connected to external reservoirs by tubing or other means to allow increased capacity. Consequently the reservoir can be easily refilled. Also, different liquids can be added depending on the reaction and the protocol defining the sample processing.
It should be understood that, in some applications, the temperature might be ambient for long periods. That is, the slides may not be heated to above the ambient temperature. This is of relevance for storage of slides overnight before or after staining or for expanded incubations with reagents.
The reservoir can hold water, aqueous buffers, formamide, alcohols, dimethyl-formamide, dimethylsulfoxide, N-methyl-pyrolidone, non-aqueous buffers or complex mixtures containing inorganic salts, detergents, pH buffers, organic solvents, glycerol, oil and/or water as well as mixtures of the above-mentioned liquids.
Further, it should be understood that the composition of the liquid might include an anti microbial agent, an UV or other protective agents.
Further, it should be understood that the composition of the liquid in the reservoir might not be the same as in the vapor phase i.e. the vapor in the atmosphere in the environment between the reservoir material and the biological sample and reagents on a carrier. By adjusting the composition of the liquid in the reservoir, the composition of the vapors over the slides may be controlled. Specifically, through adjustment of the temperature of the liquid components in the reservoir, the content in the environmental vapor phase can be influenced. Experience has proven that, by maintaining a high humidity close to 100% during the relevant processing, the water content in the sample will, by the end of such processing (typically after a heating, and cooling and storing over night) be about the optimum for obtaining a perfect staining of the sample.
Further, it should be understood that the current invention especially relates to semi or fully automated instruments. Especially, computer controlled and programmable automated instruments for handling and processing slides will benefit from this invention.
The humidity above slides positioned individually, or in rack or carrousel arrangements in instruments can be controlled by the current invention. In fact, the invention is not limited to any particular arrangement of the slides on a slide platform. The reservoirs can be positioned in a stationary position adjacent to the slides.
Alternatively, the reservoirs or slides can be moved to be adjacent to each other when humidity is to be controlled. The reservoir can be single use, disposable or more permanently used in a semi or fully automated instrument.
Of particular relevance is the use of a lid made entirely or partly of the reservoir of the invention. The lid may be placed adjacent to and preferably facing the slide, and the lid controls the humidity, i.e. a sufficiently wet lid will provide for almost 100% relative humidity. Preferably, the lid is placed over the slide while the slide is positioned over a heating device. Reagents or other liquids can be added to the slide through one or several holes in the lid.
An automated dispensing device can deliver the reagents. Similarly, liquids can be added to the reservoir by automated dispensing devices in the instrument.
Further, it should be understood that the current invention would also function as a general warmer of microscope slides or other supports, by specifying a constant time and uniform temperature and humidity.
Another application, which will benefit from the current invention, is ISH on arrays. The arrays can contain thousands of spots or dots of sample. For example, the spots or dots could comprise immobilized tissue, genetic material, DNA, cDNA or RNA. The processing and visualization protocols resemble the protocols of more traditional ISH. Similarly, the control of humidity is essential for consistent results.
Applications using flat membranes or gels, like the one used in western and northern blots and treatment of electrophoresis gels will benefit from the highly controlled humidity and temperature of the current invention.
The PCR and LCR technique is only with difficulty performed in situ on samples mounted on slides. One of the problems is the lack of standardization with respect to temperature ramp time and uniform humidity control. The PCR or LCR procedures, which include repeated changes of temperature for long periods could benefit from the current invention.
Another application, which will benefit from the current invention, is the implementation of ISH on arrays. The arrays can contain thousands of spots, dots, sample dots or tissue samples on a single small or large slide or planar support. The uniformity of treatment over the many dots with respect to temperature and humidity is particularly important to ensure reproducible results.
Also, it should be understood that the current invention could reduce the humidity. The ability of the reservoir to efficiently adsorb moisture will create a dehumidifying system. As an example, such ability could be desirable when the temperature of the slide is decreased, which implies that some vapor in the air over the slide will be released as water, and this water has to be removed from the air over the slide. By having the hydrophilic reservoir, such vapor can be adsorbed on the hydrophilic fibers.
For example, by using a dry reservoir, with no or little liquid present, the high area surface removes the liquid between the space of the slides and the reservoir. This will result in fast dehydration of the slides. Furthermore, applying heat to the slides will increase the speed and efficiency of the dehydration process. For example, as described previously, the typical ISH protocol includes a dehydration step after the stringency wash step. The stringency wash is followed by two wash steps, by which the slides are immersed in a series of baths with increasing ethanol concentration and left to air-dry, before addition of mounting medium.
By using a reservoir with the capability to adsorb liquid, the number of steps in the process can be reduced. Heat applied to the slides will further speed up the process. In summary, an efficient dehumidifying system can reduce the steps and reagents needed for dehydration of slides.
The invention further relates to a method of processing biological samples wherein at least one biological sample is arranged on a carrier member, for treatment in order to prepare the sample by staining for a visual analysis of the sample, characterised by maintaining substantially at least 80% relative humidity above the sample through the close presence of a reservoir filled with water. Preferably, the method is characterized by maintaining relative humidity in the atmosphere above the sample of substantially at least 85% and, preferably, at least 90%, and, more preferably, at least 95% relative humidity and, most preferably, 99-100% relative humidity through the close presence of a reservoir, filled with water.
When carrying out the method of processing, it is preferred to supply the reservoir with water after the arrangement of the samples on the carrier members. If the lid with the reservoir material comprising the content of water is left open for a substantial time, the water may ooze downwards flowing out of the reservoir. Preferably, the lid is closed and positioned in its normal, horizontal position when it contains water—and during the processing of the samples.
Finally, the invention relates to the use of a reservoir in an apparatus for executing a method of processing biological samples, wherein at least one biological sample is arranged on a carrier member, for treatment in order to prepare the sample by staining. Experiences have indicated that the invention is particularly useful for hybridising a sample for performing an analysis in which DNA is the target, for HPV, Her-2, Top2A; for hybridising a sample for performing an analysis in which RNA is the target; for HPV; for performing IHC analysis; for p16, Her-family including phosphorylated ER/PR, MIB-1, and for hybridising a sample for performing an analysis from the group comprising ISH, HPV, HER 2, HER2FISH, Topo II, telorners, EGFr, C-Myc, Epstein-Barr virus, Herpes simplex virus and Human cytomegalo virus, Chronic Myelogenous Leukemia (CML), acute myeloid leukemia (AML), Chromosome banding and paints.
BRIEF DESCRIPTION OF THE DRAWINGS
The object and features of the present invention can be more fully understood and better appreciated with reference to the attached drawings, which are schematic representations only and not necessarily drawn to scale, wherein:
FIG. 1 shows a preferred embodiment of an apparatus in accordance with the present invention with the lid open.
FIG. 2 shows the same apparatus as in FIG. 1 with the lid closed.
FIG. 3 shows a schematic view of an arrangement of carrier members on a bottom member of the apparatus of FIG. 1 .
FIG. 4 shows a sectional view of the apparatus of FIG. 3 along the line a-a in FIG. 3 .
FIG. 5 shows a sectional view of the apparatus in FIG. 3 along the line b-b of FIG. 3 .
FIG. 5A shows a sectional view similar to FIG. 5 , but with a heating plate in the lid.
FIG. 6 shows a sectional view similar to FIG. 5 of an embodiment of an apparatus in accordance with the present invention having an external reservoir.
FIG. 7 shows the display and keypad of the apparatus of FIGS. 1 and 2 .
FIG. 8 shows a single tissue slide on a heating plate, covered by a reservoir according to an embodiment in accordance with the invention.
FIGS. 9 and 10 show a manual version of the apparatus of FIGS. 1 and 2 .
FIG. 11 shows a slide locator assisting the location of the slides on the bottom member of an apparatus as shown in FIG. 1 , 2 , 9 , or 10 .
FIG. 12 shows a sample on a slide arranged on a heating plate and covered by a reservoir and a lid according to a method of the present invention.
FIGS. 13 and 14 show an apparatus similar to the apparatus shown in FIGS. 9 and 10 , but designed for only one slide.
FIG. 15 shows a sectional view of the apparatus of FIGS. 13-14 .
FIG. 16 shows an arrangement similar to FIGS. 12-14 , including a robot arm.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to an improved apparatus and methods for processing biological samples. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. Although various components are discussed in the context of a particular initial design, it should be understood that the various elements can be altered and even replaced or omitted to permit other designs and functionality as appropriate. Thus, the present invention is not intended to be limited to the embodiments shown but is to be accorded the widest scope consistent with the principles and features described herein. To more particularly appreciate the features and advantages of preferred apparatuses and methods in accordance with the present invention, the reader is referred to the appended FIGS. 1-16 in conjunction with the following discussion. It is to be understood that the drawings are diagrammatic and schematic representations only and are neither limiting of the scope of the present invention nor necessarily drawn to scale.
FIG. 1 illustrates as an example an embodiment of an apparatus 10 according to the present invention. The apparatus comprises a bottom member 12 and a lid member 14 . Preferably, the bottom member 12 and the lid member 14 are connected through a hinge, which is not shown. In the closed position illustrated in FIG. 2 the two members provide a closed or at least semi-closed chamber.
A plurality of biological samples on carrier members 15 may be arranged on the bottom member 12 e.g. as shown in FIGS. 3 and 11 . Typically the samples may be tissue samples on microscope slides 15 . An apparatus of this kind is manufactured and sold by StatSpin, MA, US and by DakoCytomation, Denmark A/S.
The bottom member 12 includes a temperature controlled heating plate 16 , as illustrated in FIG. 4 . The heating plate 16 can be made from heat conducting material such as a metal, e.g. such as copper. Alternatively it could be a heat-conducting polymer. The heating plate includes heating means (not shown) such as heating wires for electrical heating, as well as sensor means 34 for sensing the temperature. Such temperature regulation is well known and will not be described in further details here. Preferably, also cooling means (e.g. Peltier elements and/or fan(s) blowing air), are provided in order to enable a ramped temperature profile. The final result of the sample treatment may be highly dependent on an exact optimised temperature profile, requiring that the temperature can be changed rapidly according to the requirements defined at a protocol for the treatment of the biological samples presently arranged in the apparatus.
Preferably, the lid member 14 is provided with holding means, such as a grid, slots and/or fingers (not shown), supporting two humidity control strips 18 ( FIGS. 4-6 ), arranged to be located above the biological samples when the lid 14 is closed, thereby covering the bottom member 12 , as indicated in FIG. 2 . The strips 18 act as water reservoirs ensuring a presence of water inside the closed apparatus during the treatment of the biological samples. The strips may be attached by any known kind of attachments or adhering means, or may be integrated into the lid or cover 14 .
In a preferred embodiment, the lid member 14 may be provided with further heating and/or cooling means 16 a ( FIG. 5A ), as well as temperature sensing means. Preferably, a temperature-controlling unit in the apparatus is arranged to allow for setting the temperature of the lid to a value different from the temperature selected for the heating member 16 in the bottom member 12 in order to accelerate a release or absorption of vapor from the chamber. This could be specifically relevant during a rapid heating or cooling phase of the sample processing during which the relative humidity can be difficult to control without this extra heating or cooling of the water reservoir.
In a further embodiment, the lid member 14 may be provided with a further reservoir 28 ( FIG. 6 ) that allows refilling with liquid 28 a during the sample processing.
It is essential that the strips 18 have large internal surfaces compared to their external surfaces as well as to their total volume. The material may be of a kind comprising pores, forming the cavities accommodating the water. It is however presently preferred that the cavities are formed by spaces between randomly located bonded fibers, preferably having hydrophilic properties. The strips or reservoirs 18 can be made of a number of different materials, non-limiting examples include polymeric fiber composites and blends, glass fiber materials, expanded porous polymers, porous ceramics, Rockwool™, wood pulp, cardboard, leather or celluloses based materials.
Non-limiting examples of materials for strips or reservoirs 18 include materials containing polyethylene, polypropylene, polyurethanes, polysulfones, polyvinyl, polyacrylic compositions, ethylene Vinyl Acetate, viscose rayon, polystyrene, macroreticular polystyrene, aliphatic, or phenol-formaldehyde condensate polymers, epoxy, cotton, polysaccharide, modified polysaccharides, wood pulp, calcium carbonate, silica gels, glass fiber, bentonite, perlite or zeolite. Other preferred materials include man-made or synthetic polymeric bonded, non-bonded, woven or knitted fibers, micro fibers, textiles or tufted textiles. More preferably the materials are made of bonded polyamide, polyester, polyolefins or cellulose acetate fibers.
In the presently preferred embodiment, the strips 18 are oblong plates made of non-woven and bonded blends of hydrophilic modified polypropylene and polyethylene micro fibers. Preferably, the material has a density from 0.050 to 1.5 gram/cm 3 , more preferably from 0.075 to 0.75 gram/cm 3 . This composition provides the strips with extremely large internal surfaces. The hydrophilic properties enable the internal surfaces to adhere to tiny little water drops, providing a very large surface of water versus air, thereby enabling and improving a fast exchange and balancing between the liquid phase and the vapor phase of the water.
Preferably, the macroscopic surface area of the strips (reservoir) 18 facing towards the carrier member with the sample is more than 10% of the total carrier member area, and preferably more than 30% of the total carrier member area even more preferably more than 50% of the total carrier member area, and, in the most preferred embodiment, more than 80% of the total carrier member area.
In a presently preferred embodiment, the strips 18 are about 2 mm thick, about 28 mm wide, and about 250 mm long. This structure provides a large surface of the strip facing the surface of the sample within a short distance from the sample. Preferably, the humidity control strip is located close to the sample in order to improve the fast exchange and supply of humid air. Preferably, the strips may hold more than 10 microliters in total per slide, more preferably, more than 200 microliters in total per slide, and yet more preferably, more than 500 microliters in total per slide, and even more preferably, more than 1000 microliters in total per slide.
By mounting the control strips on the inner surface of the lid and preferably directly above the sample carriers the distance from the strips to the sample is minimized. Typically the distance may be 1 or 2 mm or even less, but always greater than zero so a layer of air and vapor separates the strip from the sample. The control strip should not get in touch with the sample.
In a further advantageous embodiment the strips may have a curved surface structure and uneven surfaces, such as a corrugated surface. Thereby the external surface comprising openings into the interior surfaces becomes large improving a rapid exchange of vapors, more specifically air and vapor of water providing almost 100% relative humidity.
In yet a further advantageous embodiment the humidity control strips 18 may have been impregnated with an anti microbial agent, an UV agent or other protective agents.
In the presently preferred embodiment the reservoir 28 is located above the sample on the carrier member so that the water supply is assisted through gravitation.
As explained earlier, a high humidity is essential to the final result of the staining of the biological samples. The presence of water is essential in order to maintain a high humidity. The treatment of the samples including several, possibly rapid temperature changes necessitates a rapid exchange between the liquid phase and the vapor phase of the water in order to ensure maintenance of a high relative humidity in the atmosphere above the samples. Such high relative humidity can be maintained through the use of the apparatus according to the invention incorporating the strips 18 .
In the presently preferred embodiment, the strips are made of materials selected for their hydrophilic properties. However, other fluids might be contemplated, and in such cases the strip material must be chosen to co-operate with such fluid, e.g. a formamide. More specifically the type, shape and size of the reservoir material should be selected to optimise surface properties to match with the liquid surface tension.
In a preferred embodiment, the apparatus comprises data processing means as well a data input and output means 20 , such as a keyboard or keypad and a display means 22 in FIGS. 1 and 7 , or is adapted for communication with a computer, such as a PC. Preferably, the data processing means may receive input from the temperature sensing means, and should be able to provide control signals to the heating and/or cooling means.
The computer may be provided with software and instructions enabling an automatic control of temperature and humidity inside the apparatus according to protocols specifying the conditions, e.g. temperatures and times, for the treatment of the samples.
In a further embodiment, the lid 14 itself is a sheet of hydrophilic material of a type or material as described previously herein for strips 18 .
Heating wires may be embedded in the hydrophilic material. Also, the material may be bi-layered.
The lid 14 may simply be arranged on top of a heating plate carrying the sample carriers (microscope slides).
The following examples show preferred methods of how to use the preferred embodiment of an automatic apparatus:
Example A
Unit Power Up
After a user assures that the unit is plugged into an appropriate outlet, the user moves a power switch (not shown) to its “ON” position. The instrument then audibly beeps to announce that the power has been turned on, a cooling fan and heating (not shown) will start and a Main Menu as shown in Table I is displayed on display means 22 , when the heating plate in the instrument has reached a default temperature of 37° C.
TABLE I
Run a PGM
Edit a PGM
Create a PGM
Example B
Denaturation and Hybridization Program
After the Main Menu screen is displayed, a cursor on the menu highlights the “Run a PGM” line of the menu. The user then presses an “Enter” key of the input and output means 20 to accept this menu item.
Subsequently, using the arrow keys, the user scrolls through various program numbers or program names. To accept the selection of a program, the user presses the “Enter” button or key of the input and output means 20 . The display 22 then confirms the PGM number/name and Denaturation and Hybridization times and temperatures, an example of which is shown in Table II. The cursor highlights the “Run PGM” line. The user then presses the “Enter” button or key to accept this choice.
TABLE II
PGM 01 Her2
82° C.: 05; 45° C. 20:00
Run PGM
Main Menu
The display 22 then prompts the user to “Add Slides and Close Lid” as illustrated in Table Ill. Before adding slides, the user inserts two Humidity Control Strips 18 into the inside slide lid. After strip insertion, and after adding the slides, the user saturates the strips 18 with distilled water or equivalent (approx. 13 mL for dry strips). The cursor then highlights “Start” line. The user presses the “Enter” button or key to run the program.
TABLE III
PGM 01 Her2
Add Slides - Close Lid
Start
Main Menu
To return to the Main Menu, the user moves the cursor to highlight the “Main Menu” line of the display 22 and presses the “Enter” button or key. The display indicates “heating” and current temperature of the slides. Once the temperature reaches a denaturation set point, the denaturation time will count down from the set time as shown in Table IV.
TABLE IV
PGM 01 Her2
Denat in Process
Denat: 82° C. 02:28
Present Temp: 82° C.
The apparatus will then automatically cool to the hybridization set temperature once denaturation is completed (Table V).
TABLE V
Please Wait
Cooling to Hyb 45° C.
Present Temp: 58° C.
The hybridization time will then count down from the set time once temperature reaches a hybridization set point.
Upon program completion, the unit will audibly beep to alert the user and the display will show “Process Complete” as shown in Table VI. The hybridization temperature will be maintained until an “End PGM/Main Menu” menu selection is accepted by pressing the “Enter” button of input and output means 20 . Before pressing the “Enter” button, the user may remove slides for further processing. If the “End PGM/Main Menu” selection is not accepted within the first minute of program completion, the hybridization time will start counting the total time at hybridization temperature.
TABLE VI
PGM 01 Her2
PROCESS COMPLETE
Total Hyb Time 21:05
End PGM/Main Menu
Example C
Run a Hybridization Only Program
After the Main Menu screen is displayed, a cursor on the menu highlights the “Run a PGM” line of the menu. The user then presses an “Enter” key of the input and output means 20 to accept this menu item.
Subsequently, using arrow keys, the user scrolls through various program numbers or program names. To accept the selection of a program, the user presses the “Enter” button or key of the input and output means 20 . The user selects a Hybridization Only program and the display 20 then confirms the PGM number/name and times and temperatures for a Hybridization Only protocol, examples of which are shown in Table VII. The cursor highlights the “Run PGM” line.
TABLE VII
PGM 02 EBV
Hyb: 55° C. 01:30
Run PGM
Main Menu
The user then installs two Humidity Control Strips 18 into the inside slide lid. After strip installation, and after adding the slides, the user saturates the strips 18 with distilled water or equivalent (approx. 13 mL for dry strips). The cursor highlights the “Start” line and the user then presses the “Enter” key or button to run the program as shown in Table VIII.
TABLE VIII
PGM 02 EBV
Add Slides - Close Lid
Start
Main Menu
The instrument will heat slides to the hybridization temperature as indicated in Table VIIIa.
TABLE VIIIa
Please Wait
Heating to Hyb 55° C.
Present Temp: 45° C.
Once hybridization temperature is reached the display changes as shown in table VIIIb and the time will count down from the set time.
TABLE VIIIb
PGM 02 EBV
Hyb in Process
Hyb 55° C. 01:30
Present Temp: 55° C.
Upon program completion, the unit audibly beeps to alert the user and the display 22 shows the message “Process Complete” (Table IX). The Hybridization temperature will be maintained until the “End PGM/Main Menu” selection is accepted by pressing the “Enter” button. Before pressing the “Enter” button, the user may remove slides for further processing. If the “End PGM/Main Menu” selection is not accepted within the first minute of program completion, the hybridization time will start counting the total time at hybridization temperature.
TABLE IX
PGM 02 EBV
PROCESS COMPLETE
Total Hyb Time 02:15
End PGM/Main Menu
Example D
Fixed Temperature Program
After the Main Menu screen is displayed, a cursor on the menu highlights the “Run a PGM” line of the menu. The user then presses an “Enter” key of the input and output means 20 to accept this menu item.
Subsequently, using arrow keys, the user scrolls through various program numbers or program names. To accept the selection of a program, the user presses the “Enter” button or key of the input and output means 20 . The user selects a Fixed Temperature program. The display 20 then confirms the PGM number/name and the Fixed Temperature (Table X) and the cursor highlights the “Run PGM” line of the display 22 .
TABLE X
PGM 03 Appl
Fixed: 65° C.
Run PGM
Main Menu
By pressing the “Enter” button or key of input and output means 20 to run the program the instrument will heat to the fixed temperature as indicated in Table XI.
TABLE XI Please Wait Heating to Fxd: 65° C. Present Temp: 30° C.
When the fixed temperature is reached, the display 22 then prompts the user to “Add Slides and Close Lid”. Before adding slides, the user installs two Humidity Control Strips into the inside slide lid. After strip installation, and after adding the slides the user saturates the strips 18 with distilled water or equivalent (approx. 13 mL for dry strips) and closes the lid. The cursor highlights the “Start” line on display 22 (Table XII). The user then presses the “Enter” button of the input and output means 20 to continue the program.
TABLE XII
PGM 03 Appl
Add Slides - Close Lid
Start
Main Menu
To return to the Main Menu, the user moves the cursor to highlight the “Main Menu” line of display 22 and presses the “Enter” button of input and output means 20 . The display 22 then indicates the present temperature of slides as shown in Table XIII and the timer counts elapsed time. (Pressing the “Enter” button by the user will reset the timer to zero).
TABLE XIII
PGM 03 Appl
Fixed Temp: 65° C.
Reset Timer 01:18:10
End PGM/Main Menu
The user may use the Arrow keys of the input and output means 20 to move the highlighted display to the “End PGM/Main Menu” line and then press the “Enter” button to end the program.
As the above examples (Example A through Example D) indicate, the reservoirs 18 which are the humidity control strips may be useful in a hybridizer. However they can be used in many other apparatuses. FIG. 8 and FIGS. 12-16 show a single tissue slide 15 on a heating plate 16 covered by a reservoir 18 according to the present invention. Such arrangement may be incorporated in several types of apparatus for processing samples, such as automatic stainers, both of the carousel type and as well as stainers with robots moving reagents and/or slides.
Also the arrangement shown in FIG. 8 and FIGS. 12-16 may be used in a tilted version. Also the reservoir 18 as shown in FIG. 8 may be incorporated into a lid 14 similar to the embodiment shown in FIG. 1 , but with only one reservoir and one slide 15 . A heating plate 16 a may be attached or embedded in the lid 14 , e.g. as shown in FIG. 5A .
In FIG. 16 a robot arm 30 is shown arranged above the lid 14 . The lid 14 is provided with a hole 24 providing an inlet for fluid to the reservoir 18 and enabling the robot to provide a fluid, such as water or a reagent to the reservoir and/or to the sample. This is in order to emphasize that the apparatus according to the present invention may be part of an automatic sample-processing instrument for processing a plurality of biological samples.
FIGS. 9 and 10 show a manual version of the apparatus, similar to the apparatus in FIGS. 1 and 2 , but without computer assisted control.
FIG. 11 shows a view similar to FIG. 3 , here with a slide locator 32 assisting the arrangement of 12 slides (A-L) on the bottom member of the apparatus in FIGS. 1 and 2 .
The arrangements as shown in the drawings, and, specifically, the provision of a reservoir, in cooperation with the temperature sensors (not shown) and in cooperation with adequate control units, such as a computer, allow for a precise control of the climate around tissue on a slide 15 . Specifically the hydrophilic adsorbent medium of the reservoir enables better staining results than hereto known when using automatic sample processing equipment.
In the following is presented seven examples taken from a validation test of the instrument.
In Example 1, the reservoir material was ordinary filter paper, not the recommended micro fiber material. In all other examples, the tests were carried out using the recommended micro fiber strips called “Hybridizer Humidity Control Strips”. These strips were oblong plates made of non-woven and bonded blends of hydrophilic modified polypropylene and polyethylene micro fibers.
Example 1
FISH Validation
This is an example with TOP2A and paper filter strips. The on average acceptance criteria of TOP2A: Scoring 1.5-3 (signal intensity and specificity). A score of at least 2 on average or a deviation score within ±0.5 on average from reference is required. Individual outliers can be excluded due to obvious reasons and if these are reported. The first run with TOP2A on Hybridizer was performed with paper filter strips (Filter strips), Table 1A. The instrument was tested with twelve slides from the same tissue block and resulted in an average score of the TOP2A signal intensities that resemble the signal intensities of the manual reference slides.
The signal intensities of Green signal, Centromer 17 on Hybridizer, score 2.0, did not resemble the intensities of the manual reference, score 3. Centromer signal intensities with a score less than 1.5 were observed for two of the twelve slides. The signal intensity of Centromer 17 was, however, on average 2, Red signal, HER2 did resemble the manual references, and therefore the acceptance criteria were barely fulfilled. The table shows Raw data of TOP2A probes on sections cut from the same formalin-fixed, paraffin embedded breast cancer tissue block; Performed on a hybridizer instrument with paper filter strips as humidity strips.
TABLE 1A
Run No. 1
Position in
Signal
Signal
Slide
Hybridizer/Manual
Intensity
Intensity
Tissue
No.
test
Red
Green
Structure
1
1
2.5
2.5
3
2
2
2.5
2.5
3
3
3
1.5
1
3
4
4
3
2.5
3
5
5
3
2.5
3
6
6
2.5
2
3
7
7
2.5
3
3
8
8
2.5
1.5
2.5
9
9
2
1.5
2.5
10
10
3
2.5
3
11
11
2
1
2.5
12
12
2
2
3
13
Manual test
2.5
3
2.5
14
Manual test
2
3
2.5
1-12
Mean
2.4
2.0
2.9
Std
0.469
0.656
0.226
13-14
Mean
2.3
3.0
2.5
Example 2
Example with TOP2A and DakoCytomation Hybridizer Humidity Control Strips
A run performed on the validation instrument No. 102 confirmed that the acceptance criteria were easily fulfilled if Hybridizer Humidity Control Strips (0.198 g/cm 3 ) were used instead of paper filter strips.
The instrument test run was as good as the manual procedure,
In conclusion, the Hybridizer passed the acceptance criteria for TOP2A. The scores of the slides were, when Hybridizer Humidity Control Strips were used, as good as the manual procedures.
The table (Table 1B) shows Raw data of TOP2A probes on sections cut from the same formalin-fixed, paraffin embedded breast cancer tissue block, performed on hybridizer instrument with Hybridizer Humidity Control Strips (3 mm thick, 0.198 g/cm 3 ). Green signal, Centromer 17; Red signal, HER2.
TABLE 1B
Run No. 1
Position in
Signal
Signal
Slide
Hybridizer/Manual
Intensity
Intensity
Tissue
No.
test
Red
Green
Structure
1
1
3
2.5
3
2
2
3
2.5
3
3
3
3
3
3
4
4
3
3
2.5
5
5
3
2.5
2.5
6
6
3
3
2.5
7
7
3
3
3
8
8
3
3
3
9
9
3
2.5
3
10
10
3
3
3
11
11
3
3
2.5
12
12
3
3
3
13
Manual test
3
3
3
1, 4
Manual test
3
3
3
1.5
Manual test
3
2.5
3
1-12
Mean
3.0
2.8
2.8
Stdv
0.000
0.246
0.246
13-15
Mean
3.000
2.833
3.000
Stdv
0.0
0.3
0.0
Example 3
HER2
The on average acceptance criteria of HER2: Scoring 1.5-3 (signal intensity and specificity). A score of at least 2 on average or a deviation score within ±0.5 on average from reference is required. Individual outliers can be excluded due to obvious reasons and if these are reported. The run with HER2 on Hybridizer was performed with Hybridizer Humidity Control Strips (0.270 g/cm 3 ). The instrument was tested with tissue sections of different thickness (2 μm to 6 μm) from the same formalin-fixed paraffin-embedded tissue block. The run resulted in scores of signal intensities and tissue structures that resembled the manual reference. No score deviation of ±0.5 grade or above on average was observed. In conclusion, the Hybridizer passed the acceptance criteria for HER2. The scores of the slides were as good as the manual procedures. Table 2 shows raw data of the HER2 Probe; performed on hybridizer instrument with Hybridizer Humidity Control Strips (2 mm thick, 0.270 g/cm 3 ). Green signal, Centromer 17; Red signal, HER2.
TABLE 2
Position in
Run No. 1
Thickness
Hybridizer/Manual
Signal Intensity
Signal Intensity
Tissue
Slide No.
of Tissue
test
Red
Green
structure
1
2 μm
1
3
3
2.5
2
2
3
2.5
2.5
3
3
3
3
2
4
Manual test
3
3
2.5
5
Manual test
3
3
2.5
6
4 μm
4
3
2.5
2.5
7
5
2.5
2.5
2.5
8
6
2.5
2.5
2.5
9
Manual test
2
2.5
2.5
10
Manual test
2.5
3
2.5
11
6 μm
7
3
3
3
12
8
2.5
2
3
13
9
3
3
3
14
Manual test
2.5
3
2.5
15
Manual test
2.5
3
3
1, 2, 3
2 μm
Mean
3.0
2.8
2.3
6, 7, 8
4 μm
Mean
2.7
2.5
2.5
11, 12, 13
6 μm
Mean
2.8
2.7
3.0
Manual 4, 5
2 μm
Mean
3.0
3.0
2.5
Manual 9, 10
4 μm
Mean
2.3
2.8
2.5
Manual 14, 15
6 μm
Mean
2.5
3.0
2.8
Example 4
MLL and ETV6
The on average acceptance criteria of MLL and ETV6: Scoring 1.5-3 (signal intensity and specificity). Score deviation of ±0.5 on average from reference is allowed. Individual outliers can be excluded due to obvious reasons and if these are reported.
The run on Hybridizer was performed with Hybridizer Humidity Control Strips (0.270 g/cm 3 ). The instrument was tested with sample specimens from the same lot of metaphase spreads. The run resulted in better scores of the MLL and ETV6 signal intensities than observed with the manual references. The structure of the cells resembled the manual references. In conclusion, the Hybridizer passed the acceptance criteria for MLL and ETV6. The scores of the slides were better than the manual procedures. The scores obtained on Hybridizer were, though, for both probes more than 0.5 grade higher in signal than the manual references, These scores are above the deviations described in the acceptance criteria, but still acceptable.
Table 3 shows raw data of translocation probes, MLL and ETV6, on metaphase spreads, performed on hybridizer instrument No. 25 with Hybridizer Humidity Control Strips (2 mm thick, 0.270 g/cm 3 ).
TABLE 3
Run in Hybridizer No. 25
Position
Signal in
Structure of
Slide
Probe
in Hy-
inter-
Signal in
inter- and
Com-
No.
mix
bridizer
phases
metaphases
metaphases
ments
1
ETV6
4
3
3
2
—
2
8
3
3
2
—
3
3
2.5
2.5
2
—
4
Manual
2
2
2
—
5
test
2
2
2
—
6
MLL
5
2.5
3
2
—
7
6
2.5
2.5
2
—
8
1
2.5
2.5
2.5
—
9
Manual
1
2
2.5
—
10
test
2
2
2
—
Signal of inter- and
Method
metaphases
Structure
Hybridizer 1-3
2.83 ± 0.26
2 ± 0
Hybridizer 6-8
2.58 ± 0.20
2.2 ± 0.29
Manual 4-5
2.0 ± 0
2
Manual 9-10
1.75 ± 0.5
2.25
Example 5
This example relates to CISH validation of HPV on Formalin-fixed paraffin-embedded tissue blocks. The on average acceptance criteria of HPV on cells: 2.5-4 signal; 0 negative control; 0-1 background; ±0.25 grade divergence from manual staining (for individual slides).
The run with HPV probes on Hybridizer was performed with Hybridizer Humidity Control Strips. The signal intensities fully resembled those of the manual references. No score deviation was observed. The background levels appeared to be lower with Hybridizer than with the manual method.
In conclusion, the scores of signal intensities of the slides were as good as the manual procedure, when the hybridisation was performed with the humidity control strips
Table 4 Raw data of HPV Probe on Tissue.
The test ran on a Hybridizer with Hybridizer Humidity Control Strips.
TABLE 4
Slide
Block
Method
number
No.
Signal
Background
Hybridizer
1
236
3
0.25
Hybridizer
2
340
3
0.25-0.5
Hybridizer
6
340
3
0.25
Hybridizer
7
236
3
0.5
Hybridizer
11
236
3
0.5
Hybridizer
12
340
3
0.75
Manual
13
236
3
0.25
Manual
14
236
3
1
Manual
15
340
3
0.75
Manual
16
340
3
0.5
Method
Signal
Background
Hybridizer
3 ± 0
0.42-0.46 ± 0.19-0.20
Slide 1, 2, 6, 7, 11, 12
Manual
3 ± 0
0.63 ± 0.32
Slide 13-16
Example 6
Telomere
The on average acceptance criteria of Telomere: Scoring 1.5-3 (signal intensity and specificity). Score deviation off 0.5 on average from reference is allowed. Individual outliers can be excluded due to obvious reasons and if these are reported.
The run on Hybridizer was performed with Hybridizer Humidity Control Strips (0.22-25 g/cm 3 ). The validation instrument was tested with sample specimens from two different lots of metaphase spreads. The run resulted in scores of signal intensities and tissue structures that resembled the manual reference for both FISH (K 5325) and Cy3 (K 5326) labelled Telomere probes. No score deviation above ±0.5 grade on average was observed. The structure of the cells resembled the manual references.
In conclusion, the Hybridizer passed the acceptance criteria for Telomere. The scores of the slides were as good as the manual procedures.
Table 5: Raw Data of Telomere Probes, on Two Different Metaphase Spreads.
Performed on hybridizer instrument with Hybridizer Humidity Control Strips (0.22-0.25 g/cm 3 ).
TABLE 5
Average
Average
Metaphase
Position in
Signal
signal
signal
Slide No.
preparation
Probe
Hybridizer
intensity
Background
intensity
background
1
080903-
Telomere/
1
3
0
3 ± 0
0 ± 0
2
MEM
FITC
2
3
0
3
3
3
0
4
Manual
3
0
3
0
5
test
3
0
6
221203-
4
3
0.5
2.67 ± 0.29
0.5 ± 0
7
MEM
5
2.5
0.5
8
6
2.5
0.5
9
Manual
3
0
3
0
10
test
3
0
11
080903-
Telomere/
7
3
0
3 ± 0
0 ± 0
12
MEM
Cy3
8
3
0
13
9
3
0
14
Manual
3
0
3
0
15
test
3
0
16
221203-
10
3
0
3 ± 0
0 ± 0
17
MEM
11
3
0
18
12
3
0
19
Manual
3
0
3
0
20
test
3
0
Example 7
EBER (EBV)
The on average acceptance criteria of EBER: Scoring 1.5-3 (signal intensity and specificity). Score deviation of ±0.5 on average from reference is allowed. Individual outliers can be excluded due to obvious reasons and if these are reported.
The run on Hybridizer was performed with Hybridizer Humidity Control Strips (0.22-25 g/cm3). The run resulted in scores of signal intensities that resembled the manual reference. No score deviation of ±0.5 grade or above on average was observed. The background appeared to be lower with Hybridizer than with the manual method.
In conclusion, the Hybridizer passed the acceptance criteria for EBER. The scores of the slides were as good as the manual procedures.
Table 6: Raw Data of EBER Probes on Two EBV-Positive Tissue.
Performed on 1-lybridizer instrument with Hybridizer Humidity Control Strips (0.22-0.25 g/cm 3 ).
TABLE 6
Slide
Position in
Signal
No.
Tissue
Hybridizer
Probe mix
intensity
Background
1A
A
1
EBER Y5200
2
0
1B
Neg. control
0
0
2A
2
EBER Y5200
2.5
0.5
2B
Neg. control
0
0
3A
B
3
EBER Y5200
2
0.5
3B
Neg. control
0
0
4A
4
EBER Y5200
2
0
4B
Neg. control
0
0
5A
A
Manual test
EBER Y5200
2.5
0.5
5B
Neg. control
0
0
6A
EBER Y5200
2.5
1
6B
Neg. control
0
0.5
7A
B
EBER Y5200
2.5
0.1
7B
Neg. control
0
0.5
8A
EBER Y5200
2
0
8B
Neg. control
0
0.5
Method
Signal intensity
Background
Hybridizer EBER 1A-4A
2.13 ± 0.25
0.25 ± 0.28
Hybridizer neg. control 1B-4B
0 ± 0
0 ± 0
Manual EBER 5A-8A
2.38 ± 0.25
0.4 ± 0.45
Manual neg. control 5B-8B
0 ± 0
0.38 ± 0.25
LIST OF REFERENCE NUMBERS
The following is a list of reference numbers used in the accompanying drawings and referred to in this specification: 10 —apparatus, Hybridizer; 12 —bottom member; 14 —lid member; 15 —carrier members, which may be microscope slides; 16 —temperature-controlled heating plate; 16 a —heating plate in lid 14 ; 18 —humidity control strips or reservoir; 20 —data input and output means including a display and key pad; 22 —display; 24 —hole; 28 —further reservoir for refilling the reservoir 18 ; 28 a —liquid within reservoir 28 ; 30 —robot arm; 32 —slide sorter.
An improved apparatus and methods for processing biological samples and a reservoir therefore have been disclosed. Although the present invention has been described in accordance with the embodiments shown and discussed, one of ordinary skill in the art will readily recognize that there could be variations to the embodiments and those variations would be within the spirit and scope of the present invention. For instance, although the preferred embodiment of the present invention is described in the context of a Hybridizer for 12 slides, it will be appreciated that the teachings of the present invention are applicable to any number of slides that are processed in any number of chambers equipped with any system for controlling temperature and humidity, e.g., in automated sample processing equipment comprising a plurality of heater plates, each of them being arranged to carry a single microscope slide with tissue. Also, even though all figures show the reservoir above the slide on the heater plate in the bottom part, it must be understood that the chamber might be turned upside down so that the reservoir would be arranged below the slide. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the invention, which is defined by the appended claims.
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An apparatus for processing at least one biological sample accommodated on at least one carrier member ( 15 ) in a chamber includes, at least one reservoir ( 18 ) able to accommodate a fluid on a surface inside the chamber adjacent to and/or facing a substantial part of the at least one biological sample. The apparatus may comprise a bottom member ( 12 ) arranged to support at least one carrier member ( 15 ) carrying at least one biological sample and a lid ( 14 ) including at least one fluid reservoir ( 18 ). The reservoir filled with water provides humidity to the chamber and impedes drying out of the sample.
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BACKGROUND OF THE INVENTION
One of the limitations of using poly(vinylidene fluoride), acronymn PVDF, resins as a material of construction in forming, for example, molded parts for pumps and valves, is the decrease in load bearing strength which occurs when the resins are heated to elevated temperatures. Another limitation of poly(vinylidene fluoride) is that it shrinks from 2 to 3% on cooling a hot molding of the resin. By incorporating carbon fibers into the resin, for example, as is described in British Pat. No. 1,324,424, its strength is improved and shrinkage on molding is reduced.
Compressed, expanded vermicular graphite, which has been coated with corrosion resistant resins including PVDF, has been disclosed as a coating material and laminate in U.S. Pat. Nos. 3,438,932 and 4,199,628. Articles formed from reinforced plastics, containing carbon or graphite fibers coated with epoxy polymers, are disclosed in U.S. Pat. No. 4,107,128. Other patents relating to carbon reinforced compositions include: U.S. Pat. No. 4,009,043 which discloses molding compositions of polymers, which can be halogen containing, along with both titanium and carbon fibers; and U.S. Pat. No. 3,885,174, in which carbon fibers coated with certain block or graft copolymers, including polyesters, epoxy, and polyimide resins are mixed with a compatible resin, i.e., one component of the graft copolymer. In the background section of U.S. Pat. No. 3,964,952, it is mentioned that, where carbon fibers are impregnated with a resin and then immersed in the same resin to form a composite, the composite has poor mechanical properties. In U.S. Pat. No. 3,682,595, a non-woven carbonaceous fabric is prepared by coating carbonaceous fibers with a resin such PVDF and then carbonizing the system.
Carbon fibers which have been coated with polyvinylpyrrolidone or an epoxy resin in order to improve their bulk density and handling characteristics, are commercially available. These coatings, however, are sensitive to hot acids and I have found that composites of PVDF and such fibers have significantly reduced tensile strength when they are immersed in hot hydrochloric acid, even though the PVDF matrix resin is acid resistant, because of wicking. This makes the composites unsuitable for making valves, pumps and other parts which will be exposed to acids. I have now prepared poly(vinylidene fluoride)-carbon fiber reinforced composites having increased tensile strength, lower mold shrinkage and increased stability to hot aqueous acids.
BRIEF SUMMARY OF THE INVENTION
In accordance with this invention, there is provided low shrinkage, strong, acid stable carbon fiber reinforced poly(vinylidene fluoride) compositions and articles molded therefrom comprising a poly(vinylidene fluoride) resin mixed with carbon fibers which have been precoated with poly(vinylidene fluoride). Also provided is a process for forming such carbon fiber reinforced compositions comprising melt blending poly(vinylidene fluoride) coated carbon fibers with a poly(vinylidene fluoride) resin in a manner such that the fibers are uniformly dispersed in the resin while attrition of the carbon fibers is minimized. This can be accomplished by extrusion blending.
DETAILED DESCRIPTION
The term "carbon fibers" as used herein is intended to encompass the various carbonaceous materials which have been used as reinforcing agents including carbon and graphite fibers and whiskers. I have found that the fiber length is important in providing enhanced reinforcement and the initial fiber length should be maintained throughout the mixing process. Fiber lengths of from about 3 to 15 mm can be used. Excellent results have been achieved using fibers of about 6 mm (1/4") in length. Carbon fibers which are about 0.4 mm in length have been found to provide negligible reinforcement. The fibers, in the form of a strand of yarn, are coated with a poly(vinylidene fluoride) resin. For ease of coating, because such resins in latex form are readily available, the fibers can be coated by dipping the yarn in a latex. The dipped yarn is passed through squeeze rolls to remove the bulk of the water, dried in a heated oven and then passed through an infra-red heater ring to fuse the resin to the fibers. The coated yarn is then cut into lengths to form coated fiber bundles which are suitable for use in the invention. The amount of resin coating should be at least about 3 percent by weight of the coated fibers with about 5-6 percent preferred. A minimum is needed to provide a good coating and formation of fiber bundles which will not fluff. Amounts greater than about 10% could be used, but no benefit would be expected.
Poly(vinylidene fluoride) resins suitable for the coatings are known in the art and are commercially available from Pennwalt Corp. under the trademark Kynar®.
The coated fibers are mixed with the poly(vinylidene fluoride) molding resin in amounts to provide a carbon fiber content of from about 5 to 20 percent by weight of the composite mixture. Amounts of less than about 5% do not provide significant reinforcement. At amounts of greater than 20%, the melt flow index of the composite becomes so low (below about 6 at 265° C.) that the material cannot be conveniently used in conventional molding processes. Amounts of around 10% by weight are preferred.
I have found that the process used to mix the coated fibers and the resins is important in obtaining reinforcement. Conventional high shearing mixing processes result in poor reinforcement due to attrition of the fibers. For example, Brabender melt-blending results in very little reinforcement. Accordingly, a mixing process must be used which minimizes the breakdown of the carbon fibers. Dry mixing followed by extrusion with controlled extruder screw speeds is suitable to retain a sufficient length for significant reinforcement.
Useful poly(vinylidene fluoride) resins are those having a molecular weight range suitable to produce molded articles. Such resins have melt viscosities of from about 10,000 to 30,000 poise. The particular resin is selected based on the application.
The invention is further illustrated by, but is not intended to be limited to, the following examples, wherein parts are parts by weight unless otherwise indicated.
EXAMPLE 1
Carbon fibers (unsized Celion C-6®, Celanese Corp.) are coated with poly(vinylidene fluoride) by immersing a strand of carbon fiber yarn in a poly(vinylidene fluoride) latex which has a solids content of about 36 percent by weight. The poly(vinylidene fluoride) has a molecular weight such that the melt viscosity of the polymer is about 20,000 poise. The dipped fibers are then passed through squeeze rolls to remove the bulk of the water and dried in a 260° F. oven. The polymer coating is then fused to the fibers by heating the fibers in an infrared heater ring and the coated fibers are chopped into 1/4" length (6 mm) fibe bundles. The coated fibers contain 5-6% by weight of poly(vinylidene fluoride). Each bundle is about 3 mm in width.
EXAMPLES 2 & 3
Two batches of PVDF coated carbon fibers, which were made by the process described in Example 1, were used to prepare carbon reinforced poly(vinylidene fluoride) resin molding compositions. The compositions were tested for mold shrinkage, tensile strength, flexibility and acid stability. The chopped carbon fibers were mixed with a poly(vinylidene fluoride) resin powder (Kynar® 901 resin, Pennwalt Corp., which was prepared by suspension polymerization and which had a melt viscosity of about 20,000 poise), in a V-cone blender for 15-20 minutes at room temperature to form a premix containing about 10 percent by weight of the coated carbon fibers. The premix was extruded three times at a temperature of about 220°-230° C. using a single screw extruder to uniformly disperse the fibers in the resin. A twin screw extruder can be used to provide single pass mixing. The single screw extruder had a 1.25" diameter with a 24/1 length to diameter ratio. A slow screw speed of about 10 rpm was used to further minimize attrition of the carbon fiber length. The The extrudate was air cooled and pelletized. The coated carbon fiber poly(vinylidene fluoride) resin composite pellets were injection molded at 450° F. into tensile bars (6"× 0.5"×0.125") which were used for testing. Instead of using resin powder in the premix, pelletized resin (Kynar® 900) can be used for easier feeding to the extruder.
The mold shrinkage was determined by ASTM D955 "Measuring Shrinkage from Mold Dimensions of Molded Plastics" in which the percent shrinkage is calculated by measuring the length of an injection-molded tensile bar (6"×0.05"×0.125") to the nearest 0.001", 24 hours after molding, compared to the original mold length. The tensile properties were determined by ASTM D638 "Tensile Properties of Plastics" in which the tensile strength and elongation of tensile bars are determined at a 0.2"/min crosshead speed. The Flexural Modulus was determined by ASTM D790 "Flexural Properties of Plastics" in which the flexural strength of the tensile bars is determined at a 0.05"/min crosshead speed. The test results are given in Table I below which also contains test results from Example 4 using polyvinylpyrrolidone (PVP) coated fibers, the values reported for uncoated carbon fiber containing PVDF in British Pat. No. 1,324,424 to Kureha, and test results for non-carbon fiber containing poly(vinylidene fluoride) resin.
EXAMPLE 4
The process of Examples 2 and 3 was repeated to prepare tensile bars except that the carbon fibers had a polyvinylpyrrolidone) coating (commercially available as Celion C-6® from Celanese Corp.). The test results on the bars are given in Table I below.
TABLE I__________________________________________________________________________ British 1,324,424Example 2 3 4 Kureha Non-Reinforced__________________________________________________________________________CompositionResin 90% PVDF 90% PVDF 90% PVDF 90% PVDF 100% PVDFCarbon Fibers 10% 10% 10% 10% 0Fiber Coating PVDF PVDF PVP -- --Fiber Length (mm) 6 6 6 1-5 --ORIGINAL PROPERTIESMold Shrinkage (%) 0.11 0.15 0.25 1.0 2.26Flex. Modulus (10.sup.6 psi) 1.22 1.21 1.07 0.40 0.25Ambient T.sub.u * (psi) 12,160 14,420 11,500 9440 6635100° C. T.sub.u 7,980 7,800 5,990 2975140° C. T.sub.u 4,680 4,640 3,310 1570Ambient E.sub.B ** (%) 7.0 8.7 8.0 >300100° C. E.sub.B 11.5 12.5 13.0 >300140° C. E.sub.B 32.0 37.0 55.0 >300ACID-EXPOSED PROPERTIES (10% HCl, 100° C., 1 week exposure)Flex. Modulus (10.sup.6 psi) 1.25 1.20 1.05 0.27% Retention 102 99 98 108Ambient T.sub.u (psi) 11,030 13,050 8610 7000% Retention 91 90 75 106Ambient E.sub.B (%) 6.6 7.8 6.7 160% Retention 94 90 84 53__________________________________________________________________________ *Where T.sub.u is the ultimate tensile strength. **Where E.sub.B is elongation at break.
From the results shown in Table I, the mold shrinkage using the PVDF coated carbon fibers was greatly reduced (less than 0.25 percent) compared to both the resin without any fibers added (2.26 percent) and using the uncoated fiber containing compositions of Kureha (1.0 percent) at the same carbon fiber content. A higher tensile strength, especially at elevated temperatures (T u above 4,500 psi at 140° C.) is possessed by the material of Examples 1 & 2. The superior tensile strength is retained to a greater extent (90 percent) than in the case with the polyvinylprrolidone coated fiber containing materials of Example 4 when the tensile bars were immersed in 10% HCl for a week. (The carbon fiber containing materials are less flexible than the pure resin as would be expected.)
When fibers coated with PVP as in Example 4 were mixed with PVDF using a Banbury mixer at either 50 rpm or 1-2 rpm at a temperature of 225° F., rather than an extrusion mixing at 225° C., the ambient tensile strengths were only 8600 psi and 9090 psi, respectively, which demonstrates that the mixing process is important and a high shear mixer, even at low speeds, caused the tensile strength to be lowered. This is believed to be due to severe attrition of the carbon fiber lengths. A similar result would be expected regardless of the fiber coating material.
Carbon fibers from other sources: Panex® (Stockpole) and Fortafil® (Great Lakes Carbon) which has fiber lengths of about 6 mm also gave an enhanced tensile strength composite at a 10% by weight level when used according to the invention, but one fiber, Thornel-VMD® (Union Carbide) with a length of only about 0.4 mm, gave no benefit in tensile strength. This demonstrates the importance of fiber length on reinforcement.
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Low shrinkage, mechanically strong, acid stable, carbon fiber reinforced poly(vinylidene fluoride) resin compositions are prepared by extrusion blending carbon fibers, which have been precoated with poly(vinylidene fluoride), with a poly(vinylidene fluoride) resin.
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RELATED APPLICATIONS
[0001] This application claims benefit of and priority to U.S. Provisional Application Ser. No. 62/138,921 filed Mar. 26, 2015 entitled Ophthalmic Lens Holder for Physical Vapor Deposition, which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the coating of optical lenses and, more particularly, to systems and methods for holding optical lenses during a lens coating process.
BACKGROUND OF THE INVENTION
[0003] Anti-reflective coatings reduce reflections off the front and back surfaces of ophthalmic lenses and therefore are desirable for creating eyeglasses with improved light transmission, visibility, and aesthetics. Typically, these anti-reflective coatings must be applied as a series of layers having a precise and relatively thin thickness. In this respect, physical vapor deposition machines, such as sputtering coaters, are often used for the coating application process.
[0004] FIG. 1 is a plan view of a horizontally rotating drum 10 for holding a lens 22 for coating a surface 22 A of the lens 22 in a vertical orientation within an interior of a sputtering box or chamber. The drum 10 includes a plurality of sides 6 that are separated from each other by divider walls 4 . As shown in FIG. 2 , each side 6 has a mounting fixture 8 onto which an item, for example the optical lens 22 , can be mounted for coating.
[0005] In operation, an ophthalmic lens 22 is mounted to the fixture 8 via a double-sided adhesive pad or tape 20 . One drawback to this mounting style is that a backside 22 B of the lens 22 must be completely covered with an adhesive tape 20 or similar covering to prevent portions of the backside 22 B of the lens 22 from also being coated. Since this back covering must precisely and completely cover the backside 22 B surface of the lens 22 , the tape 20 can be time consuming to apply. Additionally, the adhesive nature of the double-sided adhesive pad 20 often prevents the tape 20 from being reused for the coating of more than one lens 22 .
[0006] What is needed in the art is a drum and lens holder system that is more robust, reusable, and allows for a more efficient holding and exchange of lenses of varying shapes and sizes.
OBJECTS AND SUMMARY OF THE INVENTION
[0007] The present invention provides a drum and lens holder system that is more robust, reusable, and allows for a more efficient holding and exchange of lenses of varying shapes and sizes. This is achieved, in part, by providing a system for coating optical lenses comprising: a housing having at least two sides through which an aperture is formed; and a lens holder having a lens aperture that accepts an optical lens, an exterior shape and size that is complementary and is accepted within the aperture of the housing, and a magnetic back surface.
[0008] This is also achieved, in part, by providing a system for coating optical lenses comprising: a housing having a plurality of sides with first apertures; and an annular lens holder accepted within one of the first apertures, the lens holder having a second aperture that accepts an optical lens; and a securing element that maintains the lens holder within the first aperture, the securing element incorporating a magnet associated with each of the first apertures and a magnetic back surface of the lens holder.
[0009] This is further achieved, in part, by providing a method for holding an optical lens during coating comprising: inserting an optical lens within a lens holding assembly; securing the lens holding assembly within an aperture of a housing by forming a magnetic attraction between a substantially entire back surface of the lens holder and a magnet of the housing; preventing a backside of the optical lens from being coated; loading the housing into a coating device; and coating at least a portion of the optical lens while rotating the housing within the coating device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which
[0011] FIG. 1 is a plan view of a drum for a vapor deposition coater system according to one embodiment of the present invention;
[0012] FIG. 2 is an elevation view of a drum for a vapor deposition coater system according to one embodiment of the present invention;
[0013] FIG. 3 is a plan view of a drum for a vapor deposition coater system according to one embodiment of the present invention;
[0014] FIG. 4 is an elevation view of a drum for a vapor deposition coater system according to one embodiment of the present invention;
[0015] FIG. 5 is a plan view of a lens holder fixture according to one embodiment of the present invention;
[0016] FIG. 6 is a front plan view of a lens holder fixture according to one embodiment of the present invention;
[0017] FIG. 7 is a front plan view of a lens holder fixture according to one embodiment of the present invention;
[0018] FIG. 8 is a back plan view of a lens holder fixture according to one embodiment of the present invention;
[0019] FIG. 9 is an elevation view of a drum for a vapor deposition coater system according to one embodiment of the present invention;
[0020] FIG. 10 is an elevation view of a drum for a vapor deposition coater system according to one embodiment of the present invention;
[0021] FIG. 11 is a perspective view of a drum for a vapor deposition coater system according to one embodiment of the present invention;
[0022] FIG. 12A is a back plan view of a lens holder assembly according to one embodiment of the present invention;
[0023] FIG. 12B is a back plan view of a lens holder assembly according to one embodiment of the present invention;
[0024] FIG. 13A is a cross-sectional view of a lens holder assembly according to one embodiment of the present invention;
[0025] FIG. 13B is a cross-sectional view of a lens holder assembly according to one embodiment of the present invention;
[0026] FIG. 13C is a cross-sectional view of a lens holder assembly according to one embodiment of the present invention;
[0027] FIG. 14 is a plan view of a lens holder assembly according to one embodiment of the present invention;
[0028] FIG. 15 is a perspective view of a lens holder assembly according to one embodiment of the present invention; and
[0029] FIG. 16 is a perspective view of a lens holder assembly according to one embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0030] Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.
[0031] With reference to FIGS. 3 and 4 , one embodiment of the present invention employs a housing or drum 100 having a plurality of divider walls 102 that extend from the intersections of a plurality of drum sides 106 . For example, the drum 100 may employ six sides 106 , as shown in FIG. 3 , or as few as two drum sides 106 . The lens retaining system includes a spring clip ring 104 within which the lens 22 is retained or secured. The spring clip ring 104 is, in turn, secured to the drum 100 by guides 108 that are formed vertically within the divider walls 102 . The sides of the spring clip ring 104 slide within opposing guides 108 . In one embodiment, the guides 108 are, for example grooves, channels, or parallel raised lips formed within or on the surface of opposing sides of each divider wall 102 . Each guide 108 begins, for example at an upper most end of the walls 102 and extend downward.
[0032] In one embodiment, the spring clip ring 104 includes a rigid framework formed of an outer portion 110 and a lens support portion comprising a plurality of spring-loaded arms 112 that are biased inward relative to the outer portion 110 . In this respect, the plurality of arms 112 apply opposing pressure against the edge or edges of the lens 22 , thereby securing the lens 22 in a removable arrangement.
[0033] In one embodiment, the spring clip ring 104 is formed of a wire and has an internal diameter of about 82 millimeters and an external diameter of about 85 millimeters. The walls 102 have a height of, for example, about 85 millimeters and are spaced, for example, about 90 millimeters from each other. The guides 102 have a height of, for example, about 65 millimeters, a width of about 7 millimeters and a depth of about 7 millimeters.
[0034] The spring clip ring 104 is sized such that its diameter is larger than the distance between the inner surfaces of two adjacent divider walls 102 , but smaller or nearly the same size as the distance between the interior surface of the opposing guides 108 . Hence, the spring clip ring 104 can be simultaneously slid into each guide 108 , starting at the upper, open ends of the guides 108 and rests upon the lower, closed end of the guide 108 .
[0035] In one embodiment, each guide 108 is preferably located between the top of each divider wall 102 and a position about halfway down the vertical height of the wall 102 . In another embodiment, the guide 108 is located between the top of each divider wall 102 and any lower point that would maintain the spring clip ring 104 between the top and bottom of the divider walls 102 . In yet another embodiment, the guide 108 extends the entire length of the divider wall 102 , allowing the spring clip ring 104 to rest on a lower horizontal surface of the drum 100 .
[0036] With reference to FIGS. 5-9 , in another embodiment of the present invention, instead of employing spring clip ring 104 to attach the lens 22 to the drum 100 , a curved fixture 120 is employed to secure the lens 22 to the drum 100 . The fixture 120 is formed of an elongated rigid member having a generally ring, crescent, “C-shape,” or broken or incomplete-circle shape. The gap between ends of the fixture 120 is, for example, between 180 degrees and 0 degrees (i.e., a full circle). Alternatively, the fixture 120 is formed of a non-circular or a crescent shape, for example, in the shape of a square, rectangle or octagon. In certain embodiments, the fixture 120 is, for example, formed from a metallic wire having a diameter of about 78 millimeters and forms a ring shape having an overall diameter of about 85 millimeters.
[0037] With reference to FIG. 6 , in operation, a portion of a tape 122 having a single adhesive side for example, “surface saver” tape which is known in the ophthalmic lens industry, is adhered to one side of the fixture 120 . Any excess portions of the tape 122 extending beyond the sides of the fixture 120 are either trimmed or wrapped around the fixture 120 . As shown in FIGS. 7 and 8 , the ophthalmic lens 22 is positioned against the adhesive side of the tape 122 such that one side is adequately covered by the tape 122 to prevent deposition coating onto the covered side of the lens 22 .
[0038] As shown in FIG. 9 , the fixture 120 is then slid into the channel guides 108 of two divider walls 102 , leaving one side of the lens 22 completely covered with tape 122 and the other side of the lens 22 completely exposed for vapor deposition of a coating, such as an anti-reflective coating.
[0039] It should be understood that other connection and support mechanisms are contemplated for use in addition to or in alternative of guides 108 . For example, the spring clip ring 104 and the fixture 120 may employ hooks that engage openings or loops formed in or on the drum divider walls 4 . Additionally, it should be understood that the spring clip ring 104 and the fixture 120 may alternately employ attachment mechanisms that connect directly to the drum side 6 . For example, one or more hooks can be fixed to the drum side 6 , allowing the spring clip ring 104 and the fixture 120 to be supported or suspended by the spring ring outer portion 110 or the fixture 120 , respectively.
[0040] In yet another embodiment according to the present invention, with reference to FIGS. 10 and 11 , a drum 200 has, for example, six drum sides 204 . Each drum side 204 having a drum aperture 202 formed therein. In contrast to the previously described drums 10 and 100 , the drum 200 does not employ divider walls 4 , 102 . In certain situations, omission of the divider walls 4 , 102 is advantageous because it simplifies fabrication of the drum and ultimately provides for a more robust drum.
[0041] Formed within the drum aperture 202 is a drum aperture lip 208 that has a diameter that is slightly reduced from the diameter of the drum aperture 202 . Formed on a surface of the aperture lip 208 are drum magnets 220 . A difference in a diameter of the drum aperture lip 208 and a diameter of the aperture lip 208 represents a width of the drum aperture lip 208 .
[0042] The drum 200 is, for example, of a modular design employing a plurality of drum segments 206 , for example 3 drum segments 206 combine to from the completely assembled drum 200 . The drum segments 206 may be formed of a plastic or metallic material. The drum segments 206 are secured to one another by employing a system of corresponding magnets on the surfaces of the segments 206 that are intended for mating against an adjacent segment 206 . This configuration advantageously allows for easier disassembly of the drum 200 for accessing an interior of the drum 200 for cleaning, maintenance, and repair.
[0043] In order to secure the lens 22 to the drum 200 a lens holding assembly 210 is employed. The lens holding assembly 210 , shown in FIGS. 12 and 13 , has an annular or ring shape forming a lens aperture 212 . The assembly 210 may be formed of a plastic or metallic material. The lens aperture 212 is sized to receive a fixed shape lens 22 , such as an uncut semi-finished lens. Formed within the lens aperture 212 is a retaining lip 214 that has a diameter that is slightly reduced from a diameter of the lens aperture 212 and a diameter of the lens 22 .
[0044] A width of the lens holding assembly 210 , i.e. a minimum distance from an exterior surface of the annular assembly 210 to the interior surface of the lens aperture 212 may but need not be approximately equal to the width of the drum aperture lip 208 .
[0045] On a backside 216 of the holder assembly 210 are holder magnets 218 . The holder magnets 218 may form a surface or a portion of a surface of the backside 216 of the holder assembly 210 . In certain embodiments, as shown in FIGS. 12A and 13A , the holder assembly 210 is formed of a plastic and the magnets 218 may be inserted and secured within holes formed in the surface of the backside 216 .
[0046] In certain embodiments, the holder assembly 210 is formed of a metallic material and the metallic material may function as a retaining magnet or interact with the magnets 220 shown in FIG. 11 to securely retain the holder assembly 210 . In one embodiment of the present invention, as shown in FIGS. 12B and 13B , a ring magnet or magnetic material 219 may be employed on the backside 216 of the holder assembly 210 . As shown in FIGS. 13B and 15 , the ring magnet or magnetic material 219 may be secured or attached to the backside 216 of the holder assembly 210 by an adhesive 217 .
[0047] Alternatively, in one embodiment of the present invention, as shown in FIGS. 13C and 16 , a snap-ring 215 made of a magnetic material such as steel is employed on, approximate to, or near the backside 216 of the holder assembly 210 . In operation, the magnetic snap-ring 215 is fixed in place in a machined or molded groove 213 formed in the lens holder assembly 210 . This permits the lens holder assembly to be manufactured from a variety of materials including, for example, aluminum and/or plastic. This embodiment may be advantageous because the absence of the adhesive 217 reduces outgassing in vacuum and prevents eventual failure of the part due to degradation of the adhesive.
[0048] With reference to FIGS. 13A-C , in operation, the lens 22 is slid into the lens aperture 212 from the backside 216 of the holder assembly 210 until the surface 22 A of the lens 22 to be coated abuts the retaining lip 214 . Once in position, the lens 22 will occupy an approximate entirety of the area of the aperture 212 . The holder assembly 210 loaded with a lens 22 is then inserted into the drum aperture 202 . The holder assembly 210 is secured or held within the drum aperture 202 by the attraction of the magnets 218 , retaining magnet 219 , magnetic snap-ring 215 , or by the magnetism inherent in a metallic material of the holder assembly 212 and the drum magnets 220 . It is also noted that by using this holder assembly 210 , the backside 22 B of the lens 22 is protected from any overspray of the coating deposition, as described above.
[0049] In order to prevent the lens 22 from falling towards and/or out from the backside 216 of the aperture 212 and into the interior of the drum 200 , a backstop 222 is employed at each of the drum apertures 202 of the drum 200 . With reference to FIGS. 10 and 11 , the backstop 222 is secured within the interior of the drum 200 so as to be reversibly biased or spring loaded in an outwardly direction through a corresponding drum aperture 202 . One or more portions 224 of the backstop 222 may project outward from the interior of the drum 200 to and/or through a plane defined by the circumference of the drum aperture 202 .
[0050] In operation, as the holder assembly 210 loaded with the lens 22 is inserted into the drum aperture 202 , the one or more portions 224 of the backstop 222 will contact a surface 22 B of the lens 22 and prevent the lens 22 from falling from the backside 216 of the aperture 212 and into the interior of the drum 200 . However, as the attraction of the magnets 218 of the holder assembly 212 and the drum magnets 220 pull and secure the holder assembly 210 within the drum aperture 202 , the spring loaded backstop 222 deflects in a direction towards an interior of the drum 200 . Alternatively stated, the attractive force of the magnets 218 of the holder assembly 212 and the drum magnets 220 is greater than the counter force applied to the surface 22 B of lens 22 by the backstop 222 .
[0051] In certain embodiments of the present invention, the backstop 22 is in the form of a linear beam positioned and secured within the drum 200 so as to span across a portion of the corresponding drum aperture 202 , as shown in FIGS. 10 and 11 . The one or more portions 224 of the backstop 222 may be in the form of two projections that extend outward from the backstop 222 positioned within the interior of the drum 200 to and/or through a plane defined by the drum aperture 202 . It should be understood that other forms of the backstop 222 and portions 224 may also be employed depending, in part, on the shape and size of the lens 22 being coated.
[0052] In another embodiment of the present invention, in order to secure the lens 22 to the drum 200 a lens holding spring assembly 240 is employed. The lens holding spring assembly 240 , shown in FIG. 14 , has an annular or ring shape with a lens aperture 242 formed therein. The assembly 240 may be formed of a plastic or metallic material. Within the lens aperture 242 are a plurality of spring arms 244 that are biased inward to an interior of the lens aperture 242 . The lens holding assembly 240 is advantageous for the securing and coating of lenses of varying or non-standard shapes and sizes, for example, cut ophthalmic lenses. In this respect, the plurality of arms 244 apply opposing pressure against the edge of the lens 22 , thereby securing the lens 22 within the assembly 240 in a removable arrangement.
[0053] A width of the lens holding assembly 240 , i.e. a minimum distance from an exterior surface of the annular assembly 240 to the interior surface of the lens aperture 242 , may but need not be approximately equal to the width of the drum aperture lip 208 previously described.
[0054] On a backside 246 of the holder assembly 240 are assembly holder magnets 248 . The assembly holder magnets 248 may form a surface or a portion of a surface of a backside 246 of the holder assembly 240 . In embodiments in which the holder assembly 240 is formed of a plastic, the magnets 248 may be inserted and secured within holes formed in the surface of the backside 246 . In embodiments in which the holder assembly 240 is formed of a metallic material, the metallic material may function as the magnet 248 .
[0055] In operation, the lens 22 is inserted between the spring arms 244 . The holder assembly 240 loaded with a lens 22 is then inserted into the drum aperture 202 . The holder assembly 240 is secured or held within the drum aperture 202 by the attraction of the magnets 248 of the holder assembly 240 and the drum magnets 220 .
[0056] In order to prevent the backside 22 B of lens 22 from accidental coating by coating material entering the interior of the drum 200 through the annular space between the lens 22 and the interior surface of the lens aperture 242 , an assembly backing may be employed. The assembly backing may be in the form of a rigid or semi-rigid material, for example a plastic or metallic sheet or foam board, that is positioned between the lens 22 being held within the assembly 240 and the backstop 222 of the drum 200 . Alternatively, the backing may be in the form of plastic wrap or a single sided adhesive, for example “surface saver” that is wrapped over the backside 246 of the lens holder assembly 240 prior to insertion of the assembly into the drum aperture 202 .
[0057] While the above-described drums 100 and 200 have been shown in the figures as employing sides and drum apertures that present the surface 22 A of the loaded lens 22 to a coating system or devise in a substantially perpendicular orientation relative to drum bottom 105 and 205 , respectively, in certain embodiments of the present invention, it may be desirable to employ a drum 100 or 200 that orients the surface 22 A of the loaded lens 22 in an orientation relative to drum bottom 105 and 205 that is substantially non-perpendicular. Such circumstances may arise, for example, when it is desirable to apply a coating on the surface 22 A of the loaded lens 22 that varies from one side the surface 22 A to the other.
[0058] In certain embodiments of the present invention, a substantially non-perpendicular orientation of the surface 22 A of the loaded lens 22 is achieved by varying the angle of the sides 106 of the drum 100 or the sides 204 of the drum 200 . In such embodiments, the non-perpendicular orientation of the sides 102 of the drum 100 or the sides 204 of the drum 200 may be either static or adjustable.
[0059] In certain embodiments of the present invention, a substantially non-perpendicular orientation of the surface 22 A of the loaded lens 22 is achieved by varying the angle of the drum aperture 202 relative to the sides 204 of the drum 200 . In certain other embodiments of the present invention, a substantially non-perpendicular orientation of the surface 22 A of the loaded lens 22 is achieved by varying the angle of the lens aperture 212 of the lens holding assembly 210 relative to the sides 204 of the drum 200 .
[0060] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
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A system and method for coating an optical lens by, for example vapor deposition, that employs a housing or drum having a plurality of apertures that each receives a lens holder assembly. The lens holding assembly configured to hold a standard, uncut optical lenses or lens blanks or, alternatively, to hold cut, non-standard shaped and sized optical lenses.
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FIELD OF THE INVENTION
This invention is directed to fiber-containing rice-based cereals and methods of preparation. More specifically, this invention is directed to methods for providing cooked rice with enhanced levels of fiber, wherein the fiber-containing cooked rice is suitable and especially adapted for use in preparing fiber-containing rice-based cereal products and especially for preparing fiber-containing puffed rice-based cereal products.
BACKGROUND OF THE INVENTION
Fiber is an important dietary component. Typical grains (including cereals prepared from such grains), fresh vegetables and fruits, and the like are an important source of dietary fiber. Rice, including rice-based cereals, however, do not typically provide a significant amount of fiber.
Most of the nutrients (including fiber and B vitamins) of whole rice are found in the outer layer or kernel (i.e., the bran). Rice bran also contains lipase enzymes which can cause rancidity within a relatively short time after harvesting. Thus, typically the bran (along with its fiber and nutrients) are removed before using the rice to prepare commercial food products (e.g., cereals). Such treated rice (e.g., cleaned and hulled) generally contains less than about 1 percent total dietary fiber (including soluble and insoluble fiber). Thus, cereals prepared from rice are typically not good sources of fiber.
Incorporation of fiber in rice without adversely affecting its performance in cereal manufacture has not been possible on a commercial scale. For example, U.S. Pat. No. 6,248,390 (Jun. 19, 2001) provides a “fiber water” containing significant levels of water soluble dietary fiber. This fiber water can be used to enrich foods, such as rice, by cooking the foods in fiber water. Cooked rice prepared in this manner does indeed provide a good source of fiber. The cooked rice, however, is not suitable for preparing rice-containing cereals, especially, puffed rice cereals, due to both its high water levels and the stickiness of the cooked rice. Such rice is simply not suitable for use in a conventional commercial cereal making production line.
Moreover, adding fiber after the rice has been cooked (i.e., during the later stages of cereal manufacture) has not been successful. The added fiber interferes with the manufacture process (e.g., prevent other coating materials to adhere to or penetrate the cereal particles), simply fails to adhere to the cereal particles themselves, and/or tends to agglomerate the cereal particles together. In any event, a satisfactory cereal product has not been possible.
Consequently, there remains a need to provide rice-based cereals containing relatively high levels of fiber. The present invention provides such methods using a fiber-infusion process during the cooking step.
SUMMARY OF THE INVENTION
This invention is directed to fiber-containing or fiber-infused rice-based cereals and methods of preparation. More specifically, this invention is directed to methods for providing cooked rice with enhanced levels of fiber, wherein the fiber-containing cooked rice is suitable and especially adapted for use in preparing fiber-containing or fiber-infused rice-based cereal products and especially for preparing fiber-containing puffed rice-based cereal products.
In the present invention, the soluble fiber is infused into the rice during the cooking process. Dried rice, preferably cleaned and hulled rice, is first partially cooked to for a partially hydrated rice with a moisture content of about 10 to 20 percent. The partially hydrated rice is then mixed with a soluble fiber and gently mixed to form a homogenous mixture of the partially cooked rice and soluble fiber. The homogenous mixture is then further cooked to complete cooking of the rice to obtained a cooked rice with a moisture content of about 28 to about 42 percent and which is infused with the soluble fiber. Although not wishing to be limited by theory, it appears that the soluble fiber is solubilized during this final cooking step and then imbibed into the rice particles as they swell. In any event, the resulting cooked rice has an enhanced level of soluble fiber as well as good physical and chemical properties (i.e., non-sticky and suitable moisture content) which make it ideal for cereal manufacture. Indeed, the resulting cooked rice surprisingly has better physical properties (i.e., non-stickiness) than conventional rice prepared without soluble fiber normally used to prepare rice-based cereal.
The present invention provides method for producing a fiber-containing rice-based cereal, said method comprising:
(1) precooking dried rice to form a partially hydrated rice having a first moisture content of about 10 to about 20 percent; (2) adding soluble fiber to the partially hydrated rice to form a rice-fiber composition; (3) gently mixing the rice-fiber composition to form a homogeneous mixture of the partially hydrated rice and soluble fiber; (4) cooking the homogenous mixture to complete hydration of the rice to obtain a cooked rice composition wherein the rice is infused with the soluble fiber and wherein the cooked rice composition has a second moisture content of about 28 to about 42 percent; (5) drying the cooked rice composition to a third moisture content of about 15 to about 23 percent to obtain a dried cooked rice composition; and (6) treating the dried cooked rice composition to form the fiber-containing rice-based cereal; wherein the fiber-containing rice-based cereal contains about 5 to about 25 percent total dietary fiber.
This invention also provides a method of preparing fiber-infused cooked rice, said method comprising:
(1) precooking dried rice to form a partially hydrated rice having a first moisture content of about 10 to about 20 percent; (2) adding soluble fiber to the partially hydrated rice to form a rice-fiber composition; (3) gently mixing the rice-fiber composition to form a homogeneous mixture of the partially hydrated rice and soluble fiber; (4) cooking the homogenous mixture to complete hydration of the rice to obtain a cooked rice composition wherein the rice is infused with the soluble fiber and wherein the cooked rice composition has a second moisture content of about 28 to about 42 percent; and (5) drying the cooked rice composition to a third moisture content of about 15 to about 23 percent to obtain the fiber-infused cooked rice, wherein the fiber-infused cooked rice contains about 5 to about 25 percent total dietary fiber. The fiber-infused cooked rice is ideally suited for preparing fiber-enriched rice-based cereals. The fiber-infused cooked rice can, however, be used in other rice-containing food products or used to prepare other rice-containing food products.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 provides a general flow diagram illustrating the process of this invention for preparing a fiber-containing rice-based cereal product.
DETAILED DESCRIPTION
The general process of the present invention for preparing a fiber-containing or fiber-infused rice-based cereal product is shown in FIG. 1 . Rice and water are precooked to partially hydrate the rice. Generally the extent of precooking should be sufficient to provide a moisture content of about 10 to 20 percent, and preferably about 14 to about 16 percent, for the precooked rice. Optional ingredients can be present during the precooking step; such optional ingredient include, for example, colorants, salt, minerals, emulsifiers, other processing aids, and the like which are normally used in cereal manufacture. The soluble fiber is then added to the precooked rice and gently agitated (e.g., by gently rotating the cooker or other container) until a homogenous precooked rice and soluble fiber is obtained. If desired, optional additives including, for example, colorant, salt, minerals, emulsifiers, other processing aids, and the like which are normally used in cereal manufacture can be added during the mixing step rather than before the precooking step. Preferably, at least the colorant (if used) is added in this mixing step at levels normally used in cereal manufacture since the homogenous distribution of colorant throughout the rice can effectively be used to determine the length of this mixing step necessary to achieve a homogenous mixture of the precooked rice and soluble fiber. Although the time required to obtain a homogenous mixture will vary depending on the equipment used, generally a mixing time of about 10 to 60 minutes is sufficient. The agitation should generally not introduce significant mechanical stress into the mixture to break the individual rice grains, especially when the rice is intended to be puffed and otherwise desired to maintain the individual grains in the final cereal product.
Once the homogenous precooked rice and soluble fiber mixture is obtained, it is subjected to a cooking step to complete cooking of the rice. Generally, the moisture content of the final cooked is about 28 to about 42 percent, and preferably about 30 to about 35 percent. Although not wishing to be limited by theory, it appears that the soluble fiber is solubilized during this final cooking step and then imbibed into the rice particles as they swell. In any event, the resulting cooked rice has an enhanced level of soluble fiber as well as good physical and chemical properties (i.e., non-sticky and suitable moisture content) which make it ideal for cereal manufacture. Indeed, the resulting cooked rice surprisingly has better physical properties (i.e., non-stickiness) than conventional rice prepared without soluble fiber normally used to prepare rice-based cereal. The fully cooked rice is then dried or tempered to a moisture content of about 17 to 23 percent, and preferably about 19 to 21 percent. The dried cooked rice is then treated using conventional cereal manufacturing techniques (e.g., bumping, flaking, puffing, toasting, coating, and the like) to obtain the fiber-enriched cereal product of this invention. Importantly, the infused fiber does not appear to adversely effect the remainder of the process using such conventional techniques. Indeed, it has surprisingly been found that the fiber-infused cooked rice of this invention is actually less sticky than cooked rice normally used to prepare conventional rice-based cereal produces and, thus, is easier to use in the remainder of the cereal making process as compared to conventional cooked rice.
The fiber-infused rice-based cereal products of this invention generally have total dietary fiber (i.e., soluble and insoluble fiber) of about 5 to about 25 percent; more preferably the fiber-infused rice-based cereal products have total dietary fiber of about 10 to about 15 percent total dietary fiber. These values compare with a typical fiber content of less than about 1 percent (and more generally in the range of about 0.5 to about 0.7 percent) in conventional rice-based cereals.
Preferably, the precooking, mixing, and cooking steps of FIG. 1 are carried out in a single vessel, preferably in a rotatable pressurized steam cooker. In an especially preferred embodiment, the steam cooker is preheated using steam. After draining out excess water, the dry rice and water (even more preferably with optional ingredients such as emulsifiers and minerals) are added and the rice is partially cooked in the rotating cooker for about 35 to about 50 minutes at a pressure of about 9 to about 20 psi (temperature of about 240 to about 260° F.) to provide a precooked rice having a moisture of about 10 to 20 percent. Typically, the amount of water mixed with rice in this precooking stage is about 5 to about 15 percent based on the rice. After the precooked rice has obtained its desired moisture content, the steam is turned off and the cooker is vented to atmospheric pressure. After opening the cooker, soluble fiber, additional water, and other optional ingredients (i.e., salt, colorant, and the like) are added. The cooker is sealed and then rotated without steam to homogeneously mix the various ingredients; generally a mixing time of about 10 to 60 minutes is sufficient. Thereafter, steam is reintroduced and cooking is continued for about 10 to 40 minutes at a pressure of about 9 to 20 psi (temperature of about 240 to about 260° F.) to provide a cooked rice infused with soluble fiber and having a moisture of about 28 to 42 percent.
The fiber-infused rise is preferably removed from the cooker, cooled, and then dried to a moisture content of about 17 to about 23 percent and preferably to about 19 to 21 percent. The resulting dried rice is then further processed using conventional cereal making techniques (e.g., bumping, flaking, puffing, toasting, coating, and the like) to obtain the fiber-enriched cereal product of this invention.
Any soluble fiber may be used in the present invention so long as, using the process of this invention, the fiber is infused into the rice particles or grains and the presence of the particular soluble fiber does not adversely effect the remainder of the cereal making process (i.e., after preparation of the fiber infused rice) in a significant manner. Suitable soluble fibers include, for example, polydextrose, maltodextrins, resistant maltodextrins, inulin, guar gum, carbomethyl cellulose, high methoxy pectin, and the like as well as mixtures thereof. The preferred soluble fiber is polydextrose.
Advantages and embodiments of this invention are further illustrated by the following examples but the particular materials and amounts thereof recited therein, as well as other conditions and details, should not be construed to unduly limit the invention. All parts, ratios, and percentages are by weight unless otherwise directed. All publications, including patents and published patent applications, are hereby incorporated by reference.
Example 1
A rotatable steam pressure cooker was preheated for about 30 minutes at atmospherics pressure with steam of about 10 psi. Rice (35.5 lbs), water (3.5 lbs), emulsifier (29.5 g; Myvaplex—a glycerol monostearate emulsifier from Eastman Chemical Co.), and minerals (6.3 g; reduced iron/zinc oxide blend) were added to the preheated cooker. As the cooker rotated, the rice was precooked with steam at a pressure of about 15 psi (temperature at about 250° F.) for about 40 minutes to obtain the precooked rice with a moisture content of about 15 percent. After turning the steam off, the cooker was vented to atmospheric pressure; a cooker syrup (14.8 lbs) containing polydextrose as the soluble fiber was added. The cooker syrup contained water (19.8 percent), liquid polydextrose (52.2 percent; obtained from Danisco USA, Inc.), salt brine (25.2 percent; consisting of about 25 percent water and about 75 percent salt), and colorant (188 g; Caramel RT-80 from Sethness Products Co.). The cooker was sealed and then rotated without steam for about 25 minutes to form a homogenous mixture; visually, the colorant was homogeneously distributed throughout the rice. The homogenous mixture was then cooked for an additional 25 minutes at a pressure of 15 psi (temperature of about 250° F.) to obtain fiber-infused cooked rice with a moisture content of about 33 percent. After turning the steam off, the cooker was then vented to atmospheric pressure; the fiber-infused rice was cooled with air and then removed from the cooker.
The fiber-infused cooker rice was then dried to about 19 percent moisture and then used to prepare a puffed rice cereal using conventional cereal making procedures. The resulting puffed rice cereal contained about 13.9 percent total dietary fiber. In spite of the significant level of fiber, the cereal has the appearance and organoleptic properties of conventional puffed rice cereal.
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Methods for providing cooked rice with enhanced levels of fiber, wherein the fiber-containing cooked rice is suitable and especially adapted for use in preparing fiber-containing rice-based cereal products and especially for preparing fiber-containing puffed rice-based cereal products, are provided.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 10/913,748, filed Aug. 6, 2004, entitled VEHICLE INTERIOR MIRROR SYSTEM INCLUDING A RAIN SENSOR, which is a continuation of Ser. No. 10/618,334, filed Jul. 11, 2003, now U.S. Pat. No. 6,774,356, which is a continuation of Ser. No. 09/997,579, filed Nov. 29, 2001, now U.S. Pat. No. 6,593,565, which is a continuation of U.S. patent application Ser. No. 09/433,467, filed Nov. 4, 1999, now U.S. Pat. No. 6,326,613, which is a continuation-in-part of Ser. No. 09/003,966, filed Jan. 7, 1998, by Niall R. Lynam, now U.S. Pat. No. 6,250,148, the disclosures of which are hereby incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] This invention relates to a vehicle interior mirror assembly.
[0003] According to the invention there is provided a vehicle interior rearview mirror assembly comprising a housing having a front end for releasable attachment to the interior surface of the vehicle windshield, a rear end having connection means for adjustably mounting a rearview mirror unit to the housing, the housing adapted for containing a rain sensor and biasing means in use biasing the rain sensor into contact with the interior surface of the windshield, the housing containing at least one further electrical component.
[0004] The invention further provides a vehicle interior rearview mirror assembly comprising a housing having a front end for releasable attachment to the interior surface of the vehicle windshield, a rear end having connection means for adjustably mounting a rearview mirror unit to the housing, the interior of the housing comprising at least one compartment, the compartment having an opening at the front end of the housing for facing in use towards the windshield and, the compartment adapted for containing a rain sensor and for biasing the rain sensor forwardly through the first opening into contact with the interior surface of the windshield, and the housing also containing at least one further electrical component.
[0005] The invention further provides a vehicle interior rearview mirror assembly comprising a housing having a front end for releasable attachment to the interior surface of the vehicle windshield, a rear end having connection means for adjustably mounting a rearview mirror unit to the housing, the interior of the housing comprising a compartment, the compartment having a first opening at the front end of the housing for facing in use towards the windshield and the compartment having a second opening on at least one side of the housing, the compartment containing a rain sensor and means for biasing the rain sensor forwardly through the first opening into contact with the interior surface of the windshield, and the compartment containing at least one further electrical component accessible through the second opening According to the present invention there is provided a vehicle interior rearview mirror assembly comprising a housing having a front end for releasable attachment to the interior surface of the vehicle windshield, a rear end having connection means for mounting a rearview mirror unit to the housing, and an internal wall subdividing the interior of the housing into first and second compartments, the first compartment having a first opening at the front end of the housing for facing in use towards the windshield and the second compartment having a second opening on at least one side of the housing, the first compartment containing a rain sensor and means for biasing the rain sensor forwardly through the first opening into contact with the interior surface of the windshield, and the second compartment containing at least one further electrical component accessible through the second opening.
[0006] The invention further provides a vehicle interior rearview mirror assembly comprising a housing having a front end for releasable attachment to the interior surface of the vehicle windshield, a rear end having connection means for releasably mounting a rearview mirror unit to the housing, a first opening at the front end of the housing for facing in use towards the windshield, and a second opening on at least one side of the housing for facing in use towards the top edge of the windshield, the housing containing a rain sensor, means for biasing the rain sensor forwardly through the first opening into contact with the interior surface of the windshield, and at least one further electrical component accessible through the second opening. The assembly further preferably including a removable cover which mates with the housing around the second opening and in use preferably extends along the windshield towards the vehicle header, and electrical leads for the rain sensor and the further electrical component which in use are routed under the cover to the header.
[0007] The invention provides the significant advantage that a vehicle manufacturer is provided with the possibility of optionally including a variety of components with the rear view mirror assembly. This possibility is made available for example during the assembly line process where the desired components to meet a particular specification can be included in the rear view mirror assembly. Furthermore, the removable cover readily provides for the functional advantage of readily incorporating a selected component whilst at the same time providing a functionally attractive cover. The automaker is therefore provided with the considerable advantage of the possibility of providing a plurality of diverse options quickly and speedily during the assembly line process.
[0008] An embodiment of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a side view of an embodiment of a vehicle interior mirror assembly according to the invention attached to the interior surface of a windshield;
[0010] FIG. 2 is a cross-section through the mirror assembly of FIG. 1 ;
[0011] FIG. 3 is a perspective top view of the mirror assembly;
[0012] FIG. 4 is a view of the mirror assembly of FIG. 3 looking into the opening 18 ;
[0013] FIG. 5 is a view of the mirror assembly of FIG. 3 looking into the opening 20 ;
[0014] FIG. 6 is a view of the mirror assembly of FIG. 3 looking from underneath;
[0015] FIG. 7 is a perspective view of the wiring cover forming part of the mirror assembly;
[0016] FIG. 8 is a schematic view of another embodiment of vehicle interior mirror assembly according to the invention; and
[0017] FIG. 9 is a schematic view of yet a further embodiment of a vehicle into rear mirror assembly according to the invention.
[0018] In certain of the figures some components are omitted or shown in dashed outline to reveal the underlying structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring to the drawings, a vehicle interior rearview mirror assembly comprises a die cast metal housing 10 (or optionally may be formed from a plastic moulding such as engineering polymeric resin such as a filled nylon or the like) having a front end 12 and a rear end 14 , the front end 12 being releasably attached to the interior surface of the vehicle windshield 22 in a manner to be described. The interior of the housing 10 is subdivided by an internal wall 16 into first and second compartments 18 , 20 respectively, the first compartment 18 having an opening 18 a at the front end of the housing 10 which in use, and as shown in FIGS. 1 and 2 , faces towards the windshield 22 and the second compartment having an opening 20 a on the side of the housing which in use faces towards the vehicle header 24 at the top edge of the windshield. The front end 12 of the housing 10 is releasably attached to the windshield 22 using an annular mounting button, not shown, in the manner described in EP 0 928 723 and U.S. patent application Ser. No. 09/003,966, entitled “Rain Sensor Mount for Use in a Vehicle” to Niall R Lynam, now U.S. Pat. No. 6,250,148, the disclosures of which are incorporated herein by reference.
[0020] The compartment 18 contains a rain sensor 26 , preferably a compact rain sensor module available from ITT Automotive Europe GmbH of Frankfurt, Germany. The compartment 18 preferably also contains an arcuate steel spring finger 28 which is secured to the base of the compartment 18 behind the rain sensor 26 and preferably serves to bias the rain sensor 26 through the aperture in the mounting button and the opening 18 a into optical contact with the windshield 22 . Most preferably, rain sensor 26 is a module which has a cross section diameter of at least 25 millimeters (mm), more preferably at least 30 mm, but with a maximum diameter ≦50 mm, more preferably ≦40 mm, and most preferably ≦35 mm.
[0021] The compartment 20 contains at least one further electrical component which is accessible through the opening 20 a. In the present embodiment the component is a printed circuit board 30 bearing a compass sensor such as a flux gate, magnetoinductive, magnetoresistive or magnetocapacitive sensor.
[0022] At its rear end 14 the housing 10 has an integral ball 32 for releasably and adjustably mounting a rearview mirror unit 34 to the housing 10 generally in conventional manner. The mirror unit 34 comprises a mirror housing 36 containing a mirror 38 which is preferably an electro-optic mirror comprising front and rear plates separated by a space which contains an electro-optic medium such as an electrochromic medium allowing variation in the amount of light transmitted through the medium by varying the strength of an electric field applied across the medium. Alternatively a prismatic mirror element can be used. Such mirrors are well known in the art. The ball 32 constitutes one part of a ball and socket joint, the socket 36 being carried by the mirror housing 36 . The mirror housing is adjustable about the ball and socket joint. Advantageously, the housing 10 is fixedly attached to the windshield when mounted thereto. Thus, adjustment of the mirror housing to set the field of rearward view of the mirror reflective element therein does not effect the position/orientation of rain sensor and any other accessory housed in fixedly-attached housing 10 . This is particularly advantageous when the electrical accessory in housing 10 comprises a compass sensor such as a magneto-resistive sensor, a magneto-inductive sensor, a magneto-capacitive sensor or a flux-gate sensor. By having the housing 10 be fixedly attached, and by having it accommodate at least two electrical accessories (at least one of which preferably comprises a rain sensor that is mounted in the housing 10 so as to view through and preferably contact the windshield inner surface, and with the rain sensor attached to the windshield generally coaxial with the mirror unit that is adjustable about housing 10 ), a compact overall interior mirror system is provided comprising a housing accommodating a plurality of electrical accessories, the housing fixedly and detachably mounted to a receiving structure on the inner surface (typically a glass surface) of the vehicle windshield and with a mirror unit comprising a mirror support arm and a mirror housing including a reflector element, the mirror support arm/mirror housing being adjustable about the fixed housing (and optionally detachable therefrom). In this manner, the housing 10 presents a minimal footprint when viewed from outside the vehicle through the vehicle windshield.
[0023] The assembly further includes a removable cover 40 which mates with the housing 10 around the opening 20 a and extends along the windshield to the vehicle header 24 . The cover 40 , which is longitudinally symmetric, is moulded from a resilient, polymeric or plastics material and comprises a pair of opposite, substantially coplanar, longitudinal side edges 42 , FIG. 7 , which diverge from a relatively narrow rear end 44 of the cover 40 to a relative wide flared front end 46 . The flared front end 46 of the cover is open, and there is also a small opening 48 at the narrow rear end 44 . The cover 40 has an internal strengthening wall 50 whose free edge 52 is recessed below the level of the edges 42 . At its flared front end the cover 40 has a pair of forward projections 54 , and the inside surface of the cover has a pair of raised ridges 56 (only one is seen in FIG. 7 ) each extending along a respective side of the cover adjacent to the front end 46 .
[0024] The exterior surface of the housing 10 has a corresponding pair of elongated grooves or depressions 58 along each side of the opening 20 a, the exterior width of the housing across the opening 20 a being substantially the same as the interior width of the cover 40 across the grooves 58 .
[0025] The cover 40 is fitted to the housing 10 by first inserting the projections 54 into a recess 60 , FIGS. 2 and 5 , above the opening 20 a and then rotating the cover towards the windshield until the ribs 56 snap-engage the grooves 58 (the cover 40 is sufficiently resilient to permit this) and the edges 42 of the cover come to lie flat against the interior surface of the windshield 22 , as seen in FIGS. 1 and 2 . The cover 40 may be removed by pulling the narrow end 44 away from the windshield until the ribs 56 disengage the grooves 58 and then withdrawing the projection 54 from the recess 60 .
[0026] The cover 40 serves a dual purpose. First, it protects the compartment 20 a and hence the component 30 against the ingress of dust and other contaminants, yet it is easily removed to allow the component 30 to be serviced or replaced, if necessary after removing the mirror unit 34 . Secondly, it provides a conduit for electrical leads 62 , 64 and 66 respectively from the rain sensor 26 , component 30 and (if fitted) the electro-optic or other electrically operated mirror 38 .
[0027] As seen in FIG. 1 , these leads are routed under the cover 40 and through the opening 48 at the rear end 44 of the cover into the vehicle header 24 where they are connected into the vehicle electrical system.
[0028] As clearly shown in FIG. 2 , the ball joint 32 includes a passageway or a conduit through which can pass the electrical leads connecting to a component such as a eletrochromic mirror element 38 or compass display in the mirror head 34 . In particular, there is shown a lead 68 connected to a compass display 70 which displays through the mirror element. Alternatively, the display 70 can be located at other positions in the interior rear view mirror assembly, such as in a chin portion or in an eyebrow portion.
[0029] Optionally, the removable cover includes at least one opening 100 or port through which a pointed object such as the tip of a ball point pen or a needle or the like can be inserted to activate switches on a PCB located in one of the compartments. Thus, for example, the zone and/or the calibration of a compass PCB can be adjusted without the necessity to remove the removable cover.
[0030] Also, a camera may be located on the assembly for example on the housing, or mirror unit or cover and arranged to look either forwardly or rearwardly in terms of the direction of motion of the vehicle, or in another desired direction. In FIGS. 8 and 9 there is shown schematic views of other embodiments of the invention. Thus, in FIG. 8 there is shown the housing 10 containing a rain sensor 26 and another electrical component for example a printed circuit board of a compass sensor 30 , with the housing attached to the vehicle windshield 22 . The mirror unit 34 is adjustably attached to the housing 10 by a double ball adjustable mirror support arm 101 .
[0031] In FIG. 9 , the mirror support arm 101 is attached to a mirror assembly mount 102 . The housing 10 also comprises a mirror assembly mount button 103 which may be fixed to the housing 10 or integrally formed therewith. The mount 102 is detachably attached to the mirror assembly mount button 103 .
[0032] Although the component 30 has been described as a compass sensor PCB, it can be any of a number of sensors or circuits which can be made small enough to fit in the compartment 20 . Preferably, component 30 is provided as a unitary module that is received within compartment 20 . Most preferably, component 30 is electrically connected with the electric/electronic wiring provided to the rear view mirror assembly. Thus, an electronic accessory can be provided as a module, can be inserted and received in the rear view mirror assembly, and can make electrical connection (such as by a plug and socket to the rear view mirror assembly). This facilitates and enables the manufacture and supply of the rear view mirror assembly, by a mirror assembly manufacturer, to a vehicle assembly line, and the separate manufacture and supply of the electrical/electronic module to that vehicle assembly line, with the automaker conveniently inserting the electric/electronic module into the compartment of the rear view mirror assembly when the rear view mirror assembly is being mounted on a vehicle passing down a vehicle assembly line.
[0033] For example, the compartment 20 may contain a sensor or sensors for vehicle altitude and/or incline, seat occupancy or air bag activation enable/disable, or (if a viewing aperture is made in the housing 10 ) photosensors for headlamp intensity/daylight intensity measurement. Alternatively, the compartment 20 may contain a transmitter and/or receiver, along with any associated sensors, for geographic positioning satellite (GPS) systems, pagers, cellular phone systems, ONSTAR™ wireless communication, systems, vehicle speed governors, security systems, tire monitoring systems, remote fueling systems where vehicle fueling and/or payment/charging for fuel is remotely achieved, remote keyless entry systems, garage and/or security door opener systems, INTERNET interfaces, vehicle tracking systems, remote car door unlock systems, e-mail systems, toll booth interactions systems, highway information systems, traffic warning systems, home access systems, garage door openers and the like. Of course, any of the above may be mounted under the cover 40 , in addition to the component 30 in the compartment 20 .
[0034] Where the component 30 is a transmitter or receiver, or where a further component mounted under the cover 40 is a transmitter or receiver, the cover 40 may include an associated antenna. The antenna may mounted as a separate item under the cover 40 , or the cover itself may serve as the antenna, being either coated with a layer of conductive material or moulded from a conductive plastics material.
[0035] Also, a photosensor may be included in a compartment of the housing, preferably a skyward facing photosensor that views skyward through the vehicle windshield for the purpose of providing automatic headlamp activation/deactivation at dusk/dawn. Also, the housing may include a single microphone or a plurality of microphones for detecting vocal inputs from vehicle occupants for the purpose of cellular phone wireless communication.
[0036] Most preferably such microphones provide input to an audio system that transmits and communicates wirelessly with a remote transceiver, preferably in voice recognition mode. Such systems are described in commonly assigned, U.S. patent application Ser. No. 09/382,720, filed Aug. 25, 1999, now U.S. Pat. No. 6,243,003, the disclosure of which is hereby incorporated by reference herein.
[0037] In this regard it may be desirable to use audio processing techniques such as digital sound processing to ensure that vocal inputs to the vehicular audio system are clearly distinguished from cabin ambient noise such as from wind noise, HVAC, and the like.
[0038] Preferably the housing includes an analog to digital converter and or a digital analog converter for the purpose of converting the analog output of the microphone to a digital signal for input to a digital sound processor and for conversion of the digital output of a digital sound processor to an analog signal for wireless transmission to a remote transceiver.
[0039] The housing may include a variety of information displays such as a PSIR (Passenger Side Inflatable Restraint) display, an SIR (Side-Airbag Inflatable Restraint), compass/temperature display, a tire pressure status display or other desirable displays, such as those described in commonly assigned, U.S. patent application Ser. No. 09/244,726, filed Feb. 5, 1999, now U.S. Pat. No. 6,172,613, the disclosure of which is hereby incorporated by reference herein.
[0040] For example, the interior rearview mirror assembly may include a display of the speed limit applicable to the location where the vehicle is travelling. Conventionally, speed limits are posted as a fixed limit (for example, 45 MPH) that is read by the vehicle driver upon passing a sign. As an improvement to this, an information display (preferably an alphanumerical display and more preferably, a reconfigurable display) can be provided within the vehicle cabin, readable by the driver, that displays the speed limit at whatever location on the road/highway the vehicle actually is at any moment. For example, existing speed limit signs could be enhanced to include a transmitter that broadcasts a local speed limit signal, such signal being received by an in-vehicle receiver and displayed to the driver. The speed limit signal can be transmitted by a variety of wireless transmission methods, such as radio transmission, and such systems can benefit from wireless transmission protocols and standards, such as the BLUETOOTH low-cost, low-power radio based cable replacement or wireless link based on short-range radio-based technology. Preferably, the in-vehicle receiver is located at and/or the display of local speed limit is displayed at the interior mirror assembly (for example, a speed limit display can be located in a chin or eyebrow portion of the mirror case, such as in the mirror reflector itself, such as in the cover 40 , or such as in a pod attached to the interior mirror assembly). More preferably, the actual speed of the vehicle can be displayed simultaneously with and beside the local speed limit in-vehicle display and/or the difference or excess thereto can be displayed. Optionally, the wireless-based speed limit transmission system can actually control the speed at which a subject vehicle travels in a certain location (such as by controlling an engine governor or the like). Thus, a school zone speed limit can be enforced by transmission of a speed-limiting signal into the vehicle. Likewise, different speed limits for the same stretch of highway can be set for different classes of vehicles. The system may also require driver identification and then set individual speed limits for individual drivers reflecting their skill level, age, driving record and the like. Moreover, a global positioning system (GPS) can be used to locate a specific vehicle, calculate its velocity on the highway, verify what the allowed speed limit is at that specific moment on that specific stretch of highway, transmit that specific speed limit to the vehicle for display (preferably at the interior rearview mirror that the driver constantly looks at as part of the driving task) and optionally alert the driver or retard the driver's ability to exceed the speed limit as deemed appropriate. A short-range, local communication system such as envisaged in the BLUETOOTH protocol finds broad utility in vehicular applications, and particularly where information is to be displayed at the interior mirror assembly, or where a microphone or user-interface (such as buttons to connect/interact with a remote wireless receiver) is to be located at the interior (or exterior) rearview mirror assembly. For example, a train approaching a railway crossing may transmit a wireless signal such as a radio signal (using the BLUETOOTH protocol or another protocol) and that signal may be received by and/or displayed at the interior rearview mirror assembly (or the exterior sideview mirror assembly). Also, the interior rearview mirror and/or the exterior side view mirrors can function as transceivers/display locations/interface locations for intelligent vehicle highway systems, using protocols such as the BLUETOOTH protocol. Protocols such as BLUETOOTH, as known in the telecommunications art, can facilitate voice/data, voice over data, digital and analogue communication and vehicle/external wireless connectivity, preferably using the interior and/or exterior mirror assemblies as transceiver/display/user-interaction sites. Electronic accessories to achieve the above can be accommodated in housing 10 , and/or elsewhere in the interior mirror assembly (such as in the mirror housing). Examples of such electronic accessories include in-vehicle computers, personal organizers/palm computers such as the Palm Pilot™ personal display accessory (PDA), cellular phones and pagers, remote transaction interfaces/systems such as described in commonly assigned, U.S. patent application Ser. No. 09/057,428, filed Apr. 8, 1998, now U.S. Pat. No. 6,158,655, the disclosure of which is hereby incorporated by reference herein, automatic toll booth payment systems, GPS systems, e-mail receivers/displays, a videophone, vehicle security systems, digital radio station transmission to the vehicle by wireless communication as an alternate to having an in-vehicle dedicated conventional radio receiver, traffic/weather broadcast to the vehicle, preferably digitally, and audio play and/or video display thereof in the vehicle, most preferably at the interior rearview mirror, highway hazard warning systems and the like.
[0041] The information display at the interior rearview mirror assembly (such as at the mirror housing or viewable in the mirror reflector) may be formed using electronic ink technology and can be reconfigurable. Examples of electronic ink technology include small plastic capsules or microcapsules, typically 1/10 of a millimeter across or thereabouts, that are filled with a dark ink and that have in that ink white particles which carry a charge such as a positive charge. Electrodes place an electric field across the capsules and the electric field can attract or repel the charged particles in the capsules. If the white particle is attracted to the top of a capsule so that it is closest to a viewer, the display element/pixel appears white to the viewer. If the white particle is attracted to the bottom of the capsule (away from the viewer), the display element/pixel appears dark as the viewer now sees the dark ink in the capsule. Such displays are available from E Ink of Cambridge, Mass. Such electronic ink displays have the advantage of forming text or graphics that, once formed, do not disappear when the display powering voltage is disconnected (i.e. they have a long display memory). Alternately, GYRICON™ electronic ink technology developed by XEROX Corporation can be used. Here, microbeads are used that are black (or another dark color) on one side and white (or another light color) on the other side. The beads are dipolar in that one hemisphere carries a stronger (and hence different) charge than the opposing other hemisphere. The beads are small (about 1/10 th of a millimeter diameter) and turn or flip when placed in an electric field, with the respective poles of the dipolar beads being attracted to the corresponding polarity of the applied electric field. Thus, a white pixel or a black pixel can be electrically written. Once the bead has turned or flipped, it remains turned or flipped unless an electric potential of the opposite polarity is applied. Thus, the display has memory.
[0042] Other types of information displays can be used at the interior mirror location. For example, a field-emission display such as the field-emission display available from Candescent Technologies of San Jose, Calif. can be used. Field-emission displays include a plurality of charge emitting sources or guns that bombard a phosphor screen. For example, a myriad of small or microscopic cones (<1 micron tall, for example and made of a metal such as molybdenum) are placed about a millimeter from phosphors on a screen. The cones emit electrons from their tips or apexes to bombard the phosphors under an applied electric field. This technology is adaptable to provide thin display screens (such as less than 10 mm or so). Alternately, field-emission displays can be made using carbon nanotubes which are cylindrical versions of buckminsterfullerene, and available from Motorola. Such field-emission displays are particularly useful for video displays as they have high brightness and good contrast ratio, even under high ambient lighting conditions such as in a vehicle cabin by day. Such displays can be located at the interior rearview mirror, preferably, or optionally elsewhere in the vehicle cabin such as in the dash, in the windshield header at the top interior edge of the windshield, in a seat back, or the like.
[0043] A further advantage of providing a housing 10 which accommodates multiple electrical accessories, preferably in individual compartments, is that incorporation of optional accessories into a specific vehicle is facilitated. It also facilitates supply of the housing 10 and associated mirror unit by a mirror manufacturer and supply of at least one of the electrical accessories by a second, different accessory manufacturer, and with the automaker placing the at least one electrical accessory into the housing 10 at the vehicle assembly plant, preferably at the vehicle assembly line. Thus, for example, an interior mirror assembly can be manufactured by a mirror supplier that includes housing 10 , compartments 18 and 20 (or, optionally, more compartments), printed circuit board 30 (such as a compass sensor printed circuit board) in compartment 20 but with compartment 18 empty, removable cover 40 , a mirror support arm articulating about housing 20 , a mirror housing or case supported on said support arm, a reflector element in said mirror housing (preferably an electrochromic mirror element which includes an information display such as of compass direction and/or temperature displaying through said mirror element as is known in the mirror arts). A rain sensor module can be made by a separate manufacturer. The rain sensor module and the interior mirror assembly can be shipped to a vehicle assembly plant (or local to it). Then, when a particular vehicle requires a rains sensor module, the vehicle manufacturer can place the rain sensor module into compartment 18 , connect the rain sensor module to the wire harness provided to mirror assembly (preferably, the rain sensor module docks into compartment 18 in a manner that connects it electrically to the vehicle or alternatively, the rain sensor module includes a plug or socket that connects to a corresponding socket or plug already provided in housing 10 (or elsewhere on the interior mirror assembly). This allows “plug & play” accommodation of multiple accessories into the interior rearview mirror assembly. Also, the interior rearview mirror assembly may be shipped to the assembly plant with both compartments 18 and 20 empty, thus allowing, for example, the automaker to solely place a rain sensor module into compartment 18 but add no further accessory into compartment 20 .
[0044] The invention is not limited to the embodiments described herein which may be modified or varied without departing from the scope of the invention.
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An accessory mounting system suitable for mounting a plurality of accessories at a windshield portion within the interior cabin of a vehicle comprises a housing that is adapted for releasable mounting to a receiving structure on the interior surface of the windshield of the vehicle. The housing houses at least two accessories, at least one of which is selected from the group consisting of a forwardly-viewing camera and a forwardly-viewing rain sensor. Another of the at least two accessories is selected from the group consisting of: a) a vehicle altitude sensor, b) a vehicle incline sensor, c) a headlamp sensor, d) a daylight sensor, e) a geographic positioning satellite (GPS) transmitter, f) a geographic positioning satellite (GPS) receiver, g) an antenna, h) a camera, i) a microphone, j) a compass sensor, k) a rain sensor and l) a photosensor. The at least one of the two accessories housed by the housing views through the windshield of the vehicle when the housing is mounted to the receiving structure on the windshield.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of International Application No. PCT/CN2014/073342, titled “ELECTRONIC CIGARETTE BATTERY ASSEMBLY”, filed on Mar. 13, 2014, which claims the benefit of priority to Chinese patent application No. 201420086547.3, titled “ELECTRONIC CIGARETTE BATTERY ASSEMBLY”, filed with the Chinese State Intellectual Property Office on Feb. 27, 2014, the entire disclosures of which are incorporated herein by this reference.
FIELD
[0002] The present application relates to the field of electronic cigarettes, and in particular to an electronic cigarette battery assembly.
BACKGROUND
[0003] An electronic cigarette, also referred to as a virtual cigarette or an electronic tobacco cigarette, is an alternative to a conventional smoke, which is mainly used for quitting smoking and replacing the conventional smoke. The electronic cigarette has a same appearance and substantially a same taste with the conventional smoke, and even has more taste than the conventional smoke. The electronic cigarette, when smoked, can create smoke, taste and feel just like the conventional smoke. Further, the electronic cigarette has no harmful ingredients in the conventional smoke, such as tar, suspended particles, etc., and also would not create diffuse or wreathing second-hand smoke. Therefore, the electronic cigarette would not cause harm to a smoker and other person.
[0004] As shown in FIG. 1 , a conventional electronic cigarette includes an atomizing assembly 20 and a battery assembly 10 which are connected together. The electronic cigarette has a battery 11 arranged in the battery assembly 10 . A cap is provided on an end 13 , which is far away from the atomizing assembly 20 , of the battery assembly. For the purpose of facilitating a reuse, a rechargeable battery may be employed as the battery 11 . When the rechargeable battery 11 runs out, the rechargeable battery 11 is required to be removed out of the battery assembly 10 to be charged. However, this would make the rechargeable battery 11 to be removed out of and put into the battery assembly 10 frequently. The atomizing assembly 20 is detached from the battery assembly 10 to allow the rechargeable battery 11 to be charged from one end of the battery assembly 10 which is connected to the atomizing assembly 20 . However, this would make the use of the electronic cigarette inconvenient. Also, disassembling the atomizing assembly 20 and the battery assembly 10 frequently would easily lead to a problem of an unreliable electric connection between the atomizing assembly 20 and the battery assembly 10 due to the loose atomizing assembly 20 and the battery assembly 10 .
SUMMARY
[0005] In view of this, an electronic cigarette battery assembly is provided according to the present application, which overcome the problems in the conventional electronic cigarette that a rechargeable battery has to be removed out of the battery assembly for being charged, which is inconvenient and cause an unreliable electric connection between the atomizing assembly and the battery assembly due to the loose atomizing assembly and the battery assembly.
[0006] To achieve the above object, the solution of the present application is provided as follows.
[0007] An electronic cigarette battery assembly is provided according to the present application, which forms an electronic cigarette together with an atomizing assembly, and includes:
a battery rod main body including a rechargeable battery and a control module for controlling the charging and discharging of the rechargeable battery; and a charging electrode arranged at an end of the battery rod main body and electrically connected to the control module for delivering electric energy to the rechargeable battery, the charging electrode includes: an outer electrode, an electrode bracket and an inner electrode, the outer electrode is arranged at the end, is located at an inner side of the end and is fixedly connected to the battery rod main body; the electrode bracket is made of an electric insulating material, and is arranged at an inner side of the outer electrode and is fixedly connected to the inner side of the outer electrode; and the inner electrode is arranged at an inner side of the electrode bracket, and an outer side of the inner electrode is slidably connected to the electrode bracket, and an end face of the inner electrode is in a spherical cap shape and is located at an end face of the end of the battery rod main body.
[0016] Further, the outer electrode is in an annular shape.
[0017] Further, a circumferential surface of the outer electrode is provided with a retaining portion for being retained on an end face of the battery rod main body.
[0018] Further, an outer end face of the charging electrode is in a spherical cap shape.
[0019] Further, an inner wall surface of the electrode bracket is provided with a first position-limiting portion which abuts against the inner electrode for preventing the inner electrode from falling into the battery rod main body, and/or
the outer side of the inner electrode is provided with a second position-limiting portion which abuts against the electrode bracket for preventing the inner electrode from slipping off from the electrode bracket in a direction away from the battery rod main body.
[0021] Further, the charging electrode further includes an elastic piece abutting against the inner electrode to allow the inner electrode to be elastically stretchable in an axial direction of the battery rod main body.
[0022] Further, the charging electrode further includes a fixing plate which is inserted into and connected to the outer electrode, and the elastic piece has one end abutting against the inner electrode and another end abutting against the fixing plate.
[0023] Further, the elastic piece is a spring, and the inner electrode is connected to the control module by the spring.
[0024] Further, the inner electrode is provided with a protrusion, and at least a part of the spring is arranged at the circumference of the protrusion.
[0025] Further, the inner electrode is provided with a recess, and at least a part of the spring is arranged in the recess.
[0026] From the above technical solution, it can be seen that the electronic cigarette battery assembly according to the present application includes the charging electrode arranged at the end of the battery assembly. The charging electrode is connected to the rechargeable battery of the battery assembly by the control module. When the rechargeable battery is required to be charged, only the charging electrode is connected to an electric energy output end of an external charger for achieving the charging of the rechargeable battery and it is not necessary to remove the rechargeable battery out of the battery assembly and disassemble the battery assembly and the atomizing assembly, which facilitates the use of the electronic cigarette. That is, the problems, that the rechargeable battery has to be removed out of the battery assembly to be charged, in the conventional electronic cigarette can be overcome, which may otherwise my inconvenient and cause an unreliable electric connection between the atomizing assembly and the battery assembly due to the loose atomizing assembly and the battery assembly.
[0027] Further, since the inner electrode is arranged at the inner side of the electrode bracket and is slidably connected to the electrode bracket and the inner electrode has an end face of a spherical cap shape, the inner electrode is more easily to be aligned and in contact with an electric energy output end of an external charging equipment when the rechargeable battery is being charged. Especially when the battery assembly is to be socketed to a charging equipment to be charged, the inner electrode slidably connected to the electrode bracket is easily to be electrically connected to the charging equipment, and the outer electrode may also be allowed to have a good electrical connection to the charging equipment, which ensures a reliable charging. Also, dirt is not apt to be accumulated at the spherical cap-shaped end face of the charging electrode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] For more clearly illustrating embodiments of the present application or technical solutions in the conventional technology, drawings referred to describe the embodiments or the conventional technology will be briefly described hereinafter. Apparently, the drawings in the following description are only some examples of the present application, and for those skilled in the art, other drawings may be obtained based on these drawings without any creative efforts.
[0029] FIG. 1 is a view showing the structure of an electronic cigarette in the conventional technology;
[0030] FIG. 2 is a view showing the structure of an electronic cigarette battery assembly according to an embodiment of the present application;
[0031] FIG. 3 is a view showing the structure of an electronic cigarette battery assembly according to another embodiment of the present application; and
[0032] FIG. 4 is a view showing the structure of an electronic cigarette battery assembly according to yet another embodiment of the present application.
DETAILED DESCRIPTION
[0033] The technical solutions of the embodiments of the present application will be described clearly and completely hereinafter in conjunction with the drawings of the embodiments of the present application. Apparently, the embodiments described are only some examples of the present application, and not all implementation. Other embodiments obtained by those skilled in the art based on the embodiments of the present application without any creative efforts all fall into the scope of the present application.
First Embodiment
[0034] FIG. 2 is a view showing the structure of an electronic cigarette battery assembly forming an electronic cigarette together with an atomizing assembly according to an embodiment of the present application.
[0035] As shown in FIG. 2 , the battery assembly according to this embodiment includes a battery rod main body 10 and a charging electrode 30 located at an end 13 of the battery rod main body 10 . Another end of the battery rod main body 10 is connected to the atomizing assembly.
[0036] The battery rod main body 10 includes a rechargeable battery 11 and a control module 12 for controlling the charging and discharging of the rechargeable battery 11 .
[0037] The charging electrode 30 is connected to the control module 12 , and the control module 12 is also connected to the rechargeable battery 11 .
[0038] The charging electrode 30 includes an outer electrode 31 , an electrode bracket 32 and an inner electrode 33 . The outer electrode 31 is in an annular shape and arranged at the end 13 of the battery rod main body 10 . The outer electrode 31 is fixedly connected to an inner side of the battery rod main body 10 by glue or the like. The circumferential surface of the outer electrode 31 is provided with a retaining portion 311 , which is retained on an end face of the battery rod main body 10 . By providing the retaining portion 311 , the outer electrode 31 may be prevented from falling into the battery rod main body 10 .
[0039] The electrode bracket 32 is arranged at an inner side of the outer electrode 31 and fixedly connected to the outer electrode 31 . An inner wall surface of the electrode bracket 32 is provided with a first position-limiting portion 321 , which abuts against the inner electrode 33 so as to prevent the inner electrode 33 from falling into the battery rod main body 10 . When the inner electrode 33 moves toward another end of the battery assembly in an axial direction of the battery assembly due to an external force caused by a dropping battery assembly, the position of the inner electrode 33 is limited by the first position-limiting portion 321 , thus preventing the inner electrode 33 from falling into the battery rod main body 10 .
[0040] The inner electrode 33 is arranged at an inner side the electrode bracket 32 and slidably connected to the electrode bracket 32 . The outer electrode 31 and the inner electrode 33 are connected to the control module 12 of the electronic cigarette by wires.
[0041] An end face of the inner electrode 33 is in a spherical cap shape, and is located at an end face of the end 13 of the battery rod main body 10 for being connected to an electric energy output end of external charging equipment.
[0042] The electrode bracket 32 is made of an electric insulating material, such as a plastic or ceramic material, etc. Herein, the material of the electrode bracket 32 is not limited. An outer end face of the charging electrode 30 is in a spherical cap shape.
[0043] When the rechargeable battery 11 needs to be charged, only the charging electrode 30 is required to be connected to an electric energy output end of an external charger for achieving the charging of the rechargeable battery 11 .
[0044] From the above technical solution, it can be seen that the electronic cigarette battery assembly according to this embodiment includes the charging electrode 30 . The charging electrode 30 is connected to the rechargeable battery 11 of the electronic cigarette by the control module 12 . When the rechargeable battery 11 needs to be charged, only the charging electrode 30 is required to be connected to an electric energy output end of an external charger for achieving the charging of the rechargeable battery 11 , that is, it is not necessary to remove the rechargeable battery 11 out of the battery assembly 10 , which facilitates the use of the electronic cigarette. That is, the problems that, the rechargeable battery 11 has to be removed out of the battery assembly 10 to be charged, in the conventional electronic cigarette can be overcome, which may otherwise be inconvenient and has an unreliable electric connection.
[0045] Further, since the inner electrode 33 is arranged at the inner side of the electrode bracket 32 and is slidably connected to the electrode bracket 32 and the end face of the inner electrode 33 is in the spherical cap shape, the inner electrode 33 is more easily to be aligned and in contact with an electric energy output end of an external charging equipment when the rechargeable battery 11 is being charged. Especially when the battery assembly is socketed on a charging equipment for being charged, the inner electrode 33 slidably connected to the electrode bracket 32 is easy to be electrically connected to the charging equipment, and the outer electrode 31 may also be allowed to have a good electrical connection to the charging equipment, which ensures a reliable charging. Also, dirt is not apt to be accumulated on the spherical cap-shaped end face of the charging electrode 30 , which ensures the reliable charging.
[0046] Furthermore, the outer electrode 31 is in the annular shape, which also increases the contact area of the charging electrode 30 and the electric energy output end of the external charging equipment, achieving a more full contact and a better charging effect.
Second Embodiment
[0047] FIG. 3 is a view showing the structure of an electronic cigarette battery assembly according to another embodiment of the present application.
[0048] As shown in FIG. 3 , a charging electrode 30 of the battery assembly according to this embodiment further includes an elastic piece and a fixing plate 35 . The elastic piece abuts against the inner electrode 33 to allow the inner electrode 33 to be elastically stretchable in an axial direction of the battery rod main body 10 . The fixing plate 35 is inserted into and connected to the outer electrode 31 . The elastic piece has one end abutting against the inner electrode 33 and another end abutting against the fixing plate 35 . In this embodiment, the elastic piece is a spring. That is, the battery assembly according to this embodiment is that a spring 34 is added in the battery assembly according to the above embodiment. Apparently, the elastic piece may also be an elastic sheet or an elastic soft rubber block, etc., which is not limited herein. In this embodiment, the spring 34 also functions to connect the inner electrode 33 and the control module 12 .
[0049] A protrusion 331 is provided at a bottom of the inner electrode 33 . The circumference of the protrusion 331 is surrounded by a part of the spring 34 and is connected to the control module 12 .
[0050] By providing the spring 34 , the inner electrode 33 slidably connected to the electrode bracket 32 may be allowed to be stretchable when in a charging process, which allows the inner electrode 33 to be in a better contact with the electric energy output end of the external charger during the connection, and prevents a poor charging effect due to a poor contact.
[0051] Since the outer electrode 31 is inserted into and connected to the fixing plate 35 , the charging electrode 30 , which has been assembled, is inserted into the battery rod main body 10 when the battery assembly is assembled. Therefore, the assembling process is convenient and production efficiency is improved.
Third Embodiment
[0052] FIG. 4 is a view showing the structure of an electronic cigarette battery assembly according to yet another embodiment of the present application.
[0053] As shown in FIG. 4 , the spring 34 in the above embodiment is remained in the battery assembly according to this embodiment.
[0054] The spring 34 functions to connect the inner electrode 33 and the control module 12 .
[0055] The difference between the battery assembly according to this embodiment and the battery assembly according to the previous embodiment lies in that a recess 332 is provided at the bottom of the inner electrode 33 and a second position-limiting portion 333 is provided at an outer side of the inner electrode 33 . The second position-limiting portion 333 abuts against the electrode bracket 32 so as to prevent the inner electrode 33 from slipping off from the electrode bracket 32 in a direction away from the battery rod main body 10 . A part of the spring 34 extends into the recess 332 , and is connected to the control module 12 . By providing the spring 34 , the inner electrode 33 slidably connected to the electrode bracket 32 can be extended in the charging process, which allows the inner electrode 33 to be in a better contact with the electric energy output end of the external charger during the connection, and avoids a poor charging effect due to a poor contact. By providing the second position-limiting portion 333 , the inner electrode 33 can be more reliably connected.
[0056] Finally, it should also be noted that the relationship terminologies such as “first”, “second” and the like are only used herein to distinguish one entity or operation from another, rather than necessitate or imply that the actual relationship or order exists between the entities or operations. Furthermore, terms of “include”, “comprise” or any other variants are intended to be non-exclusive. Therefore, a process, method, article or device including a plurality of components includes not only the listed components but also other components that are not enumerated, or, also include the components inherent for the process, method, article or device. Without other limitations, the component defined by the statement “comprising (including) one . . . ” does not exclude the case that other similar components may exist in the process, method, article or device having the above component.
[0057] The embodiments in the specification are described in a progressive manner. Each of the embodiments is mainly focused on describing its differences from other embodiments, and references may be made among these embodiments with respect to the same or similar portions among these embodiments.
[0058] Based on the above description of the disclosed embodiments, the person skilled in the art is capable of carrying out or using the present application. It is obvious for the person skilled in the art to make many modifications to these embodiments. The general principle defined herein may be applied to other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to these embodiments illustrated herein, but should be defined by the broadest scope consistent with the principle and novel features disclosed herein.
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An electronic cigarette battery assembly, including a charging electrode, the charging electrode including an inner electrode arranged on the inner rim thereof and having a spherical cap end face, and an outer electrode arranged outside the inner electrode and having a ring shape; the charging electrode and the rechargeable battery of the electronic cigarette being connected by means of a control module, when it is necessary to charge the rechargeable battery, one need only connect the charging electrode to the electric power output terminal of the external charger in order to charge the rechargeable battery. There is no need to remove the rechargeable battery, thus the invention is very convenient to use and solves the problems of existing electronic cigarettes, wherein it is inconvenient to remove a rechargeable battery for charging and the electrical connection is unreliable due to loosening of the battery.
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The invention relates to a method of servo-control in a braking system having electric brakes.
BACKGROUND OF THE INVENTION
Modern aircraft have braking systems including electric brakes provided with electromechanical actuators.
Each actuator comprises a pusher facing a stack of disks and moved under drive from an electric motor to apply a braking force on the stack of disks in selective manner.
Such brakes are generally under force control based on a braking setpoint.
The invention applies more particularly to an actuator provided with a sensor for sensing pusher position, but not including a force sensor capable of measuring the force applied by the pusher against the stack of disks.
Under such circumstances, in order to be able to servo-control the force applied by such actuators, it is necessary to estimate the force being applied by a pusher as a function of parameters that can be measured, such as the position of the pusher, or indeed the power supply current being drawn by the electric motor.
Alternatively, the braking setpoint can be converted into a position setpoint, whereupon position servo-control can be performed.
The servo-control that is implemented generally depends on parameters, relationships, and models that are estimated a priori. However, the conditions under which a brake operates can change during the lifetime of the brake, thus making servo-control thereof less accurate.
OBJECT OF THE INVENTION
An object of the invention is to provide a method for countering a possible drop in servo-control performance during the lifetime of a brake.
BRIEF DESCRIPTION OF THE INVENTION
To achieve this object, the invention provides a method of servo-control in a vehicle brake system including at least one electric brake having at least one actuator comprising a pusher facing friction elements and driven by an electric motor to apply a force selectively against the friction elements in response to a braking setpoint, the method making use of a plurality of relationships between various operating parameters of the actuator including a relationship between a pusher position and a corresponding force applied by the pusher to the friction elements, and according to the invention, the method includes the step of adjusting said particular relationship between position and force.
It has been found that this relationship is very sensitive to friction element wear. Adjusting the relationship in accordance with the invention makes it possible to compensate drift in the operating conditions of the brake due to said friction element wear.
Preferably, the adjustment step comprises the following operations:
operating the brake under operating conditions in which the force applied by the pusher against the friction elements depends essentially on a power supply current flowing through the electric motor; in one or more positions of the pusher, measuring the power supply current of the electric motor, and deducing a corresponding force therefrom; and from the position and force pairs determined in this way, deducing a correction for the relationship between position and force.
In a first particular implementation of the invention, said operating conditions comprise moving the pusher at constant speed.
In a second particular implementation of the invention, the operating conditions include one or more pauses in the position of the pusher.
In a third particular implementation of the invention, said operating conditions comprise periodically displacing the pusher with small amplitude about an operating point.
In which case, and preferably, the periodic displacement is implemented in superposition on a controlled displacement of the pusher in response to the braking setpoint.
Advantageously, the adjustment step is implemented at least once per utilization cycle of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood in the light of the following description given with reference to the figures of the accompanying drawings, in which:
FIG. 1 is a section view of an electric brake having electromechanical actuators;
FIG. 2 is a block diagram of the servo-control used for controlling the actuators;
FIG. 3A is a graph showing how the position (bold line) and the power supply current (fine line) vary as a function of time in a first particular implementation of the method of the invention;
FIG. 3B is a graph showing how the relationship between force and pusher position is adjusted in the first implementation;
FIG. 4A is a graph showing variation in the position (bold line) and in the power supply current (fine line) vary as a function of time in a second particular implementation of the method of the invention;
FIG. 4B is a graph showing how the relationship between force and pusher position is adjusted in the second implementation;
FIG. 5A is a graph showing variation in the position (bold line) and the power supply current (fine line) vary as a function of time in a third particular implementation of the method of the invention; and
FIG. 5B is a graph showing how a force/position pair is obtained in the third implementation.
DETAILED DESCRIPTION OF THE INVENTION
The method of the invention is described in detail herein in application to an aircraft that has some number of braked wheels, of the kind shown in FIG. 1 . Each of the braked wheels comprises a rim 5 suitable for receiving a tire (not shown) and mounted to rotate on an axle 6 carried by one of the undercarriages of the aircraft. The axle 6 has mounted thereon a ring 7 carrying actuators 8 . A torsion tube 9 is secured to the ring 7 and extends into the rim 5 and terminates with a backstop 10 . The ring 7 , and thus the torsion tube 9 , are prevented from turning relative to the axis 6 by keying means (not shown).
Between the rest 10 and the actuators 8 there extends a stack of disks 11 made up of rotor disks that are constrained in rotation with the rim 5 , and stator disks that are constrained in rotation with the torsion tube 9 .
Each of the actuators 8 comprises a body 12 in which a pusher 13 is mounted facing the stack of disks 11 to move linearly under drive from an electric motor contained inside the body 11 so as to apply a force selectively to the stack of disks 11 , which force, by inducing friction forces between the rotors and the stators in the stack of disks, contributes to slowing down rotation of the rim 5 , thereby braking the aircraft. Each of the actuators 8 includes a position sensor 14 for measuring the linear displacements of the pusher 13 .
The actuators 8 are associated with a control module 50 capable of operating in a controlled mode in which each pusher 13 is moved relative to the stack of disks 11 by the associated electric motor in response to a braking setpoint which is generated in particular on the basis of signals coming from brake pedals 51 actuated by the pilot.
In such actuators, the torque imposed by the motor on the motor and gearbox unit for transforming the rotary motion of the motor into linear movement in translation of the pusher is directly proportional to the magnitude of the current feeding the motor. This can be written as Cem=K.i where Cem is the electromagnetic torque, K is a proportionality coefficient, and i is the power supply current drawn by the electric motor.
Nevertheless, not all of the electromagnetic torque Cem is consumed in the action exerted by the pusher 13 against the stack of disks. Some fraction of the electromagnetic torque Cem is consumed to overcome inertial effects (acceleration or deceleration of the pusher and the associated moving masses). Another fraction of the electromagnetic torque Cem is consumed to compensate for static friction and for viscous friction (i.e. friction that depends on speed) opposing the displacement of the pusher 13 . This can be written as follows:
Cem=Ci+Cfs+Cfv+Cu
where:
Ci is the inertial torque;
Cfs is the static friction torque;
Cfv is the viscous friction torque; and
Cu is the useful torque.
The useful torque gives rise to a force F such that Cu=a.η.F, where a is a transmission coefficient directly associated with the configuration of the motor and gearbox unit, and where η is the efficiency of said transmission.
The control module 50 is adapted to servo-control the actuators in the manner illustrated by FIG. 2 .
The braking setpoint F is initially transformed into a position setpoint x . For this purpose, use is made of a relationship R between the position of the pusher 13 and the force exerted by the pusher 13 on the stack of disks 11 .
This setpoint x forms the input to a position feedback loop. This setpoint is subtracted from the position x of the pusher 13 as measured by the position sensor 14 .
The resulting difference ε x is processed by a first transfer function G of the PID (proportional integral differential) type so as to be transformed into a current setpoint ī. This setpoint has subtracted therefrom the current i as measured by the current sensor 15 which in this case is integrated in the control module 50 .
The resulting difference ε i is then processed by a transfer function H (a PID) and is then delivered to the electric motor of the actuator.
It has been found that the relationship R between position and the force exerted by the pusher is particularly sensitive to disk wear. A specific object of the invention is to adjust this relationship R to take account of such wear.
For this purpose, and in the particular implementations described above, forces F p corresponding to a plurality of positions x p of the pusher are estimated, and the resulting estimated pairs (x p , F p ) are used for adjusting the relationship R between position and force, e.g. by using a conventional regression method.
In a first particular implementation of the method of the invention as shown in FIGS. 3A and 3B , the pusher 13 is caused to advance at constant speed.
Since its speed is kept constant, the effects of inertia are zero, such that the torque Ci is zero. Care is also taken to maintain the speed at a value that is low enough to ensure that the viscous friction force Cfv always remains negligible.
In graph 3 A, the bold curve representing the positions taken by the pusher 13 is then in the form of a straight line, with the time origin being taken at the moment the pusher 13 comes into contact with the stack of disks 11 .
During a first stage in which the pusher 13 is not in contact with the stack of disks, the useful torque Cu is zero, such that the entire electromagnetic torque serves to overcome static friction. By measuring the power supply current i 0 in this situation, a measurement is obtained of the static friction:
Cf=K.i 0
The current i 0 is visible on the fine line curve for current. It is the constant current taken by the motor before the pusher 13 comes into contact with the stack of disks 11 .
During a second stage in which the pusher 13 is in contact with the stack of disks 11 , the useful torque is not zero and can be deduced directly from the measured current i :
Cu=K. ( i−i 0 )
In the invention, at a plurality of positions x p for which the pusher 13 is in contact with the stack of disks 11 , the corresponding power supply current i p is measured while the pusher 13 continues to move at constant speed. Each measured current is associated with a force by the following relationship:
F p =K. ( i p −i 0 )/ aη
In the graph of FIG. 3A , there can be seen for an instant t p , the corresponding position measurement x p (right-hand axis) and the corresponding power supply current i p (on the left-hand axis).
By repeating these measurements several times over, and by associating each measured current i p with a force F p using the above relationship, a series of pairs (x p , F p ) is obtained as represented by crosses on the graph of FIG. 3B . These pairs are used in the invention to adjust the relationship R that is used in performing servo-control between position and force.
For example, if the servo-control makes use of a relationship R of the form x=αF+β, then the coefficients α and β are adjusted in conventional manner using conventional regression formulae.
This adjustment step is preferably implemented after the undercarriages have been lowered and before the aircraft lands. Thus, the relationship R between position and force is readjusted prior to each landing so as to take account of the state of wear of the disks.
In a second particular implementation of the method of the invention as shown in FIGS. 4A and 4B , the corresponding power supply current i p is measured while the pusher 13 is held stationary in said position. Under such conditions, the inertial torque Ci and the viscous friction torque Cfv are zero.
To this end, and as can be seen in FIG. 4A , the pusher 13 is caused to move with some number of pauses during which the pusher 13 remains stationary. In the graph of FIG. 4A , there can be seen the position x p and the current i p that correspond to an instant t p taken during one of these pauses.
By taking care to make use of positions in which the useful torque Cu is much greater than the static friction torque Cf, i.e. in which the power supply current i p is much greater than the current i 0 , it is possible to estimate a corresponding force F p on the basis of the measured power supply current i p by using the following relationship:
F p =K.i p /a.η
By repeating these measurements several times over, and by associating each measured current i p with a force F p using the above-explained relationship, a series of pairs (x p , F p ) is obtained as illustrated by crosses on the graph of FIG. 4B . These pairs are used in accordance with the invention to adjust the relationship R that is used for servo-controlling position and force.
In a third particular implementation of the method of the invention, while the pusher 13 is in a position in contact with the stack of disks 11 , a periodic displacement of small amplitude is applied thereto, as shown in FIG. 5A .
Under such circumstances, the inertial torque, the static friction torque Cfs, and the viscous friction torque Cfv have an average value of zero, such that on average the useful torque Cu is directly equal to the electromagnetic torque Cem.
The associated force is thus estimated by the following relationship:
F p =K.i p /aη′
where i p in this case is an average of the power supply current during the periodic displacement of the pusher, and η′ is a weighted efficiency taking account of the fact that the efficiency of the actuator differs depending on whether the pusher 13 is moving in one direction or in the opposite direction.
In order to establish this average, the power supply current i j is measured at a variety of positions x j . The resulting pairs (x j , i j ) are represented by points in the graph of FIG. 5B . The mean of the positions x j is then determined, which is retained as a measured position x p =<x j >, and the mean of the currents i j is obtained which is used as the associated power supply current i p =<i j >.
The force F p is deduced from this current i p in application of the above-stated relationship.
By repeating this operation several times over, a series of pairs (x p , F p ) is obtained. These pairs are used in the invention to adjust the relationship R between position and force as used for servo-control purposes.
It should be observed that these measurements can be taken while the actuator 8 is being servo-controlled to track the braking setpoint F . It suffices to superpose small-amplitude periodic movements at a frequency higher than the frequencies characteristic of the braking system on the displacements of the pusher 13 in response to the braking setpoint F .
By adjusting the relationship between position and force of the pusher it is possible significantly to improve the performance of the electric brake. By way of numerical example, on a brake for a commercial aircraft of the Airbus A320 or Boeing 737 type, the case is considered of a braking setpoint that is equal to the maximum force for which the brake is deigned. At this setpoint, a fixed and non-adjustable relationship R would produce a displacement setpoint of the order of 2 millimeters regardless of the state of wear of the disks.
When implementing the step of adjusting the relationship R in accordance with the invention, the displacement setpoint becomes about 1.6 millimeters for a stack of new disks and about 2.3 millimeters for a stack of worn disks, giving differences of the order of ±15% relative to the setpoint obtained from a non-adjusted relationship.
At one extreme, this adjustment serves to avoid applying pointless excess pressure to the stack of disks, pointlessly fatiguing the brake and prematurely wearing down the disks, and at the other extreme it avoids applying insufficient force, leading to poor braking performance.
The invention is not limited to the above description, and on the contrary covers any variation coming within the ambit defined by the claims.
In particular, although it is stated that the adjustment step is implemented on each flight of the aircraft, i.e. on each utilization cycle thereof, the adjustment step could be implemented in other circumstances, for example in response to the friction elements crossing a wear threshold, or indeed periodically, once every ten flights or 100 flights, or when replacing friction elements, or indeed when performing maintenance in a workshop.
Although it is stated that a linear type relationship is used between pusher position and force, the invention is not limited to relationships of this type; the relationship could be non-linear.
Although the braking setpoint as described herein is a force setpoint, it is also possible to apply the invention when the setpoint is expressed in terms of a percentage of a maximum force.
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The invention relates to a method of servo-control in a vehicle brake system including at least one electric brake having at least one actuator comprising a pusher facing friction elements and driven by an electric motor to apply a force selectively against the friction elements in response to a braking setpoint, the method making use of a plurality of relationships between various operating parameters of the actuator including a relationship between a pusher position and a corresponding force applied by the pusher to the friction elements. According to the invention, the method comprises the step of adjusting a particular relationship between position and force.
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This is a continuation-in-part of Ser. No. 06/644,135 filed Aug. 23, 1984 which is a continuation of Ser. No. 06/511,128 filed July 6, 1983 abandoned.
The present invention relates in general to power supply switching circuits, and in particular to a device for providing automatic switching as a function of detected voltage levels.
BACKGROUND OF THE INVENTION
Power supply switching circuits are employed in many different applications, e.g. where the interruption of power from a particular power supply is a foreseeable event and an alternative source of power must be switched into operation in its place. Prior art switching circuits exist which are assembled from discrete components. Such circuits may be interposed between a load and the power sources, or they may themselves include an auxiliary power source. Although these circuits provide effective and power-efficient solutions to the problem, they generally employ bipolar junction transistors which cannot be integrated with CMOS processes. Additionally, such circuits generally employ capacitors and other components that are relatively difficult to integrate.
Real time clocks are among a variety of loads to which it is desirable to provide continuous power. Such clocks typically comprise power-consuming oscillators and memories. They may be used simply to provide data for a display of current time, or they may be employed to provide a timing mechanism for initiating various functions in different kinds of environments. Such clocks are required to remain in continuous operation, even when the system in which the clock is employed is not operating, so that the clock's normal power source may be turned off.
In the prior art as well as in the present invention, low power batteries provide a power source to such clocks when regular system power is off. This arrangement supplies to only those components which are required to track current time and thus power consumption is minimized. However, many prior art circuits permit a small current flow from regular system power to the batteries. Such a charging feature is undesirable when battery power is provided by certain types of long-life batteries, e.g. lithium batteries.
Real time clocks of the type described typically consist of integrated circuits. Ideally, the power supply switching circuit (though not the power supplies themselves) is located on the same chip as the load, e.g. the clock serviced by the power supply. Also, the switching circuit should be of minimum size. Current carrying elements in the circuit should be both of relatively low resistance and minimum size. Among the advantages of such a monolithic, integrated arrangement versus a system arrangement, are savings of space on the chip, reduced cost and improved quality control in the manufacturing process. However, for the reasons discussed above and because space on an integrated chip is typically at a premium, it has not been possible to date to integrate these components, except at excessive cost.
OBJECTS OF THE INVENTION
It is a primary object of the present invention to provide new and improved power supply switching circuits which avoid the disadvantages associated with prior art circuits of this type.
It is an additional object of the present invention to provide a new and improved power supply switching circuit which isolates the auxiliary power supply from the main power supply.
It is another object of the present invention to provide a new and improved power supply switching circuit which, together with the load serviced by the power supply, can be fabricated as a single, monolithic, integrated circuit chip.
It is a further object of the present invention to provide a new and improved, integrated power supply switching circuit of reduced cost and of relatively compact size.
It is still another object of the present invention to provide a new and improved MOSFET power supply switching circuit which can be fabricated using n-channel, p-channel, p-well CMOS, or n-well CMOS architectures.
It is yet a further object of the invention to provide a new and improved MOSFET power supply switching circuit which provides maximum turn-on voltages to current-carrying MOSFETs in order to allow the MOSFETs to be of minimum size.
It is yet another object of this invention to provide a power supply switching circuit that can function properly with batteries that have open circuit voltages that are significantly greater than the closed circuit voltage of the battery (i.e., when a load is connected across the battery).
SUMMARY OF THE INVENTION
The present invention achieves the foregoing objects by means of a switching circuit which provides separate current paths from one of at least two input terminals to a single output terminal. The invention permits access to one of two separate sources of power, one at a time, each source of power being connected to a separate one of the aforesaid input terminals.
In a preferred implementation of the present invention two power switching MOSFETs are employed, one in each of the two current paths, and they are turned on and off in response to the relative polarities of the voltages appearing on the two input terminals. The shutting down of the regular or main system power source, or its failure, will produce a relative change of polarity of the potential on the input terminals. This change of polarity turns on one MOSFET to connect the load across the auxiliary power source, while turning off the other MOSFET to break the connection of the load across the regular system power source. Restoration of regular system power will restore the first MOSFET to conduction, while cutting off the second MOSFET. Thus, the load is again connected across regular system power and the auxiliary power source is isolated from the regular system power source.
The present invention minimizes the amount of space the power supply switching circuit requires on the chip, while allowing ready integration of the circuit. Thus, the invention obtains the fullest advantage from the use of integrated components.
These and other objects of the invention, together with the features and advantages thereof, will become apparent from the following detailed specification, when read together with the accompanying drawings in which applicable reference numerals have been carried forward.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a prior art power supply switching circuit which utilizes discrete circuit components.
FIG. 2 in block diagram form a single chip containing a power supply switching circuit in accordance with the present invention, as well as the load serviced by the power supply and other circuit components.
FIG. 3 shows one embodiment of a power supply switching circuit in accordance with the present invention.
FIG. 4 shows a preferred embodiment of the present invention using n-channel body switches in p-well architecture.
FIG. 5 shows another embodiment of the present invention, similar to FIG. 4, but using p-channel body switches in n-well architecture.
FIG. 6 shows another embodiment of the present invention, which is similar to FIG. 4, but uses additional elements to ensure proper operation when the battery open circuit voltage may be substantially greater than the closed circuit voltage.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 illustrates a prior art power supply switching circuit which is capable of switching the load to a back-up power supply when required. The prior art circuit appears in an article by S. Ciarcia, Byte, "Everyone Can Know The Real Time," Vol. 7, No. 5, May 1982, pps. 34-58. As shown, the device is constructed from discrete components which are external to an integrated circuit real time clock, the latter being disposed on a chip 301. A system power potential of 5 volts is normally available at input 360 to power the chip.
In operation, the base of an npn transistor 322 is driven high with respect to the emitter of the same transistor, so as to turn the transistor on. This action connects the base of a pnp transistor 321 to ground and leaves the base of the latter transistor negative with respect to its emitter. Transistor 321 is thus driven into conduction and connects input 360 to an input terminal 302 on chip 301. Diode 342 and resistor 345 act to partially isolate a battery 361 from system power and the chip. Battery 361 has a potential of approximately 3 volts. Should system power fail, or be turned off, the base-to-emitter voltage on transistor 322 will fall to zero and cut transistor 322 off. This action, in turn, disconnects the base of transistor 321 from ground and turns transistor 321 off. Battery 361 can then supply chip 301 via diode 342 and input terminal 302.
FIG. 2 illustrates in block diagram form the integrated power supply switching circuit which constitutes the subject matter of the present invention. As shown, the circuit is disposed on a single integrated chip 500, together with a real time clock 200. Input terminals 11 and 12, as well as a reference terminal 13, are brought to one edge of the chip as externally accessible pins. Either terminal 11 or 13 may serve as a voltage reference terminal.
Terminals 11, 12 and 13 are connected to circuit 100. A regular source of system power, shown as a first DC power supply 41, is connected with its anode to terminal 13 and its cathode to terminal 11. An auxiliary power source, shown as a second DC power supply 40, is connected with its anode to reference terminal 13 and its cathode to terminal 12. An output terminal 15 of circuit 100 may be brought to an externally accessible pin, if desired. A "power down" lead 56 connects power switching circuit 100 to real time clock 200. Clock 200 is connected to reference terminal 13 by way of a conductive path 14. The real time clock is also connected to output terminal 15 by an additional conductive path 16.
When power source 41 is on, output terminal 15 is connected through the power supply switching circuit to input terminal 11. Thus, real time clock 200 is connected between input terminal 11 and reference terminal 13 and receives power. When power source 41 is off, or not available, power supply switching circuit 100 detects a change in the relative polarities of the potential on input terminals 11 and 12 and connects output terminal 15 through the power supply switching circuit to input terminal 12. This action connects the real time clock between input terminals 12 and reference terminal 13 and thus prevents a loss of power to the clock by providing it with auxiliary power.
With respect to the following specific embodiments of the invention, the terminals of a MOSFET will be referred to as source, gate, drain, and body. These terms do not necessarily imply that either source or drain is at a potential higher or lower than the other, nor that any potential difference exists between the terminal called source and the gate on the body. Furthermore, the term source does not imply any direct or indirect connection to the body of the MOSFET. Moreover, depending upon the connection of the body, either side of the MOSFET can serve as source or drain.
Referring now to FIG. 3, power supplies 40 and 41 are connected to input terminals 11 and 12 and to reference terminal 13 substantially in the same manner as described with respect to FIG. 2. In a preferred embodiment of the invention, power supplies 40 and 41 provide voltages of 3 volts and 5 volts respectively. A first MOSFET 24 consists of an enhancement mode, n-type device which operatively connects output terminal 15 to input terminal 11. The source and drain of MOSFET 24 are connected to terminals 11 and 15 respectively. The gate of MOSFET 24 is connected to input terminal 12. A second MOSFET 22 consists of an enhancement mode, n-type device which operatively connects output terminal 15 to input terminal 12. The source and drain are connected to terminals 12 and 15 respectively. The gate of MOSFET 22 is tied to a junction 71. MOSFETs 22 and 24 are the power switching means in the circuit and accordingly each is constructed to be a minimum impedance device.
Third and fourth MOSFETs 32 and 31 are shown connected in series across input terminal 11 and reference terminal 13. Each of the last-recited MOSFETs has its source connected to the corresponding terminal and its drain connected to junction 71. The gates of MOSFETs 31 and 32 are connected to input terminal 12. MOSFET 32 is an enhancement mode, n-channel switching device, while MOSFET 31 is an enhancement mode, p-channel device. MOSFET 31 is constructed so that it will have a resistive value from source to drain in its operative state that is at least an order of magnitude greater than the resistive value from drain to source of MOSFET 32 in the operative state of the latter.
The operation of the circuit shown in FIG. 3 is as follows. As long as the main DC power source 41 is available, i.e. as long as it remains operative and connected between terminals 11 and 13, the potential on input terminal 11 relative to the potential on reference terminal 13 will be 5 volts negative. The potential on input terminal 12 relative to reference terminal 13 will be 3 volts negative. Accordingly, the voltage applied to the source of MOSFET 31 will be approximately 3 volts positive with respect to the voltage on its gate. Hence, MOSFET 31 will conduct so as to connect junction 71 to reference terminal 13. Concurrently, MOSFET 32 is also in an operative state inasmuch as the source of MOSFET 32 will be 2 volts negative with respect to its gate. Thus, MOSFET 32 will conduct so as to connect junction 71 to input terminal 11.
MOSFETs 31 and 32 together act as a voltage divider when both are operative, i.e. when both conduct. Because MOSFET 31 has a conductance of less than 1/10 that of MOSFET 32, the potential of the signal appearing at junction 71 will be relatively close to the potential appearing on input terminal 11, i.e. approximately 41/2 volts negative with respect to reference terminal 13 in one example. Because the gate of MOSFET 22 is connected to junction 71, and the source of MOSFET 22 is connected to input terminal 12, the gate of MOSFET 22 will be more negative than its source and hence MOSFET 22 will not conduct during this interval. However, n-channel MOSFET 24 has its gate connected to input terminal 12 and its source to input terminal 11. Consequently, its gate will be positive with respect to its source and thus MOSFET 24 will conduct and thereby connect input terminal 11 to output terminal 15. Accordingly, an electrical load connected between terminals 13 and 15 is effectively connected between input terminal 11 and reference terminal 13.
When system power is turned off, or if system power fails, the value of the potential on input terminal 11 will rise to approximately the reference value, i.e. the potential of reference terminal 13. This will, in turn, leave the potential on input terminal 12 approximately 3 volts below the potential on both input terminal 11 and reference terminal 13. As noted above, the potential on input terminal 12 is 3 volts more negative than the potential on the reference terminal. Hence, MOSFET 31 remains conductive and couples junction 71 to reference terminal 13. However, MOSFETs 24 and 32, having gates tied to input terminal 12 and sources connected to input terminal 11, will each exhibit a drop in potential from source to gate. Thus, MOSFETs 24 and 32 will be biased into cutoff. With MOSFET 32 in a cutoff condition, the potential on the gate of MOSFET 22 will be that of the reference terminal. Since the source of MOSFET 22 is connected to input terminal 12, its gate will be positive with respect to its source. This will drive MOSFET 22 into conduction, thereby connecting input terminal 12 through MOSFET 22 to output terminal 15. Accordingly, a load connected between terminals 13 and 15 will be effectively connected between terminals 12 and 13 and receive power from auxilary power source 40.
FIG. 4 illustrates a preferred embodiment of the invention which incorporates portions of the circuit of FIG. 3 described above. Discussion of these circuit portions is therefore not repeated below. In addition to the elements included in the latter circuit, the embodiment illustrated in FIG. 4 further comprises first and second n-channel MOSFET body switches 61 and 62 and a CMOS inverter 50. In the preferred embodiment of FIG. 4, MOSFETs 22, 24 and 32, as well as body switches 61 and 62, share a common body, i.e. they may be fabricated in a common well. This is schematically indicated in the drawing by junction 70. This type of architecture reduces manufacturing costs as well as reducing the space required by those components on a chip. The sources of body switches 61 and 62 are shorted to the common body. This is indicated in the drawing by the connections of these sources to junction 70. The drain of body switch 61 is connected to the source of MOSFET 22 and terminal 12. The drain of body switch 62 is connected to the sources of MOSFETs 24 and 32 and terminal 11. The gate of switch 61 is tied to the gate of MOSFET 22 and to junction 71.
CMOS inverter 50, which is indicated by a broken line block in FIG. 4, is connected across reference terminal 13 and output terminal 15. An inverter input terminal 55 is connected to junction 71. A first inverter output terminal, or "power down" lead, is designated by the reference numeral 56 and is connected to the gates of MOSFET 24 and body switch 62. A first inverter power supply terminal 57 is connected to reference terminal 13. A second inverter power supply terminal 58 is connected to output terminal 15.
Inverter 50 comprises a p-channel MOSFET 51 and an n-channel MOSFET 52. The drain of MOSFET 51 and the drain of MOSFET 52 are jointly connected to output terminal 56. The source of MOSFET 51 is connected to first inverter power supply terminal 57 while the source of MOSFET 52 is connected to second inverter power supply terminal 58. The gates of both MOSFETs are connected to inverter input terminal 55. The gate of MOSFET 24 is connected to output terminal 56 of CMOS inverter 50, instead of input terminal 12, as was the case in FIG. 3. Output terminal 56 also provides a "power down" signal to real time clock 200, i.e. a signal indicating that system power has been turned off, or has failed.
It will be understood that the polarity of the power sources and the conductivity type of the MOSFETs in the above-discussed embodiments of FIGS. 3 and 4 may be reversed if desired. That is to say, p-channel n-well MOSFETs may be substituted for n-channel p-well MOSFETs and vice versa. Under certain conditions the latter arrangement may be preferred. P-well architecture can provide faster switching but is more expensive to fabricate. The circuit of FIG. 5, showing such a substitution of conductivity type MOSFETs, is therefore substantially analogous to the circuit of FIG. 4 and thus needs no further discussion. The reference numerals in FIG. 5 differ from those of FIG. 4 for like components only by the addition of the "100" prefix.
With respect to MOSFETs 22, 31 and 32, the operation of the circuit shown in FIG. 4 is substantially the same as that of the circuit of FIG. 3 and therefore requires no reiteration The remainder of the circuit operates as follows. When DC power supply 41 is available, input terminal 11 will be held at a value of 5 volts below reference terminal 13. Input terminal 12 will have a potential imposed thereon by DC power supply 40 which is approximately 3 volts below reference terminal 13. As described above, the signal at junction 71 will be at a potential close to that on terminal 11. Consequently, the gate of p-channel MOSFET 51 in inverter 50 will be negative with respect to its source, thereby biasing MOSFET 51 into conduction. The gate of n-channel MOSFET 52 will also be negative with respect to its source, consequently biasing MOSFET 52 off. Thus, the gates of MOSFET 24 and substrate switch 62 will be connected to reference terminal 13 through CMOS inverter 50. The source-to-gate voltages of each of substrate switch 62 and MOSFET 24 will be positive, turning both the switch and the MOSFET on. This arrangement substantially increases the potential difference from gate to source of MOSFET 24 compared with that of the circuit shown in FIG. 3.
Because MOSFET 22 and MOSFET 24 carry significant currents in their respective operative states, it is important that their respective resistive values, when these MOSFETs are on, be minimized. In accordance with the present invention, the potential between gate and source of the conducting, power-carrying MOSFET, i.e. the turn-on voltage of the MOSFET, is increased to a maximum. This allows MOSFET 24 to be reduced in size without any increase in resistivity over the circuit shown in FIG. 3. As a consequence, notwithstanding the fact that the circuit of FIG. 4 requires additional circuit components as compared to the circuit of FIG. 3, an overall reduction in the amount of space occupied on the chip, is achieved.
When power supply 41 is off, MOSFET 32 will be driven into cutoff and the signal on junction 71 will rise to the value on the reference terminal, as described above for the embodiment of FIG. 3. This action will, in turn, reduce the potential drop from source to gate of MOSFET 51 below its threshold value, thereby cutting it off. As the potential on junction 71 rises, so also will the potential on the gate of MOSFET 22 rise. Because the source of MOSFET 22 is connected to input terminal 12, MOSFET 22 will be driven into conduction, as described above with reference to FIG. 3.
The source of MOSFET 52 is now connected to input terminal 12 through MOSFET 22 and consequently MOSFET 52 will turn on. The gates of MOSFET 24 and of body switch 62 will be connected to input terminal 12 through CMOS inverter 50 and MOSFET 22. This will leave the gates of MOSFET 24 and switch 62 negative with respect to their sources, thereby cutting both the MOSFET and the switch off. At this point of the operation, output terminal 15 is cut off from input terminal 11 and is connected to input terminal 12. Since the gate of body switch 61 is tied to the gate of MOSFET 22, the MOSFET and the body switch will turn on simultaneously.
The inclusion of body switches 61 and 62 allows MOSFETs 22, 24 and 32, as well as the body switches to share a common body. Since body switch 62 conducts simultaneously with MOSFETs 24 and 32 and body switch 61 conducts simultaneously with MOSFET 22, forward biasing of the intrinsic pn junctions of the conducting MOSFETs is avoided without spurious short circuits developing through the common body.
The operation of the embodiment of FIG. 5 is analogous to the operation of FIG. 4 and therefore needs no separate discussion or reiteration.
The circuit shown in FIG. 6 is directed to ensuring proper operation in certain situations: (i) if the open circuit voltage of auxiliary power supply 40 is substantially greater than the closed circuit voltage of the auxiliary power supply 40; or (ii) if the output voltage of the main power supply 41 does not increase rapidly when that main power supply 41 is again connected to the circuit--e.g., the main power supply 41 is controlled by a rheostat. For example, when the auxiliary power supply 40 is connected to the circuit shown in FIG. 4, the amplitude of the voltage at the junction 71 will increase (with respect to the reference terminal 13) relatively slowly. As a result, MOSFET 24 may turn on, connecting the main power supply 41 to the drain of MOSFET 22 before MOSFET 22 turns off, disconnecting the auxiliary power supply 40. As a result, the main power supply 41 may charge the auxiliary power supply 40 and simultaneously start biasing the gate of MOSFET 32 back towards cutoff; MOSFET 32 may then turn off but MOSFET 22 may still remain turned on--the result being auxiliary power supply 40 is being charged and the power down lead 56 will also falsely indicate that the main power supply 41 remains inoperable.
However, the circuit shown in FIG. 6 (with like elements labelled with the same number), solves this problem by adding a noninverting coupling means comprising of inverters 50a and 80 connected in series between the gate of MOSFET 22 and the junction 71a. An optional feedback inverter 90 is also included and it should be noted that all three inverters 50a, 80 and 90 function in the same manner as inverter 50 described above, i.e., the outputs 56a, 86, 96 of the inverters 50a, 80 and 90 will transition between a voltage level approximately equal to the voltage level at the reference terminal 13 and a voltage level approximately equal to the voltage level at the output terminal 15. Because inverters 50a, 80 and 90 have a gain that theoretically approaches infinity, each inverter's output (56a, 86 and 96) will make a rapid transition between those two levels Although feedback inverter 90 is not necessary, the inverter 90 hastens the speed at which the output 86 of inverter 80 transitions between the two voltage levels.
Thus, as MOSFET 32 starts to conduct when power supply 41 is reconnected, the output of inverter 50a will rapidly transition from a voltage approximately equal to the voltage level at input terminal 12 to a voltage level approximately equal to the voltage level at reference terminal 13--thereby turning on MOSFET 24 and connecting input terminal 11 to output terminal 15. Within an exceedingly short time span (e.g., less than a microsecond) the output 86 of inverter 80 will rapidly transition from a voltage approximately equal to the voltage at reference terminal 13 to the voltage at input terminal 12--thereby turning off MOSFET 22 and disconnecting input terminal 12 from output terminal 15. Thus, within a time period of less than a micro-second, MOSFET 22 turns on while MOSFET 24 turns off. This allows MOSFET 32 to remain conducting. Accordingly, the auxiliary power supply 40 is rapidly disconnected and is not charged by the main power supply 41.
And although it is not shown, it is obvious a similar modification incorporating the differences between FIGS. 4 and 6 could be done for the n-well architecture shown in FIG. 5.
In the exemplary embodiments of the invention described above and shown in FIGS. 4, 5 and 6, real time clock 200 constitutes the load which is switched between a primary and an auxiliary power source. It will be readily apparent that the invention is not so limited and that it may be used as a reliable power switching device with different kinds of loads. For example, the circuit may be monolithically integrated with memory circuits. In such an application, information can be efficiently preserved during "power down" cycles in a microprocessor. Various substitutions and modifications may also be made in the type of components used. For instance, power supplies and transistors that are different from those shown and described may be used within the scope of the present invention.
While certain embodiments of the present invention have been disclosed herein, it will be clear that numerous modifications, variations, substitutions, changes and full and partial equivalents will now occur to persons skilled in the art without departing from the spirit and scope of the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
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A power supply switching circuit is disclosed which provides for automatically switching an electrical circuit load from a main power source to an auxiliary power source, yet maintains the two power sources isolated from each other. The power supply switching circuit is readily integrated with its electrical load to form a monolithic integrated circuit. A pair of MOSFETs provides alternate connections of the load to the respective power sources. The circuit effectively connects the gate and source of the appropriate MOSFET across the available power source and thus assures the maximum turn-on voltage is applied to the MOSFET.
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CROSS-REFERENCE TO PRIORITY APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 of DE 10061967.3, filed Dec. 13, 2000, DE 10120819.7, filed Apr. 27, 2001 and DE 10144411.7, filed Sep. 11, 2001, all of which are incorporated by reference herein in their entireties and relied upon.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a process for the preparation of 4-haloalkyl-3-pyridinecarbonitriles (4-haloalkylnicotinonitriles) and their further reaction to give 4-haloalkylnicotinic acid derivatives having insecticidal activity.
[0004] 2. Background Art
[0005] 4-Haloalkylnicotinamides are useful starting substances for the preparation of pesticides, such as are described, for example, in WO-A 98/57969, EP-A 0580374 and DE-A 10014006.
[0006] These compounds can be prepared in two stages from 4-haloalkylnicotinic acids, whose synthesis is described, for example, in EP-A 0744400.
SUMMARY OF THE INVENTION
[0007] A simple process has surprisingly now been found for the preparation of 4-haloalkylnicotinonitriles having formula (I) below, from which 4-haloalkylnicotinic acids can be obtained in one step by hydrolysis.
[0008] The invention therefore relates to a process for the preparation of 4-haloalkylnicotinonitriles, having the formula (I):
[0009] wherein R F is (C 1 -C 4 -haloalkyl, preferably CF 3 , said process comprising:
[0010] (a) reacting a 3-amino-1-haloalkyl-2-propen- 1-one having the formula (II):
R F —C(O)—CH═CH—NH 2 (II)
[0011] wherein R F is defined as above, in a condensation reaction with at least one compound having a formula selected from the group consisting of (III), (IV), (V), (VI) and (VII):
(R 1 Z)CH═CH—CN (III)
(R 1 Z) 2 C—CH 2 —CN (IV)
Hal—CH═CH—CN (V)
Hal 2 CH—CH 2 CN (VI)
HC≡C—CN (VII)
[0012] wherein R 1 is alkyl, Hal is Cl or Br and Z, which is identical or different, is O, S, NR 1 or OCO;
[0013] to afford at least one compound selected from the group consisting of (VIII), (IX) and (X):
R F —C(O)—CH═CH—NH—CH═CH—CN (VIII)
R F —C(O)—CH═CH—NH—CH(ZR 1 )—CH 2 —CN (IX)
R F —C(O)—CH═CH—NH—CH(Hal )—CH 2 —CN (X)
[0014] wherein R F , R 1 , Z and Hal are as defined above; and
[0015] (b) subjecting the reaction product of (a) to a ring closure reaction.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Preferably, the symbols in the formulae (I)-(X) have the following meanings:
[0017] R F is preferably CH 2 F, CFCl 2 , CF 2 Cl, CF 3 or C 2 F 5 , particularly preferably CF 3 ;
[0018] R 1 is preferably (C 1 -C 4 )-alkyl, such as methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, t-butyl, particularly preferably methyl or ethyl, very particularly preferably methyl;
[0019] Z is preferably O or NR 1 ; and
[0020] halo is F, Cl, Br, or I, or preferably F or Cl.
[0021] The invention also relates to the use of 4-haloalkylnicotinonitriles as intermediates for the preparation of plant protection agents, in particular pesticides, such as insecticides.
[0022] The invention furthermore relates to a process for the preparation of 4-haloalkylnicotinamides having the formula (XI):
[0023] wherein R F is as defined above and wherein the 4-haloalkylnicotinonitrile having the formula (I):
[0024] obtained according to the above process is hydrolyzed.
[0025] A particular economic advantage compared with the known synthesis from the acid lies in the fact that by the process according to the invention no activated acid derivative, such as, for example, an acid chloride, is necessary and no reaction with ammonia has to be carried out.
[0026] The invention furthermore relates to compounds of the formulae (VIII), (IX) and (X) and their salts:
R F —C(O)—CH═CH—NH—CH═CH—CN (VIII)
R F —C(O)—CH═CH—NH—CH(OR 2 )—CH 2 —CN (IX)
R F —C(O)—CH═CH—NH—CH(Hal)—CH 2 —CN (X)
[0027] wherein R F , Z and Hal have the meanings indicated above and R 2 is an alkyl group. The formulae (VIII), (XI) and (X) in this case include all stereoisomers of the compounds, such as (Z) and (E) isomers on the double bonds, e.g. the (Z,Z), (Z,E), (E,Z) and (E,E) isomers of the compound (VIII) and in each case the (Z) and (E) isomers of the compounds (IX) and (X). R 2 is preferably a linear or branched alkyl group having 1 to 6 carbon atoms, for example methyl, ethyl, n-propyl, iso-propyl, n-butyl or tert-butyl; methyl and ethyl are preferred, and methyl is particularly preferred.
[0028] The invention likewise relates to the use of compounds of the formula (VIII), (IX) and/or (X) as intermediates for the preparation of plant protection agents, in particular pesticides, such as insecticides.
[0029] 4-Amino- 1,1,1-trifluoro-3-buten-2-one (II), as a preferred starting material, is known and can be prepared, for example, as described in EP-A 0744400, by reacting an acid halide of the formula (XII):
CF 3 —COX (XII)
[0030] wherein X is a halogen atom,
[0031] with a compound of the formula (XIII):
CH 2 ═CHOR 3 (XIII)
[0032] wherein R 3 is an alkyl group,
[0033] to give a compound of the formula (XIV):
R F —C(O)—CH═CH(OR) (XIV)
[0034] from which, by reaction with ammonia, compound (II) is obtained.
[0035] Compounds of the formulae (III) to (VII) are known. They are commercially obtainable or can be prepared by known methods familiar to the person skilled in the art, such as are described, for example, in J. Chem. Soc. 1969, 406-408; Bull. Soc. Chim. Fr. 1948, 594 and J. Org. Chem. 29, 1964, 1800-1808.
[0036] R 3 is preferably a linear or branched alkyl group having 1 to 6, preferably 1 to 4, carbon atoms, for example methyl, ethyl, n-propyl, iso-propyl, n-butyl or tert-butyl; methyl and ethyl are preferred, and methyl is particularly preferred.
[0037] According to the invention, compound (II) is reacted in a condensation reaction with one or more compounds of the formulae (III) to (VII) to give compound (VIII), (IX) and/or (X).
[0038] The condensation of compound (H) with one or more compounds (III) to (VII) and the subsequent ring closure reaction are shown in the following scheme:
[0039] The condensation of (II) with (III)-(VII) is preferably carried out under reduced pressure (particularly preferably at a pressure in the range of from about 5 to about 150 mbar, very particularly preferably from about 10 to about 100 mbar). At the same time, the preferably low-boiling components are distilled off from the reaction mixture and in the process allow complete reaction of both starting materials. The vacuum is advantageously selected such that the boiling point of the eliminated compound R 1 ZH, such as CH 3 OH, EtOH, BuOH, is below, preferably about 50 to 10° C. below, the reaction temperature, and the boiling point of the solvent is above, preferably about 50 to 150° C. above, the reaction temperature. As the same time, the formation of by-products is largely suppressed, and the reaction rate increases.
[0040] The ratio of the two components (II) and (III) to (VII) in the reactions can vary to a large extent, depending on the compounds employed and further reaction conditions. Customarily, the molar ratio of the components (II):(III) to (VII) is about 1.0-1.2:1, preferably about 1.02-1.06:1. Depending on the compound employed, the reaction temperature and the other reaction conditions can be varied within wide limits. In general, the reaction temperature is in the range from about −20° C. to about +100° C., preferably from about 0° C. to about +30° C. and the reaction time is customarily from about 0.5 to about 12 h, preferably from about 1 to about 6 h. The reaction conditions also vary, depending on which compound of the formula (III) to (VII) is employed.
[0041] For the reaction with compounds of the formula (III)/(V), the reaction temperature is preferably from about −10 to about +75° C. For efficient conversion, the reaction is expediently carried out in the presence of a base. Suitable bases are, for example, alkali metal hydrides, such as NaH or KH; alkyllithium compounds, such as n-butyllithium or t-butyllithium; alkali metals, such as sodium or potassium; alkali metal hydroxides, such as NaOH or KOH; alkoxides, such as Na methoxide, Na ethoxide, K methoxide or K t-butoxide; or basic heterocycles, such as pyridine or quinoline. Alkali metal hydrides are preferred; NaH and K t-butoxide are particularly preferred. The bases can be employed individually or as a mixture. The amount of the base employed can vary within wide limits, depending on what is employed as a compound of the formula (III) or (V), whether and in which solvent the reaction is carried out and the further reaction conditions. In general, from about 1.0 to about 1.2 equivalents by weight of base, preferably from about 1.05 to about 1.1 equivalents by weight of base, are employed per mole of compound of the formula (II).
[0042] The reaction is preferably carried out in a solvent. In this process, the components (II) can be introduced into the solvent and these solutions reacted with (III) or (V) together with base. Preferred solvents are polar aprotic solvents, such as N,N-dimethylformamide or acetonitrile; halogenated hydrocarbons, such as methylene chloride or chloroform; ethers such as diethyl ether, dimethoxyethane or tetrahydrofuran; alcohols, such as methanol or ethanol; or basic heterocycles, such as pyridine or quinoline. Polar aprotic solvents are preferred; N,N-dimethylformamide (DMF) and dimethoxyethane (DME) are particularly preferred. Mixtures of the solvents mentioned can also be employed. The amount of the solvent employed can vary within wide limits and depends, for example, on whether and which base is added. In general, the amount of the solvent used is from about 1 to about 30, preferably from about 4 to about 15, parts by weight per part by weight of the compound (III) or (V).
[0043] The preparation of compounds of the formula (VIII) by reaction of the compound of the formula (II) with a compound of the formulae (IV), (VI) and/or (VII) is carried out in two stages, the compound of the formula (IX) or (X) firstly being formed with elimination of alcohol or elimination of H-Hal and then in a second stage a further alcohol molecule or H-Hal molecule being eliminated, which leads to the compound of the formula (VIII).
[0044] In all reactions, instead of the pure compounds, the salts can also be employed or obtained, depending on the reaction procedure.
[0045] By way of example, the reaction below with compound (IV) as a second component is illustrated:
[0046] In order to obtain the compounds of the formula (IX) and/or (X) in pure form, the condensation reaction is preferably carried out at low temperatures, preferably from about −10 to about 0° C.; the reaction time is then preferably from about 0.2 to about 4 h. For the further reactions to give compounds of the formula (VIII), the reaction must be carried out at higher temperatures, preferably from about 20 to about +25° C., the reaction time for this second stage preferably being from about 3 to about 10 h.
[0047] For a given reaction, the person skilled in the art can select suitable reaction conditions in a simple manner, it being possible to combine the general and preferred ranges indicated as desired.
[0048] If the condensation reaction is carried out in the presence of a base which contains an alkali metal, the compounds (VIII), (IX) and/or (X) form alkali metal salts which, under certain circumstances, can be present in the reaction product. In such cases, a neutralization step is added to the condensation reaction, the reaction product being treated, for example, with a mineral acid, such as hydrochloric acid or sulfuric acid.
[0049] Working-up takes place by methods which are known and familiar to the person skilled in the art, such as extraction by shaking, washing and drying.
[0050] The compound (VIII) has the following tautomers and isomerizes rapidly, in particular in the dissolved state:
[0051] Accordingly, the isolated compound (VIII) can contain a compound of the formula (VIII)′:
R F —C(O)—CH═CH—N═CH—CH 2 —CN (VIII)′
[0052] Correspondingly, the compound (IX) has the following tautomers:
[0053] The formulae (VIII), (IX) and (X) include all these tautomers and salts of the compounds.
[0054] The ring closure reaction of the compounds (VIII), (XI) and/or (X) to give the compound (I) is advantageously carried out in a solvent. Alcohols are preferred, particularly preferably primary (C 1 -C 6 )-alcohols; methanol and ethanol, in particular methanol, are very particularly preferred. Mixtures of the solvents mentioned can also be employed. The compounds (VIII), (IX) and/or (X) can in this case be introduced into the solvent, or the solvent is added to the reaction mixture. The amount of the solvent employed for the ring closure reaction can vary within wide limits, depending on the starting compound and reaction conditions. In general, it is from about 1 to about 30, preferably from about 4 to about 15, parts by weight per part by weight of compound (VIII) or (IX) and/or (X).
[0055] The ring closure reaction of the compounds (VIII), (IX) and/or (X) is advantageously carried out in an alcohol as solvent and in the presence of a preferably weak base to give the intermediates (XV), (XVI) and/or (XVII). On subsequent acidification, compound (I) is formed, according to the scheme:
[0056] Here, R F is (C 1 -C 4 )-haloalkyl, preferably CF 3 , and R 1 is a, preferably straight-chain, (C 1 -C 6 )-, preferably (C 1 -C 4 )-, in particular (C 1 -C 2 )-, alkyl radical and M is H + or a monovalent cation, such as Na + , K + , Li + , ½Ca 2+ , ½Mg 2+ , HN((C 1 -C 4 )-alkyl) + 3 .
[0057] It is automatically understood here that the nature of the radical M depends on the base used and its strength. Suitable bases are, for example, alkali metal carbonates, hydrogencarbonates and acetates, such as the corresponding Li, Na, K and Cs salts; alkaline earth metal carbonates and hydrogencarbonates, such as the corresponding Mg and Ca salts; alkali metal hydrides, such as NaH and KH; alkyllithium compounds, such as n-butyllithium; alkali metals, such as Na and K; alkali metal hydroxides, such as NaOH and KOH; alkali metal alkoxides, such as NaOMe, NaOEt, KOMe and KOtBu; basic heterocycles, such as pyridine, 4-N,N-dimethylaminopyridine and quinoline; or ammonia.
[0058] Alkali metal and alkaline earth metal carbonates, hydrogencarbonates and acetates, such as Li 2 CO 3 , Na 2 CO 3 , NaHCO 3 , K 2 CO 3 , CaCO 3 and MgCO 3 , are preferred. Li 2 CO 3 , Na 2 CO 3 and K 2 CO 3 are particularly preferred; Li 2 CO 3 and K 2 CO 3 are very particularly preferred. By means of the two last-mentioned bases, it is possible in particular to increase the selectivity of the reaction in the direction of the desired final product (I).
[0059] The bases can be employed individually or as a mixture. In general, from about 0.05 to about 1 equivalent, preferably from about 0.1 to about 0.8 equivalent, of base are employed per mole of compound of the formula (VIII), (IX) and/or (X). The base can optionally be filtered off after the reaction and employed again.
[0060] The activity and selectivity of the base can be controlled by phase-transfer catalysts (PTCs). Suitable PTCs are typically crown ethers, cryptands, quaternary ammonium, phosphonium and onium compounds. Examples which may be mentioned are 12-crown-4, 15-crown-5, 18-crown-6, dibenzo-18-crown-6, dicyclohexyl-18-crown-6, tetrabutylammonium chloride and bromide, tetrabutylphosphonium chloride and bromide. 18-Crown-6 is preferred. The PTC is customarily employed in an amount from about 1 to about 10, preferably from about 1 to about 5 mol %, based on the compound (VIII), (IX) and/or (X).
[0061] The intermediates of the formula (XV) and (XVI) and/or (XVII) can be isolated according to customary methods known to the person skilled in the art, for example by removing the solvent and washing the residue. The invention likewise relates to these compounds.
[0062] It is preferred, however, to react the intermediates of the formula (XII), (XV) and/or (XVII) by treating with acid to give compound (I) without prior isolation.
[0063] Strong acids are preferred here, such as aqueous or gaseous HCl, HBr, H 2 SO 4 and CF 3 COOH. The pH of the reaction mixture is in general adjusted to from about 1 to about 2, which is customarily achieved by use of from about 0.1 to about 1 equivalent of acid, based on the theoretical amount of compound (I).
[0064] The hydrolysis of the nitrile (I) to give the acid amide (XI) can be carried out according to methods which are known and familiar to the person skilled in the art, such as are described, for example, in Houben Weyl, Methoden der organischen Chemie [Methods of Organic Chemistry].
[0065] In a further, preferred variant of the process according to invention, the synthesis of the compounds (I) and (XI) is carried out in a one-pot reaction, i.e., without intermediates of the formula (VIII) to (X) and/or (XII) being isolated.
[0066] The compounds (I) and (XI) are used, for example, as intermediates in the preparation of plant protection agents, in particular pesticides, such as insecticides. In particular, they are suitable for further reaction to give compounds such as are described in WO-A 98/57969, EP-A 0580374 and DE 10014006.8. These documents are expressly incorporated by reference herein and relied upon, particularly in regard to the compounds of the respective formula (I) and the working examples thereof.
[0067] The invention also relates to the process for the preparation of 4-trifluoromethylnicotinic acid derivatives having insecticidal activity according to WO-A 98/57969, EP-A 0580374 and/or DE 10014006.8, 4-trifluoromethylnicotinonitrile being prepared as described above, optionally hydrolyzed and additionally reacted further in the processes described in the cited documents to give the final compounds of the respective formula (I) having insecticidal activity.
[0068] Reference is expressly made to the contents of the German patent applications 10061967.3, 10120819.7 and 10144411.7, whose priority the present application claims, and the attached abstract; it is regarded by citation as part of this description.
[0069] The invention is further explained by the following examples, without being restricted thereby.
EXAMPLE 1
[0070] Preparation of isomer mixture of 3-(4,4,4-trifluoro-3-oxo-1-butenyl)-2-propenenitrile
[0071] In a three-necked flask, 61.6 g (0.55 mol) of potassium tert-butoxide were introduced into 250 ml of dimethoxyethane under N 2 and the solution was cooled to 0° C. 4-Amino-1,1,1-trifluoro-3-buten-2-one, 69.5 g (0.5 mol), was added dropwise at this temperature in the course of 30 min and then 60.3 g (0.525 mol) of 3,3-dimethoxypropionitrile were added dropwise. The mixture was then stirred at 30° C. for 3-4 h. The reaction mixture was added to ice and acidified to pH 3-4 using HCl. The precipitate was filtered off and washed with water.
[0072] 71 g of product (75%), mp: 123-126° C.
[0073] [0073] 19 F NMRδ: −77.6 (4 singlets) ppm.
EXAMPLE 2
[0074] Preparation of 4-trifluoromethyl-3-pyridinecarbonitrile
[0075] In a three-necked flask, 19 g (0.1 mol) of 3-(4,4,4-trifluoro-3-oxo-1-butenyl)-2-propenenitrile were dissolved in 200 ml of methanol and 1 g of Li 2 CO 3 was added. The reaction mixture was heated under reflux for 4-6 h, cooled to 30° C. and 10 ml of aqueous HCl were added. The reaction mixture was stirred for 2 h, the methanol was removed in vacuo and the product was extracted with diethyl ether. The solvent was removed and 4-trifluoronicotinonitrile was purified by vacuum distillation. 14 g (81%) of the product of bp 80° C./18 mbar were obtained.
[0076] NMR 1 H (CDCl 3 )δ: 8.87 (s, 1H), 8.81 (d, 1H, 3 J (H,H) = 5 Hz), 7.51 (d, 1H) ppm.
[0077] NMR 19 F δ: −64.5 (s, CF 3 ) ppm.
EXAMPLE 3
[0078] Preparation of 4-trifluoromethyl-3-pyridinecarbonitrile
[0079] The reaction was carried out as described in EXAMPLE 2, but instead of Li 2 CO 3 , 1 g of K 2 CO 3 was taken.
[0080] Yield 75%.
EXAMPLE 4
[0081] Preparation of 4-trifluoromethyl-3-pyridinecarbonitrile
[0082] The reaction was carried out as described in EXAMPLE 2, but instead of Li 2 CO 3 , 1 g of sodium acetate was taken.
[0083] Yield 64%.
EXAMPLE 5
[0084] Preparation of 4-hydroxy-6-methoxy-4-(trifluoromethyl)-1,4,5,6-tetrahydro-3-pyridinecarbonitrile
[0085] In a three-necked flask, 1.9 g (0.01 mol) of 3-(4,4,4-trifluoro-3-oxo-1-butenyl)-2-propenenitrile were dissolved in 20 ml of methanol under N 2 and 0.2 g of NaOMe were added. The reaction mixture was stirred at RT for 10-14 h and the methanol was then largely removed in vacuo. 50 ml of dry diethyl ether were added. The product was purified by recrystallization from ethyl acetate. 1.5 g of product were obtained as a white solid. M.p. 121-123° C.
[0086] 1H NMR (CD3OD) (ABX spin system) 1.72 dd (H A ), 1.91 dd (H B ), 3.22 (s,3H), 4.52 dd (1H), 6.88 (s, 1H) ppm.
[0087] The product reacted with HCl at RT to give 4-trifluoromethyl-3-pyridinecarbonitrile Yield 95%.
EXAMPLE 6
[0088] Preparation of isomer mixture of 3-methoxy-3-(Z and E)-4,4,4-trifluoro-3-oxo-1-butenyl)propionitrile
[0089] In a three-necked flask, 61.6 g (0.55 mol) of potassium tert-butoxide were introduced into 250 ml dimethoxyethane under N 2 and the solution was cooled to 0° C. 4-Amino-1,1,1-trifluoro-3-buten-2-one, 69.5 g (0.5 mol), was added dropwise at this temperature in the course of 30 min, and 43.5 g (0.525 mol) of 3-methoxypropionitrile were then added dropwise. The mixture was then stirred at 5-10° C. for 3-4 h. The reaction mixture was added to ice and acidified to pH 3-4 using HCl. The product was extracted with diethyl ether, dried and the solvent was removed in vacuo.
[0090] 81 g were obtained (74%), oil.
[0091] [0091] 19 F NMRδ: −77.5(s); 77.6(s) ppm.
EXAMPLE 7
[0092] Preparation of isomer mixture of 3-(4,4,4-trifluoro-3-oxo-1-butenylamino)acrylonitrile
[0093] In a 1 l four-necked flask having a thermometer, KPG stirrer, dropping funnel with bubble counter, descending condenser with cooled (−10° C.) receiver and vacuum connection, 117 g of potassium tert-butoxide were introduced into 700 ml of DMF under N 2 and the solution was cooled to 0° C. 142 g of 4-amino-1,1,1-trifluoro-3-buten-2-one were added dropwise at this temperature in the course of 30 min. After addition was complete, 117 g of 3,3-dimethoxypropiononitrile were added dropwise at this temperature. The dropping funnel was removed, and the pressure in the system was slowly reduced to 20-25 mbar.
[0094] The mixture was then heated at 30-35° C. for 3-5 h and stirred under a vacuum of 20-25 mbar, the low-boiling products (methanol, tert-butanol) simultaneously being removed in vacuo and condensed in the receiver.
[0095] The reaction mixture was added to 1000 g of ice with 40 ml of HCl (d 1.19) at 0-10° C. and, if necessary, adjusted to pH 2-3 using HCl. After 1 h, the precipitate was filtered off, washed with ice water and the product was dried. 175 g (92%) of 3-(4,4,4-trifluoro-3-oxo-1-butenyl)acrylonitrile were obtained as an isomer mixture of 4 stereoisomers.
[0096] M.p.: 120-126° C. Purity 99%
EXAMPLE 8
[0097] Preparation of isomer mixture of 3-(4,4,4-trifluoro-3-oxo-1-butenylamino)acrylonitrile (comparative example)
[0098] The reaction was carried out as described in EXAMPLE 1, but at normal pressure.
[0099] Yield 71%. Purity 93%.
EXAMPLE 9
[0100] Preparation of 3-(4,4,4-trifluoro-3-oxo-1-butenylamino)acrylonitrile
[0101] The reaction was carried out as described in EXAMPLE 1, but NaOMe was taken as the base.
[0102] Yield 86%.
EXAMPLE 10
[0103] Preparation of isomer mixture of 3-(4,4,4-trifluoro-3-oxo-1-butenylamino)acrylonitrile
[0104] The reaction was carried out as described in EXAMPLE 1, but NaOtBut was taken as the base.
[0105] Yield 89%.
EXAMPLE 11
[0106] Preparation of 4-trifluoromethylnicotinonitrile
[0107] In a three-necked flask, 19 g (0.1 mol) of 3-(4,4,4-trifluoro-3-oxo-1-butenyl)acrylonitrile were dissolved in 200 ml of methanol and 0.5 g of Li 2 CO 3 was added. The reaction mixture was heated under reflux for 10 h. Methanol was removed in vacuo and 30 ml of HCl were added. After 1 h, the product was extracted, the solvent was removed and 4-trifluoromethylnicotinonitrile was purified by vacuum distillation. 14.5 g (84%) of the product of b.p. 80° C./18 mbar were obtained.
[0108] NMR 1 H (CDCl 3 )δ: 9.35(s), 8.0 (d, 1H, 3 J( H,H)= 5 Hz), 7.8 (d, 1H, ═CH), 3.8 (s, 2H); 2.2 (s, 3H) ppm.
[0109] NMR 19 F“: −64.5 (s, CF 3 ) ppm.
EXAMPLE 12
[0110] Preparation of 3-(4,4,4-trifluoro-3-oxo-1-butenylamino)acrylonitrile
[0111] Tubular reactor: 60 cm glass tube of internal diameter 4 cm, having a heatable jacket, half-filled with glass balls, cooled receiver and vacuum connection with cold trap.
[0112] Preparation of reaction mixture
[0113] N-Methylpyrrolidinone (NMP) (800 ml) was cooled to 0° C. and 69.5 g of 4,4,4-trifluoro-1-aminobut-2-en-3-one, 92 g of 30% NaOMe in methanol and 60 g of 3,3-dimethoxypropionitrile were slowly added successively at this temperature. This mixture was transferred to the receiver.
[0114] Reaction procedure
[0115] The tubular reactor was fully filled with NMP, the jacket was heated to 80-85° C. and a vacuum of 30-35 mbar was applied. The reaction mixture was added uniformly to the tubular reactor from the receiver within 1 h. The reaction time was 7-8 min at 80-85° C., methanol being condensed in the cold trap. After addition was complete, a further 120 ml of NMP were added dropwise in order to displace the reaction mixture completely from the reactor. The reaction mixture was added to ice water and HCl and, if necessary, adjusted to pH 2-3 using HCl. The precipitated product was filtered off and washed with water.
[0116] 88 g (90%) of 3-(4,4,4-trifluoro-3-oxo-1-butenyl)acrylonitrile having the purity w.w % 99% as an isomer mixture of 4 stereoisomers were obtained.
[0117] M.p.: 124-126° C.
[0118] While the invention has been described in terms of various preferred embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present invention be limited solely by the scope of the following claims.
|
4-Haloalkylnicotinonitriles having the formula (I)
which are suitable as intermediates in the preparation of pesticides, are obtained by:
(a) reacting a 3-amino-1-haloalkyl-2-propen-1-one
R F —C(O)—CH═CH—NH 2 (II)
in a condensation reaction with a compound of the formula (III) to (VII),
(R 1 Z)CH═CH—CN (III)
(R 1 Z) 2 CH—CH 2 —CN (IV)
Hal—CH═CH—CN (V)
Hal 2 CH—CH 2 CN (VI)
HC≡C—CN (VII),
to give a compound of the formula (VIII), (IX) and/or (X),
R F —C(O)—CH═CH—NH—CH═CH—CN (VIII)
R F —C(O)—CH═CH—NH—CH(ZR 1 )—CH 2 —CN (IX)
R F —C(O)—CH═CH—NH—CH(Hal)—CH 2 —CN (X),
wherein R F is (C 1 -C 4 )-haloalkyl, R 1 is alkyl, Hal is Cl or Br and each Z, independently, is O, S, NR 1 or OCO; and
(b) subjecting the reaction product to a ring closure reaction.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a facilitated transport membrane with improved permeance and selectivity to alkene-based unsaturated hydrocarbons, which includes a solid state polymer electrolyte and additionally a non-volatile surfactant that remarkably enhances the long-term operation stability. More particularly, the present invention relates to a facilitated transport membrane prepared by coating a solid state polymer electrolyte layer, comprising a surfactant, a salt of a transition metal and a non-volatile polymer, on a porous supporting membrane excellent in permeability and mechanical strength, thereby the facilitated transport membrane having high permeability and selectivity to alkenes and long-term operation stability and comprising the complex of a metal and a polymer ligand in the solid state polymer electrolyte has a long-lasting activity as a carrier of alkene even under a long-term dry operating condition.
2. Background of the Related Art
Hydrocarbon mixtures of alkenes such as ethylene and propylene and alkanes such as ethane and propane are primarily produced during a naphtha cracking process. Alkenes such as ethylene and propylene are an important raw material in the petrochemical industry. For that reason, the alkene/alkane separation technology is of great importance in the related industry. Distillation is chiefly used as a separation method for alkene/alkane mixtures such as ethylene/ethane or propylene/propane. However, the separation of those mixtures requires large-scale facilities and high energy expenses, because the alkene in the alkene/alkane mixture is similar to the alkane in molecular size and such physical properties as relative volatility.
For example, the distillation method needs a 120 to 160-stage distillation column at a temperature of −30° C. and a high pressure of about 20 atmospheres for separation of an ethylene/ethane mixture, or a 180 to 200-stage distillation column with a reflux ratio of greater than 10 at −30° C. and several atmospheres. There is thus a need for a novel separation method as a substitute for the conventional distillation method that requires large-scale facilities and high energy expenses.
A substitute for the conventional distillation method is a membrane-based separation method, which has amazingly progressed for the past several decades in the field of gaseous mixture separation, such as N 2 /O 2 , N 2 /CO 2 , or N 2 /CH 4 separation.
Such a classical separation membrane for gaseous mixtures is not suitable to acquire a satisfactory separation performance for an alkene/alkane mixture because the alkene of the mixture is very similar in molecular size and physical property to the alkane. In this regard, a facilitated transport membrane based on a different concept from the classical separation membrane for gaseous mixtures is suggested as a separation membrane having a high separation performance for alkene/alkane mixtures.
The membrane-based separation performance is achieved depending on the difference in permeability among the constituent substances of the mixture. The materials of the membrane mostly have a limitation on their application because of a counter-correlation between permeability and selectivity. The use of the facilitated transport concept increases both permeability and selectivity and thereby extends the application range of the membrane. With a carrier contained in the membrane that reacts reversibly with a specific constituent substance of the mixture, the reversible reaction gives an additional transport of the specific substance and facilitates the substance transport. Accordingly, the total substance transport is the sum of the substance transport caused by the Fick law and the carrier-mediated transport, which is called “facilitated transport”.
A supported liquid membrane is an example of the membrane based on the principle of the facilitated transport. The supported liquid membrane is prepared by coating a porous thin film with a solution of a carrier in a solvent such as water and operated in the liquid state. Such a supported liquid membrane is somewhat satisfactory in separation performance.
U.S. Pat. Nos. 3,758,603 and 3,758,605 (by Steigelmann and Hughes), for example, disclose a supported liquid membrane containing silver salts having a selectivity to ethylene/ethane of about 400 to 700 and a permeability to ethylene of 60 GPU [1 GPU=1×10 −6 cm 3 (STP)/cm 2 cmHgsec], the separation performance of the membrane is considerably satisfactory. However, the supported liquid membrane has the facilitated transport ability only in a wet condition, causing a loss of the solvent and a reduced separation performance with an elapse of time and not maintaining the initial separation performance for a long time.
To solve this problem, Kimura et al. suggests a facilitated transport membrane using silver salts and an ion exchange membrane (U.S. Pat. No. 4,318,714). However, the membrane has the facilitated transport ability only in a wet condition as in the case of the supported liquid membrane.
In addition, U.S. Pat. Nos. 5,015,268 and 5,062,866 (by Ho) disclose a method for forming a complex of silver salts with a water soluble polymer, such as polyvinylalcohol. However, the separation performance is satisfactory only upon passing a feed gas saturated with water or swelling the membrane with ethylene glycol or water. In all the above-stated methods, the separation membranes are required to contain water or a similar solvent and maintain a wet condition. A loss of the solvent over time is thus unavoidable when these membranes are used in separating a dry mixture of hydrocarbon gases that does not contain a solvent such as water. So, there is a need for a method for periodically feeding a solvent to maintain the separation membrane in a wet condition. But, such a method is inapplicable to the actual separation.
Krause et al. suggests another facilitated transport membrane as disclosed in U.S. Pat. No. 4,614,524, in which an ion exchange membrane such as Nafion is ion-exchanged to a silver ion and plasticized with glycerol. The membrane exhibits a low selectivity to ethylene/ethane of only about 10 when using a dry feed mixture or even no selectivity without a plasticizer, and causes a loss of the plasticizer with an elapse of time.
In a supported liquid membrane, a volatile plasticizer, or saturating a feed gas with vapor of the volatile plasticizer is required to maintain the activity of the carrier. Such a supported liquid membrane is also impractical because it causes a loss of the plasticizer with an elapse of time to deteriorate the membrane stability and requires removal of the plasticizer such as water periodically in order to maintain the activity of the carrier from the separated product.
Accordingly, as a substitute for the conventional distillation method that requires high facility and energy expenses in separation of alkene/alkane mixtures, there is a need for a separation membrane excellent in selectivity and permeability and destitute of a volatile component to have a long-term lasting activity even when a dry feed mixture is used.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a stabilized solid polymer electrolyte facilitated transport membrane that substantially obviates one or more problems due to limitations and disadvantages of the related art. An object of the present invention is to provide a facilitated transport membrane suitable for separation of alkenes from alkanes in an alkene/alkane mixture and excellent in permeability and selectivity to alkenes and long-term operation stability in a dry operating condition, thereby maintaining the activity of the carrier without the supply of a liquid solvent.
To achieve the object of the present invention, there is provided a facilitated transport membrane suitable for separation of alkene-based hydrocarbons that includes: a polymer electrolyte layer comprising a salt of a transition metal selectively and reversibly reactive to an alkene, a non-volatile polymer, and a surfactant for maintaining the activity of the transition metal, the polymer electrolyte layer being in a solid state at an operating temperature; and a porous supporting membrane.
Hereinafter, the present invention will be described in detail.
The facilitated transport membrane according to the present invention comprises a solid polymer electrolyte selectively permeable to alkenes, and a porous supporting membrane for supporting the solid polymer electrolyte.
The supporting membrane as used herein may include any membrane that is excellent in permeability and maintains a satisfactory mechanical strength. For example, a general porous polymer membrane or a porous ceramic supporting membrane is suitable as the supporting membrane. Also, the supporting membrane may have any shape of flat sheet, spiral wound or hollow fiber.
The solid polymer electrolyte as used herein comprises a metal salt that acts as a carrier, a non-volatile polymer, and a non-volatile surfactant that stabilizes the electrolyte. The metal salt in the electrolyte is not simply dispersed in or blended with the polymer but solvated into a metal cation and a salt anion on the polymer. The surfactant as used herein maintains the activity of the metal salt and remarkably increases the stability of the polymer electrolyte. Accordingly, unlike the conventional membrane, the facilitated transport membrane of the present invention needs neither water for maintaining the activity of the carrier nor another additive for swelling the polymer matrix, and selectively enhances the transfer of alkenes in a dry condition with remarkably increased operation stability.
In the facilitated transport membrane of the present invention, the electrolyte comprising a metal salt acting as a carrier and a non-volatile polymer has a substantial effect on the selective separation of alkenes, and its characteristic determines the selective permeable separation of alkenes from the corresponding alkanes.
The metal salt comprising the cation of the transition metal and the anion of the salt is solvated into ions on the polymer so that the cation of the metal reacts reversibly with the double bond of the alkenes to form a complex that participates in the facilitated transport. Namely, the cation of the transition metal in the electrolyte has an interaction with the anion of the salt, the polymer and the alkene, of which the selection guarantees a membrane excellent in both selectivity and permeability. The stability of the selected polymer and the metal complex formed also plays an important role in the long-term operation.
It is well known that some transition metals react reversibly with alkenes in the solution (See. Chem. Rev. 1973). The ability of the transition metal ion as a carrier is largely dependent on the intensity of the π-complexation with alkenes. The intensity of the π-complexation with alkenes is determined primarily by the electronegativity, which is a measure of the relative strength of an atom in a molecule to attract bonding electrons to itself. The electronegativity values of transition metals are presented in Table 1.
TABLE 1
The Electronegativity Values of Transition Metals
Transition Metals
Sc
Ti
V
Cr
Mn
Fe
Co
Ni
Cu
Electronegativity
1.4
1.5
1.6
1.7
1.6
1.8
1.9
1.9
1.9
Transition Metals
Y
Zr
Nb
Mo
Tc
Ru
Rh
Pd
Ag
Electronegativity
1.3
1.3
1.6
2.2
1.9
2.2
2.3
2.2
1.9
Transition Metals
La
Hf
Ta
W
Re
Os
Ir
Pt
Au
Electronegativity
1.0
1.3
1.5
2.4
1.9
2.2
2.2
2.3
2.5
With the greater electronegativity, the metal atom draws bonding electrons more strongly. If the electronegativity of the metal is excessively high, the metal is not suitable for the facilitated carrier because it is susceptible to irreversible reaction with the n electrons of the alkene; otherwise, if the electronegativity is too low, the metal is also impractical as a carrier due to its weak interaction with the alkene.
For reversible reaction between the transition metal ion and the alkene, the electronegativity of the metal is preferably in the range of 1.6 to 2.3. Examples of the suitable transition metal may include Mn, Fe, Co, Ni, Cu, Mo, Tc, Ru, Rh, Pd, Ag, Re, Os, Ir, Pt, or complexes thereof.
To increase the reversible reactivity of the transition metal ion with the alkene, the anion of the transition metal plays an important role in determining the intensity and the rate of the interaction between a carrier and alkene. In order for the transition metal to act as a carrier, the transition metal salt MX is solvated on the polymer to form a complex as given by the following reaction I:
MX+[G]→M—X—[G] [Reaction 1]
Here, [G] and M—X—[G] represent the functional group of the polymer and the complex, respectively. The ability of solvation of a transition metal salt into the polymer is usually dependent on the dielectric constant of the polymer. Transition metal salts are not readily dissolved in a polymer when the polymer has a low polarity. With the lower lattice energy of the transition metal salt, the anion forms a weak ionic bond or ion pair with the cation and the salt is easily dissolved in a polymer.
It is therefore preferable to select the anion of the transition metal salt that has a low lattice energy with respect to the cation of the transition metal, in order to facilitate the salvation of the transition metal salt. The lattice energies of the representative transition metals are presented in Table 2.
TABLE 2
Lattice Energies of Metallic Salts [KJ/mol]
Li +
Na +
K +
Ag +
Cu +
Co 2+
Mo 2+
Pd 2+
Ni 2+
Ru 3+
F −
1036
923
823
967
1060
3018
3066
Cl −
853
786
715
915
996
2691
2733
2778
2772
5245
Br −
807
747
682
904
979
2629
2742
2741
2709
5223
I −
757
704
649
889
966
2545
2630
2748
2623
5222
CN −
849
739
669
914
1035
NO 3 −
848
756
687
822
854
2626
2709
BF 4 −
705
619
631
658
695
2127
2136
ClO 4 −
723
648
602
667
712
CF 3 SO 3 −
779
685
600
719
793
CF 3 CO 2 −
822
726
658
782
848
In the facilitated transport membrane of the present invention, the transition metal salt preferably has a lattice energy of less than 1,000 KJ/mol, reducing the tendency of the anion of the transition metal salt to form a strong ion pair with the cation. Among the metal salts listed in Table 2, the suitable anion may include F − , Cl − , Br − , I − , CN − , NO 3 − , BF 4 − ClO 4 − , CF 3 SO 3 − or CF 3 CO 2 − that forms a salt with Ag + or Cu + and is not specifically limited to those listed in Table 2.
The tendency of the anion to form a strong ion pair with the cation decreases in the order of F − <<Cl − <Br − <I − ˜SCN − <ClO 4 − ˜CF 3 SO 3 − <BF 4 − ˜AsF 6 − , with a decrease in the lattice energy. Those anions suitable for the facilitated transport membrane due to their low lattice energy are widely used for electrochemical devices such as batteries or electrochemical capacitors. Examples of such an anion may include, if not specifically limited to, SCN − , ClO 4 − , CF 3 SO 3 − , BF 4 − , AsF 6 − , PF 6 − , SbF 6 − , AlCl 4 − , N(SO 2 CF 3 ) 2 − , and C(SO 2 CF 3 ) 3 − .
The facilitated transport membrane of the present invention may include not only monosalts of the transition metal but also complex salts of the transition metal, such as (M 1 ) x (M x ) x′ X y or (M 1 ) x (X 1 ) y (M 2 ) x′ (X 2 ) y′ or organic salt-transition metal salt (where M 1 and M 2 each represent a cation and X, X 1 and X 2 each represent an anion; and, x, x′, y, and y′ represent any stoichiometrically suitable values), or physical mixtures of at least two of them.
Examples of the complex salt of the transition metal may include RbAg 4 I 5 , Ag 2 HgI 4 , RbAg 4 I 4 CN, AgHgSI, AgHgTeI, Ag 3 SI, Ag 6 I 4 WO 4 , Ag 7 I 4 AsO 4 , Ag 7 I 4 PO 4 , Ag 19 I 15 P 2 O 7 , Rb 4 Cu 16 I 7 Cl 13 , Rb 3 Cu 7 Cl 10 , AgI-(tetralkyl ammonium iodide), AgI—(CH 3 ) 3 SI, C 6 H 12 N 4 .CH 3 I—CuI, C 6 H 12 N 4 .4CH 3 Br—CuBr, C 6 H 12 N 4 .4C 2 H 5 Br—CuBr, C 6 H 12 N 4 .4HCl—CuCl, C 6 H 12 N 2 .2CH 3 I—CuI, C 6 H 12 N 2 .2CH 3 Br—CuBr, C 6 H 12 N 2 .2CH 3 Cl—CuCl, C 5 H 11 NCH 3 I—CuI, C 5 H 11 NCH 3 Br—CuBr, and C 4 H 9 ON.CH 3 I—CuI. But, numerous combinations similar to the complex salts or the salt mixtures as exemplified in the scope of the present invention are also available and the complex salt of the transition metal is not specifically limited to the above-mentioned examples. The tendency of the polar transition metal salt to solvate on the polymer is dependent on the polarity of the polymer. It is thus necessary to choose a polymer having a high polarity in order to increase the interaction with the transition metal salt. The polarity of the polymer is indicated as a dielectric constant. The dielectric constant ε of the polymer at the room temperature can be calculated by Equation 1:
ε≈σ/7.0 and σ=(E coh /V)×0.5 [Equation 1]
In the above equation, σ is the solubility parameter, E coh the cohesive energy, V the molar volume. The cohesive energy and the molar volume can be measured by a group contribution method suggested by Fedors (See. D. W. van Krevelen, in “Properties of Polymers”, p196). The dielectric constants of the representative polymers are presented in Table 3.
TABLE 3
Solubility
Dielectric
POLYMER
Parameter
Constant
Polypropylene
16.41
2.34
Poly (tetrafluoroethylene)
20.32
2.9
Polycarbonate
22.30
3.29
Poly (N-isopropyl acrylamide)
24.57
3.51
Poly (phenylene sulfide)
26.75
3.82
Poly (methylmethacrylate)
20.32
2.90
Poly (methylene oxide)
20.41
2.92
Poly (methacrylate)
21.60
3.09
Poly (ethyleneimine)
22.30
3.19
Poly (N-dimethyl methacrylate)
23.62
3.37
Poly (vinyl acetate)
21.60
3.09
Poly (epichlorohydrin)
21.87
3.12
Poly (acrylamide)
39.25
5.61
Poly (oxy-2,6-dimethyl-1,4-
22.91
3.27
phenylene)
Poly (2-ethyl-2-oxazoline)
25.73
3.68
Poly (vinyl pyrrolidone)
27.38
3.91
Poly (acrylonitrile)
29.45
4.21
Poly (methacrylamide)
33.26
4.75
Poly (vinyl alcohol)
39.00
5.57
Poly (N-dimethyl acrylamide)
25.21
3.60
Preferably, the polymer suitable for the solid electrolyte of the facilitated transport membrane according to the present invention has a large dielectric constant of greater than 2.7 so as to readily form a complex with the transition metal salt.
Among the representative polymers listed in Table 3, examples of suitable polymers having a dielectric constant within the defined range include poly(tetrafluoroethylene) (PTFE), polycarbonate, poly(N-isopropyl acrylamide) (NIPAM), poly(phenylene sulfide), poly(methyl methacrylate), poly(methylene oxide), poly(styrene), poly(methacrylate), poly(vinyl acetate), poly(epichlorohydrin), poly(acrylamide), poly(oxy-2,6-dimethyl-1,4-phenylene), poly(2-ethyl-2-oxazoline), poly(vinylpyrrolidone), poly(acrylonitrile), poly(methacrylamide), poly(vinylalcohol), poly(ethyleneimine), poly(N-dimethyl acrylamide), or poly(N-dimethyl methacrylamide).
The facilitated transport membrane of the present invention may include those polymers alone, the homopolymers or copolymers of the polymers, or derivatives containing the polymers as a backbone or a side chain, or physical mixtures of the polymers. Besides the polymers listed in Table 3, other numerous polymers are suitable for the present invention and the polymer as used herein is not specifically limited to the above-mentioned examples. The surfactant used as a stabilizer of the carrier is a compound having both a hydrophobic group and a hydrophilic group and classified into an anionic surfactant, a cationic surfactant, an amphiphilic surfactant, and a non-ionic surfactant.
The anionic surfactant is classified into a carbonate type; a sulfuric acid ester salt type (e.g., higher alcohol sulfuric acid ester salt, sulfuric acid ester, sulfated oil, sulfated fatty acid ester, sulfated oleic acid, etc.); a sulfonate type (e.g., alkylbenzene sulfonate salt, alkylnaphthalene sulfonate salt, AEROSOL-OT, paraffin fulfonate salt, IGEPON-T type, etc.); and a phosphoric acid ester salt type (e.g., higher alcohol phosphoric acid ester salt, etc.). The examples of the suitable anionic surfactant may include sodium laurylate, sodium stearate, sodium oleate, sodium laurylalcohol sulfuric acid ester, ammonium laurylalcohol sulfuric acid ester, mixtures of Ziegler alcohol sulfuric acid ester salts, mixtures of improved oxoalcohol sulfuric acid ester salts, sodium alkylbenzene sulfonate, IGEPON-T type, AEROSOL-OT type, benzene sulfonate, dodecylbenzene sulfonate, tetrapropylene benzene sulfonate (ABS), branched ABS, hard ABS, sodium linear alkylbenzene sulfonate (LAS), calcium dodecylbenzene sulfonate, calcium alkylbenzene sulfonate, α-olefin sulfonate (AOS), zinc dialkyldithiol phosphate, and so forth.
The cationic surfactant is largely classified into an amine type (primary amine, secondary amine and tertiary amine), and a quaternary ammonium salt type. The amine type cationic surfactant prepared from a higher alkyl amine includes higher alkyl amine salts and higher alkyl amine ethylene oxide addition products, and the amine type cationic surfactant from a lower alkyl amine includes a SOROMINE A type, a SAPAMINE A type, an ACOVEL A type and an imidazorine type. The quaternary ammonium salt type cationic surfactant prepared from a higher alkyl amine includes alkyltrimethyl ammonium salts and alkyldimethyl benzyl ammonium salts, and the quaternary ammonium salt type cationic surfactant from a lower alkyl amine includes a spamine type quaternary ammonium type and a pyridinium salt type. Examples of the cationic surfactant may include lauryl trimethyl ammonium chloride, lauryl trimethyl ammonium methosulfate, dihydroxyethylstearylamine, SOROMINE A, SAPAMINE A, ACOVEL A, AMINE O, 2-heptadecanylhydroxyethylimidazoline, ONYXAN HSB (refined-onyx Div., Milmaster Onyx Corp.), lauryltrimethylammonium chloride, laurylmethylbenzylammonium chloride, or benzalconium chloride, SAPAMIN, CATANAC SN, setylpyridinium chloride, serylpyridinium bromide, stearamide methylpyridinium chloride, ZELAN AP (Dupont), VELAN PF (I.C.I. Co.) and so forth.
The amphiphilic surfactant is classified into a carbonate type, a sulfuric acid ester salt type, a sulfonate type and a phosphoric acid ester salt type. Examples of the amphonionic surfactant may include lecithin, laurylaminopropionic methyl, sodium laurylaminopropionate, TEGO (Goldschmidt Co.), laurylmethyl betaine, stearyldimethyl betine, lauryldihydroxyethyl betine and so forth.
The non-ionic surfactant has a hydrophilic group and a hydrophobic group. Examples of the non-ionic surfactant may include polyalkyl glucoside, alkyl glucamide, higher alcohol ethylene oxide addition product, alkylphenol ethylene oxide addition product, higher fatty acid ethylene oxide addition product, polyalcohol fatty acid ester ethylene oxide addition product, higher alkylamine ethylene oxide addition product, fatty acid amide ethylene oxide addition product, ethylene oxide addition product of fatty oil, and polypropylene glycol ethylene oxide addition product. The polyalcohol type surfactant includes fatty acid ester of glycerol, fatty acid ester of pentane erithritol, fatty acid ester of sorbitol and sorbitane, fatty acid ester of sugar, fatty acid amide of alkylamine, or alkylester of polyalcohol. Examples of the non-ionic surfactant may include polyethylene glycol lauric acid diester, polyethylene glycol oleic acid diester, PLORONIC (BASF Wyandotte Corp.), pentaerithritol mono palmitate, sorbitane ester type activator (SPN), TWEEN (Atlas Co.), lauric acid monoester, palmitic acid monoester, EXTRA type (Stepan Co.), SUPER-AMIDE (Onyx Co.) and so forth.
Now, a description will be given to a method for preparing the facilitated transport membrane of the present invention.
The preparation of the facilitated transport membrane comprises dissolving a transition metal salt, a polymer and a surfactant in a liquid solvent to prepare a coating solution, applying the coating solution on a porous supporting membrane, and drying the coated membrane. The liquid solvent as used herein may be any solvent that solvates the transition metal and the polymer without damaging the supporting membrane. When the polymer of the solid polymer electrolyte is aqueous, water is usable as the solvent.
The content of the transition metal salt, the polymer and the surfactant in the coating solution is determined in consideration of the thickness of the solid electrolyte layer immediately after the application of the coating solution and after the drying step. For example, the contents of the transition metal salt, the polymer and the surfactant in the coating solution is 5 wt. % so as to form a solid electrolyte layer having a thickness of 100 μm before drying the coating solution and a final thickness of 5 μm after the drying step. Preferably, the weight fraction of the polymer in the polymer electrolyte layer is less than 50 wt. %. It is also desirable that the mole ratio of the transition metal to the surfactant is in the range from 10,000:1 to 10:1, because the surfactant may have an adverse effect on the permeability of the membrane when the mole ratio is beyond the above limits.
The method for applying the electrolyte coating solution on the porous supporting membrane is well known in the art and may include blade/knife coating, Mayer bar coating, dip coating, air knife coating, or the like. Preferably, the solid electrolyte layer on the supporting membrane has a small dry thickness after the drying step. However, an extremely small dry thickness of the solid electrolyte layer may fail to close up the pores of the porous supporting membrane or cause a hole due to a pressure difference in operation, thereby deteriorating the selectivity of the membrane. Accordingly, the dry thickness of the solid electrolyte layer is preferably in the range from 0.05 μm to 10 μm, more preferably in the range from 0.1 μm to 3 μm.
Another characteristic of the facilitated transport membrane thus prepared is a high selectivity to alkenes. The selectivity increases with an increase in the permeability of alkene with respect to alkane. Accordingly, the facilitated transport membrane has a higher separation performance with an increase in the selectivity and thus more suitable for actual application.
The mixed hydrocarbon feed stream separable by the facilitated transport membrane of the present invention may contain principally at least one alkene and at least one alkane, and additionally methane, hydrogen, acetylene, carbon monoxide, carbon dioxide, or the like. Examples of the alkene may include ethylene, propylene, butylenes, isobutylene, etc., and those of the alkane may include ethane, propane, butane, isobutane, etc.
The facilitated transport membrane of the present invention includes a polymer electrolyte that is solid at the operating temperature. The operating temperature as used herein refers to a temperature at which the facilitated transport membrane is actually used. Preferably, the facilitated transport membrane of the present invention is used at an operating temperature that maintains the solid state of the electrolyte and is lower than the dissociation temperature of the transition metal, i.e., below 300° C.
The facilitated transport membrane of the present invention not only has a high selective permeability to alkene but also a high activity in a completely dry condition because it comprises a metal salt and a non-volatile polymer. Furthermore, the facilitated transport membrane is destitute of volatile components and contains a stability to maintain the activity of the metal complex, which guarantees a high long-term operation stability and makes the membrane suitable for alkane/alkene separation.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter, the present invention will be described in further detail by way of the following examples, which are not intended to limit the scope of the present invention. The permeance is the pressure-normalized flux measured by the volume of the passing gas through the membrane with a soap bubble flow meter. The unit of the permeance is GPU (1×10 −6 cm 3 (STP)/cm 2 cmHg sec). The selectivity is defined as the mole ratio of the mole fraction of alkene in the feed stream to that in the permeate stream.
EXAMPLE 1
0.4 g of poly(vinylpyrrolidone) (PVP, Mw=1,000,000, Aldrich Co.), 0.703 g of silver tetrafluoroborate (AgBF 4 ) and 0.01054 g of alkyl polyglucopyranoside (n-octyl β-D-glucopyranoside, APG) were mixed with 1.6 g of water with stirring to prepare a solution (PVP content=20 wt. %, [CO]:[Ag]=1:1 in mole ratio). The solution was coated on a porous asymmetric supporting membrane (supplied by Saehan Co.) using a Mayer bar. The coated membrane was completely dried in a drying oven of 40° C. for 2 hours and a vacuum oven for 48 hours. The membrane was cut in a size of 2×2 cm 2 and evaluated in regard to gas permeance. The permeance was measured with an ethylene/ethane mixed gas (50:50 vol. %) at the room temperature with the up stream pressure of 40 psig and the down stream pressure of zero psig. The volume of the passing gas was measured with a soap-bubble flow meter, and the selectivity was determined from the composition measured by the gas chromatography. The results are presented in Table 4.
As seen from Table 4, the membrane prepared in Example 1 had a permeance and selectivity equal to or greater than the conventional membrane containing no surfactant (in Comparative Example 1).
TABLE 4
[AgBF 4 ]:[APG]
Gas Permeance
Selectivity
Comparative
300:0
37.0
50.6
Example 1
Example 1
300:1
35.8
57.9
EXAMPLE 2
0.4 g of poly(vinylpyrrolidone) (PVP, Mw=1,000,000, Aldrich Co.), 0.703 g of silver tetrafluoroborate (AgBF 4 ) and 0.035 g of alkyl polyglucopyranoside (n-octyl β-D-glucopyranoside, APG) were mixed with 1.6 g of water with stirring to prepare a solution (PVP content 20 wt. %, [CO]:[Ag]=1:1 in mole ratio). The solution was coated on a porous asymmetric supporting membrane (supplied by Saehan Co.) using a Mayer bar. The coated membrane was completely dried in a drying oven of 40° C. for 2 hours and a vacuum oven for 48 hours. The membrane was cut in a size of 2×2 cm 2 and evaluated in regard to gas permeance. The permeance was measured with an ethylene/ethane mixed gas (50:50 vol. %) at the room temperature with the up stream pressure of 40 psig and the down stream pressure of zero psig. The volume of the passing gas was measured with a soap-bubble flow meter, and the composition was determined by the gas chromatography. The results are presented in Table 5.
As seen from Table 5, the membrane prepared in Example 2 had a permeance and selectivity equal to or greater than the conventional membrane containing no surfactant.
TABLE 5
[AgBF 4 ]:[APG]
Gas Permeance
Selectivity
Comparative
100:0
37.0
50.6
Example 1
Example 2
100:1
35.2
58.7
EXAMPLE 3
0.4 g of poly(vinylpyrrolidone) (PVP, Mw=1,000,000, Aldrich Co.), 0.703 g of silver tetrafluoroborate (AgBF 4 ) and 0.01054 g of alkyl polyglucopyranoside (n-octyl β-D-glucopyranoside, APG) were mixed with 1.6 g of water with stirring to prepare a solution (PVP content=20 wt. %, [CO]:[Ag]=1:1 in mole ratio). The solution was coated on a porous asymmetric supporting membrane (supplied by Saehan Co.) using a Mayer bar. The coated membrane was completely dried in a drying oven of 40° C. for 2 hours and a vacuum oven for 48 hours. The membrane was exposed to UV rays in a room for one month and then cut in a size of 2×2 cm 2 for evaluation of gas permeance. For a comparison, the membrane prepared in Comparative Example 1 was exposed under the same conditions. The measurement was performed in the same manner as described in Example 1.
The membrane exposed under UV rays for one month in Example 3 had no particular change in permeance or selectivity. This result shows that the transition metal carrier is stable.
TABLE 6
Exposed
Gas
Time
[AgBF 4 ]:[APG]
Permeance
Selectivity
Comparative
One
300:0
45.8
7.8
Example 2
month
Example 3
One
300:1
35.7
50.9
month
EXAMPLE 4
0.4 g of poly(vinylpyrrolidone) (PVP, Mw=1,000,000, Aldrich Co.), 0.703 g of silver tetrafluoroborate (AgBF 4 ) and 0.01054 g of alkyl polyglucopyranoside (n-octyl β-D-glucopyranoside, APG) were mixed with 1.6 g of water with stirring to prepare a solution (PVP conten=20 wt. %, [CO]:[Ag]=1:1 in mole ratio). The solution was coated on a porous asymmetric supporting membrane (supplied by Saehan Co.) using a Mayer bar. The coated membrane was completely dried in a drying oven of 40° C. for 2 hours and a vacuum oven for 48 hours. The membrane was exposed to UV rays in a room for 15 days and then cut in a size of 2×2 cm 2 for evaluation of gas permeance. For a comparison, the membrane prepared in Comparative Example 1 was exposed under the same conditions. The measurement was performed in the same manner as described in Example 1.
The membrane exposed under UV rays for 15 days in Example 4 had no particular change in permeance or selectivity. This result shows that the transition metal carrier is stable.
TABLE 7
Exposed
Gas
Time
[AgBF 4 ]:[APG]
Permeance
Selectivity
Comparative
15 days
300:0
39.1
25.5
Example 3
Example 4
15 days
300:1
32.2
58.4
EXAMPLES 5 AND 6
0.4 g of poly(vinylpyrrolidone) (PVP, Mw=1,000,000, Aldrich Co.), 0.703 g of silver tetrafluoroborate (AgBF 4 ) and 0.035 g of alkyl polyglucopyranoside (n-octyl β-D-glucopyranoside, APG) were mixed with 1.6 g of water with stirring to prepare a solution (PVP content=20 wt. %, [CO]:[Ag]=1:1 in mole ratio). The solution was coated on a porous asymmetric supporting membrane (supplied by Saehan Co.) using a Mayer bar. The coated membrane was completely dried in a drying oven of 40° C. for 2 hours and a vacuum oven for 48 hours. The membrane was exposed to UV rays in a room for a defined period of time and then cut in a size of 2×2 cm 2 for evaluation of gas permeance.
The membranes exposed under UV rays for a defined period of time in Examples 5 and 6 had no particular change in permeance or selectivity. This result shows that the transition metal carrier is stable.
TABLE 8
Exposed
Gas
Time
[AgBF 4 ]:[APG]
Permeance
Selectivity
Example 5
15 days
100:1
33.0
68.1
Example 6
One month
100:1
35.6
57.7
EXAMPLES 7, 8 AND 9
1 g of poly(2-ethyl-2-oxazoline) (POZ, Mw=500,000, Tg=60°C., Aldrich Co.) and 2 g of silver tetrafluoroborate (AgBF 4 ) were mixed with 97 g of water. Alkyl polyglucopyranoside (n-octyl β-D-glucopyranoside, APG) was then added to the solution at a mole ratio of 100:1. The resulting solution was coated on a porous asymmetric supporting membrane (supplied by Saehan Co.) using a Mayer bar. The coated membrane was completely dried in a drying oven of 40° C. for 2 hours and a vacuum oven for 48 hours. The membrane was exposed to UV rays in a room for a defined period of time and then cut in a size of 2×2 cm 2 for evaluation of gas permeance.
The gas permeance was measured at the room temperature with the feed stream pressure of 60 psig and the down stream pressure of zero psig. The volume of the passing gas was measured with a soap-bubble flow meter. The permeance and selectivity to propylene and propane are presented in Table 9.
The membranes exposed to UV rays for a defined period of time had no particular change in permeance or selectivity. This result shows that the transition metal carrier is stable.
TABLE 9
Exposed
Propylene
Time
[AgBF 4 ]:[APG]
Permeance
Selectivity
Example 7
Zero
100:0
14.2
142
Example 8
15 days
100:1
15
140
Example 9
One
100:1
15.2
140
month
Comparative
One
100:0
18.5
70
Example 4
month
EXAMPLES 10, 11 AND 12
Procedures were performed in the same manner as described in Example 7 to prepare a complex membrane of POZ, silver trifluoromethane sulfonate (AgCF 3 SO 3 ) and alkyl polyglucopyranoside (n-octyl β-D-glucopyranoside, APG). The content of the aqueous POZ solution was 1 wt. % and the mole ratio of AgCF 3 SO 3 , POZ and APG was 100:50:1. The permeance to pure propylene and propane was measured in the same manner as described in Examples 7, 8 and 9. The permeance and selectivity to propylene and propane are presented in Table 10.
TABLE 10
Exposed
Propylene
Time
[AgBF 4 ]:[APG]
Permeance
Selectivity
Example 10
Zero
100:0
21.2
˜200
Example 11
15 days
100:1
22
˜200
Example 12
One
100:1
23
˜200
month
Comparative
One
100:0
25.2
˜150
Example 5
month
EXAMPLE 13
Procedures were performed in the same manner as described in Example 7 to prepare a complex membrane of POZ, silver trifluoromethane sulfonate (AgCF 3 SO 3 ) and TWEEN 20. The content of the aqueous POZ solution was 1 wt. % and the mole ratio of AgCF 3 SO 3 , POZ and TWEEN 20 was 100:50:1. The membrane exposed to UV rays for a defined period of time had no particular change in permeance or selective permeance. This result shows that the transition metal carrier is stable.
EXAMPLE 14
Procedures were performed in the same manner as described in Example 7 to prepare a complex membrane of POZ, silver trifluoromethane sulfonate (AgCF 3 SO 3 ) and PLURONIC F38 (BASF Co.). The content of the aqueous POZ solution was 1 wt. % and the mole ratio of AgCF 3 SO 3 , POZ and PLURONIC F38 was 100:50:1. The membrane exposed to UV rays for a defined period of time had no particular change in permeance or selectivity. This result shows that the transition metal carrier is stable.
The novel facilitated transport membrane prepared by coating a porous supporting membrane with a polymer electrolyte comprising an appropriate salt of a transition metal, a surfactant and a non-volatile polymer forms a complex of the non-volatile polymer ligand and the metal ion of the metal salt contained in the polymer electrolyte, causing a selective and reversible reaction between the metal ion of the complex and the double bond of an alkene to facilitate the transport of the alkene and thereby enable a selective separation of the alkene, and maintaining the activity of the electrolyte in a solid state containing the metal salt and the non-volatile polymer in a complete dry condition. In addition, the facilitated transport membrane destitute of a volatile component in operation contains the surfactant for maintaining the activity of the metal ion to guarantee long-term operation stability, and is therefore suitable for alkane/alkene separation.
The forgoing embodiments are merely exemplary and are not to be construed as limiting the present invention. The present teachings can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art.
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A facilitated transport membrane with improved permeance and selectivity to alkene-based unsaturated hydrocarbons is provided. The facilitated transport membrane includes a solid state polymer electrolyte and additionally a non-volatile surfactant that enhances long-term operation stability. In preparing the facilitated transport membrane for separation of alkenes, a porous supporting membrane is coated with a solid polymer electrolyte layer having a non-volatile polymer, a non-volatile surfactant, and a salt of a transition metal capable of complexing selectively and reversibly with alkenes.
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FIELD OF THE INVENTION
The current invention is directed to a spring clip for attaching two members. More specifically, the current invention is directed to a spring clip having a snap-lock feature that allows a panel to be releasably attached to a support member.
BACKGROUND OF THE INVENTION
A variety of spring clip devices have been used in the past for releasably attaching two members together--that is, attaching the members in a manner that allows them to be readily detached and then re-attached. One example of the application of such spring clips is in the attachment of a fascia cover panel to a rack module containing electronic equipment. Such spring clips typically have a barbed anchoring device. The spring clips are semi-permanently attached to the panel by inserting the barbed anchoring device into a slot in the panel. The barbs dig into, or at least microscopically penetrate, the wall of the slot. At assembly, a bracket projecting from the rack module is forced over a U-shaped spring portion extending from the clip, thereby securing the fascia cover panel to the rack module.
If the spring clip fails or is damaged, a not infrequent occurrence, it must be replaced. Unfortunately, although spring clips of the type heretofore known in the art allow the fascia cover panel to be readily removed, the clip itself is not easily removed from the panel because the barbs must be dis-engaged from the slot. Moreover, such dis-engagement often results in damage to the slot surface, thereby decreasing the ability of the slot to anchor the replacement clip.
Consequently, it would be desirable to provide a spring clip for releasably attaching two members that although firmed anchored to one of the members, could be easily removed in the event that the spring clip had to be replaced.
SUMMARY OF THE INVENTION
It is a feature of the current invention to provide a spring clip system for releasably attaching two members that, although firmly anchored to one of the members, can be easily removed in the event that the spring clip had to be replaced. This and other features is accomplished in a system for releasably attaching a first member, such as the carrier of a fascia cover panel, to a second member, such as an electric component rack module. The releasable attaching system of the current invention includes (i) a support plate that extends from a carrier portion of the fascia cover panel, (ii) an L-shaped latch extending from the rack module, and (iii) a spring clip adapted to be firmly anchored to the support plate without penetrating or otherwise damaging its surface.
The support plate extends from the edge of an opening in the carrier. It is approximately rectangular in shape and has upper and lower edges. Two shoulders are formed along the end portions of its upper edge and a ridge is formed along the center portion of its lower edge.
The spring clip has (i) two spaced apart and forwardly projecting U-shaped spring elements extending from its upper edge, (ii) a locking tab extending approximately perpendicularly from its lower edge, and (iii) a rearwardly projecting U-shaped spring element extending from the center portion of the upper edge between the two forwardly projecting spring elements.
To install the spring clip onto the support plate, the forwardly projecting spring elements are placed over the shoulders on the support plate upper edge. A force is then applied to slide the spring clip further onto the support plate until the locking tab snaps over the ridge at the bottom edge of the support plate, thereby placing the support plate between the locking tab and the forwardly projecting spring elements so as to firmly anchor the spring clip to the support plate.
To install the fascia cover panel, the latch is pressed against the rearwardly projecting spring element so as to become trapped behind a knee in the spring element. The fascia cover panel is removed by merely applying sufficient force to elastically deform the rearwardly projecting spring element so as to disengage the latch from knee.
The spring clip is replaced by merely applying sufficient pulling force to the rearwardly projecting spring element. This causes the forwardly projecting spring clip elements to elastically deform sufficiently to allow the locking tab to be released from its engagement with the ridge on the lower edge of the support plate, thereby releasing the spring clip.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded isometric view, partially schematic, of an electronic rack module and its fascia cover panel assembly employing the spring clip of the current invention.
FIG. 2 is an isometric view of the portion of the fascia cover panel carrier shown in FIG. 1 in the vicinity of the spring clip support plate.
FIG. 3 is an isomeric view similar to FIG. 2 but looking in the opposite direction.
FIG. 4 is an isometric view of the spring clip of the current invention.
FIG. 5 is a cross-section showing the spring clip being installed on the fascia cover panel carrier.
FIG. 6 is a cross-section similar to FIG. 5 showing the fascia cover panel carrier being installed on the rack module bracket.
FIG. 7 is an isometric view similar to FIG. 2 showing the spring clip installed on the fascia cover panel carrier support plate.
FIG. 8 is an isometric view similar to FIG. 7 showing the fascia cover panel carrier installed on the rack module bracket.
FIG. 9 is a cross-section through the fascia cover panel carrier and the rack module showing two spring clips in operation.
FIG. 10 is a cross-section similar to FIG. 5 showing the spring clip being removed from the fascia cover panel carrier.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is an exploded view showing a rack module 1, such that used to house electronic components in a computer, and its decorative fascia cover panel assembly 2. The fascia cover panel assembly 2 is comprised of a sheet metal carrier 4 and a molded plastic cover 3 that is attached to the carrier 4. Since the components of the spring clip system according to the current invention are formed on the carrier 4, the plastic cover 3 has been omitted from the remaining figures and the invention explained with reference to the carrier 4 only. However, it should be understood that the plastic cover 3 is attached to the carrier 4 during the assembly and disassembly operations discussed below.
Since access must frequently be gained to the rack module 1, for example for purposes of maintenance, the fascia cover panel assembly 2 is releasably attached to the rack module using the spring clip system of the current invention. Accordingly, as shown in FIG. 1, two mounting brackets 6, each of which features two L-shaped latches 14, are attached to the face of the rack module 1 using, for example, screws 22.
The carrier 4 has openings 8, one of which is shown in FIGS. 2 and 3, that are spaced so as to be aligned with each of the bracket latches 14. At each opening 8, an approximately rectangular support plate 11 extends perpendicularly from the planar surface of the carrier 4 in the direction toward the rack module 1. Each support plate 11 has a center portion 47 flanked on either side by end portions 48. In addition, the support plate 11 has a free edge at its distal end that forms a ridge 18 along the central portion 47 as well as two recessed shoulders 16 along the end portions 48. Another edge at the proximal end of the support plate 11 forms a raised ridge 20 along the center portion 47. The end portions 48 are attached to the edge of the opening 8 at their proximal ends. As explained further below, the support plate 11 forms an anchoring device for anchoring the spring clip of the current invention to the carrier 4. In addition, a tab 10 extends perpendicularly from the planar surface of the carrier 4 toward the rack module 1.
The spring clip 24 according to the current invention is shown in FIG. 4. The spring clip 24 is comprised of a center body portion 26 from which three approximately U-shaped spring elements and a locking tab 32 extend. Preferably, the spring clip 24 is formed from a material suitable for use in springs, such as heat treated beryllium copper.
The first U-shaped spring element 28 extends rearwardly from the upper edge of the spring clip body 26 and is comprised of an arcuate section 37 that extends from the center body 26 and two essentially straight legs 38 and 40 that are connected along a knee 39. Preferably, in the undeformed state, the leg 40 is not parallel to the center body portion 26 but forms an acute angle A with respect to it. In the preferred embodiment, the angle A is approximately 5°.
The second and third U-shaped spring elements 30 extend forwardly from the upper edge of the spring clip body 26 and are each comprised of a first arcuate section 42 attached to the center body, a straight leg 44, and a second arcuate edge section 46 that extends forwardly away from the center body portion 26. The leg 44 is spaced from the forward face of the center body portion 26 so as to form a retaining cavity 36.
The locking tab 32 extends forwardly from the lower edge 34 of the spring clip body 26 at an angle of approximately 90°.
The installation of the spring clip 24 onto the carrier support plate 11 is shown in FIG. 5. Initially, the spring elements 30 are placed over the shoulders 16 of the support plate 11, relying to the arcuate edges 46 to aid the spring elements 30 in slipping over the shoulders. The raised ridge 18 of the support plate 11 helps to ensure that the spring clip 24 is properly centered on the support plate during the installation process. In this position, the locking tab 32 rests against the face of the support plate center portion 47, as shown in FIG. 5.
A force F 1 is then applied, as shown in FIG. 5, that causes the spring elements 30 to elastically deform, thereby allowing the spring clip 24 to slide down onto the support plate 11. The deformation of the spring elements 30 creates a spring force F 5 that causes the locking tab 32 to be pressed against the face of the support plate 11. When the spring clip 24 has been pressed down sufficiently far onto the support plate 11, the locking tab 32 "snaps" over the ridge 20. In the installed position, the end portions 48 of the support plate 11 are enclosed within the cavities 36 of the spring clip 24, as shown in FIGS. 6 and 7. The "snapping" of the locking tab 32 over the edge of the support plate 11 provides assurance that the support plate is firmly secured between the locking tab 32 and the spring elements 30.
Preferably, the distance between the leg 44 and the spring clip center body 26--that is, the width of the cavity 36--is less than the thickness of the end portions 48 of the support plate 11 so that the spring elements 30 apply a compressive force to the support plate that ensures engagement of the locking tab 32 and stable mounting of the spring clip 24. Also, the distance between each of the apexes of the arcuate sections 42 of the spring elements 30 and the locking tab 32 is slightly less than the distance from the ridge 20 to the shoulders 16 of the support plate 11. This further ensures that the locking tab 32 will remain firmly seated against the ridge 20, thereby providing further stability in the anchoring of the spring clip 24 to the support plate 11. According to an important aspect of the current invention, the spring clip 24 is firmly anchored to the support plate 11 without penetrating or otherwise compromising its surface.
After the four spring clips 24 have been firmly anchored to the carrier support plates 11, the carrier 4 is then positioned adjacent the rack module 1 so that the spring clips are aligned with bracket latches 14, as shown in FIG. 6. A force F 2 is then applied to press the carrier 4 against the rack module 1. The latches 14 are spaced with respect to the spring clips 24 so that the latches contact the legs 38 of the spring elements 28. This causes the spring elements 28 to elastically deformed inwardly, as shown in phantom in FIG. 6, thereby allowing the latches 14 slip over the knees 39 in the spring elements.
When the installation is completed, the ends of latches 14 are disposed behind the knees 39 of the spring elements 24, as shown in FIGS. 8 and 9. This prevents the carrier 4 from being pulled away from the rack module 1 unless sufficient force is applied to again deform the spring elements 28 so that the latches 14 can slip past the knees 39 of the spring clips 24. As a consequence, the carrier 4 is securely, but releasably, attached to the rack module 1.
In the preferred embodiment, the latches 14 are spaced with respect to the spring clips 24 so that, when completely installed, the legs 40 of the spring elements 28 press against the latches so that the spring elements remain in a partially elastically deformed state, as shown in FIG. 9. Looking at the right hand spring clip 24 shown in FIG. 9, it can be seen that as a result of this interference, the latch 14, acting through the spring element 28, creates a spring force F 4 that presses the spring clip 24 against the face of the support plate 11, thereby ensuring that the locking tab 32 does not become disengaged in service.
Thus, the spring element 28 serves not only to attach the carrier 4 to the rack module 1 and to stabilize the carrier 4 in the lateral direction, as discussed below, it also acts in conjunction with the spring elements 30 to ensure that the locking tab 32 maintains its engagement with the ridge 20 and that the spring clip 24 remains firmly anchored to the support plate 11 in service.
The force F 4 also tends to drive the carrier 4 toward the left. However, the force F 4 is opposed by a similarly created force F 4 ' from the left hand spring clip 24 that tends to drive the carrier 4 to the right. As a consequence, the forces F 4 and F 4 ' tend to restrain relative movement between the carrier 4 and the rack module 1 in the direction parallel to the carrier face, thereby stabilizing the carrier 4 on the rack module 1.
As shown in FIG. 8, when the latch 14 has been captured by the spring element 28, the tab 10 rests on the latch, thereby providing vertical support for the carrier 4.
To remove the carrier 4 from the rack module 1, a sufficient pulling force is applied normal to the surface of the carrier to deform the spring elements 28 and allow the latches 14 to once again slip past the knees 39 in the spring elements.
In the event that a spring clip 24 must be replaced, one need merely apply a sufficient pulling force F 3 to the spring element 28, which forms a convenient finger grip, to elastically deform the spring elements 30, as shown in FIG. 10. This causes the center body portion 26 of the spring clip 24 to pull away from the support plate 11, thereby disengaging the locking tab from the ridge 20. According to an important aspect of the invention, the removal of the spring clip 24 is not only easily performed, but it does not in any way damage the support plate 11. Thus, the effectiveness of the replacement spring clip will not be compromised.
Although the invention has been explained with reference to the attachment of a fascia cover panel assembly to an electronic component rack module, the invention is applicable to the joining of other members, especially removable panels. Accordingly, the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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A spring clip for releasably attaching a first member, such as the carrier of a fascia panel cover, to a second member, such as an electric component rack module. The spring clip is anchored to a support plate extending from carrier. The spring clip has two forwardly extending U-shaped spring elements that cooperate with a locking tab and a rearwardly extending U-shaped spring element. Deformation of the forwardly extending spring elements during installation of the spring clip causes the locking tab to snap onto the lower edge of the support plate, thereby firmly anchoring the spring clip to the support plate. A latch extending from the rack module engages the rearwardly extending spring element so as to secure the fascia cover panel to the rack module. Application of a force to the rearwardly extending spring element causes elastic deformation of the forwardly extending spring elements and disengages the locking tab.
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FIELD OF THE INVENTION
The present invention relates to a method and a system for verifying the identity of an individual, and more particularly, a method and a system for providing enhanced identity verification security utilizing encryption and biometric techniques.
BACKGROUND OF THE INVENTION
In today's information age, the competitive edge of many companies and public trust in government institutions can depend on the security of the information held in its databases. Breaches of that security are a highly topical issue for both designers and users of database systems.
Therefore, it is desirable to provide a secure method to both identify and authenticate users of information services. Conventional biometric systems provide a partial solution to the aforementioned need. As used herein, the term “biometric” refers to the automated process of determining positive identification on the information contained within one or more of an individual's unique physiological characteristics. In general, a biometric authentication system includes a statistical model for a particular user, such as a mixture Gaussian speech model. A person is considered to be authenticated if the system provides a score below a rejection threshold. Other persons in the population, due to physiological differences, score much more poorly and likely appear outside the acceptance region. The biometric statistical model is represented using a set of statistical parameters, such as the average spectrum. The statistical parameters are typically stored in a data structure as part of a database used by the authentication algorithm. Fingerprints, hand geometry, voice pattern, retinal pattern, iris scans, signatures and others all constitute sources of unique physiological characteristic which can establish identity.
Traditional biometric systems store their biometric information in databases in an unencrypted form. There are drawbacks in storing information in such manner. Whenever information is stored in unencrypted form this situation can lead to any number of planned attacks by prospective unauthorized individuals. It may be possible, for example, for an unauthorized user to copy a parameter of an authorized user in such a way as to gain access to a system. For example, if the database was stolen by a prospective attacker, the attacker would be able to choose the most closely matching statistical model in the database and claim to be that person.
Therefore, there is a need for a system that stores biometric information in a secure manner so as to prevent the occurrence of theft and attacks from unauthorized personnel.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method and a system utilizing encrypted bio-characteristics for verifying the identity of an individual to permit access to a general database or other secured resource.
In one aspect of the invention, a method for the secure handling of data, comprising the steps of: acquiring a database of personal identifiers and data comprising repetitively: acquiring a biometric sample; acquiring a personal identifier; acquiring a password; generating a biometric model from the biometric sample; creating a first encryption key from the password; performing an encryption operation on the biometric model; storing an encrypted biometric record in a biometric database wherein the biometric record includes the encrypted biometric model and personal identifier stored in plaintext;
The method further provides means for verifying the identity of an individual to authorize access to a general database comprising the steps of: acquiring a current biometric sample; acquiring a current personal identifier; acquiring decryption key generation data; comparing the personal identifier with the database, and on a match with a personal identifier in the database; creating a decryption key from said decryption key generation data; performing a decryption operation on the retrieved biometric record utilizing the decryption key to decrypt the encrypted biometric model from the retrieved record; comparing the decrypted biometric model with the current biometric sample to determine statistical equivalence; when statistical equivalence is found verifying the individual as authorized to access the general database.
The method and system preferably further provides re-encrypting the retrieved decrypted biometric record comprising the steps of: creating a second encryption key; performing an encryption operation on said retrieved decrypted record utilizing the second encryption key; restoring the re-encrypted record in the biometric database.
According to another aspect of the invention, the encryption key is derived from a random combination of answers provided by the individual during a challenge/response session, where the system prompts the individual with a series of challenge questions. The challenge questions are preferably directed to personal information unique to each individual. An encryption key is created by concatenating a subset of the provided answers. The method, according to the present embodiment, comprises the steps of: acquiring a database of personal identifiers and data comprising repetitively: acquiring a biometric sample; acquiring a personal identifier; prompting the individual with a series of challenge questions; creating a random challenge list including a set of integers, where each random integer is an index to one of the challenge questions (i.e a pointer); concatenating those answers to challenge questions whose index is an element of the challenge list to create a first encryption key; generating a biometric model from the biometric sample; performing an encryption operation on said biometric model using the first encryption key; storing an encrypted biometric record in the encrypted biometric database wherein the biometric record includes the encrypted biometric model, wherein the encrypted answers to challenge questions. The personal identifier is preferably stored in plain text and the challenge list in plain text.
The means for verifying the individual includes means for receiving answers from individuals to questions contained in the retrieved challenge list. The answers can then be concatenated to create the decryption key to recover the biometric model.
According to a further aspect of the invention, the derivation of the secret key is made robust to mistakes in answering the challenge questions, requiring the individual to answer only m of the n challenge questions correctly (i.e. (m of n) threshold test). The present embodiment is advantageous in that the entire key is recoverable whenever any m shares of the key are available. In accordance with the present embodiment, the encryption key is divided into n-shares at an enrollment step and the biometric record is accordingly encrypted with the n-share key. At a verification step, answering any m out of n challenge questions correctly yields m-shares of the entire n-share key thereby permitting decryption of the biometric record.
The presently described embodiment provides means for verifying the identity of an individual to authorize access to a general database comprising the steps of: prompting the user for a personal identifier; comparing the personal identifier of a given individual with the database, and on a match with a personal identifier in the database retrieving the biometric record; extracting the challenge list from the retrieved biometric record and asking challenge questions whose index matches the elements (i.e. pointers) of the challenge list; combining the received answers to the challenge questions to create a decryption key; performing a decryption operation on answers along with decrypting the biometric model; generating a new challenge list randomly; and using the answers from the decrypted information to form a new encryption key. Preferably, the model and the answers are re-encrypted and stored with the new challenge list.
The re-encrypting the retrieved biometric record preferably comprising the steps of: creating a second encryption key; performing an encryption operation on said retrieved decrypted record utilizing the second encryption key; restoring the re-encrypted record in the biometric database.
The system may optionally provide the individual who fails in the biometric portion of the test an additional opportunity by asking additional questions in a second challenge/answer session.
According to yet a further aspect of the invention, derivation of the (m,n) thresholding scheme, as described above, is further modified whereby the challenge questions may incorporate some aspect of the individuals biometric. For example, in contrast to the previous aspects where the challenge questions were all directed to personal information such as social security number or address, for example, the present embodiment incorporates certain aspects of the individual's biometric, such as a challenge question directed to an aspect of the individual's biometric stated as: “How large is your hand?”, or “Is your voice more like person A or B?”.
In a yet further embodiment, the biometric record is encrypted with a large randomly generated encryption key. The large key is chosen once for each biometric record and not updated. The large key is used to encrypt the biometric record, and then the key is encrypted with a second, smaller encryption key derived from user supplied data as described by previous embodiments. This embodiment further contemplates using two databases. A first database would store the biometric model and personal information from the challenge/response part of the enrollment, encrypted with the large key. A second database would store the large key, encrypted by the smaller second key. The present embodiment is advantageous in that only the large encryption key needs to be re-encrypted at each authorization session rather than the entire database record.
These and other advantages of the invention will become more fully apparent when the following detailed description of illustrative embodiments thereof, which is to be read in conjunction with the accompanying drawings in which the same reference numerals are used throughout the various figures to designate same or similar components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are diagrams illustrating the process steps associated with enrollment and authorization in a biometric database in accordance with the teachings of the prior art.
FIG. 3 is a general block diagram of the organization of a biometric database according to the present invention.
FIGS. 4 a and 4 b are system diagrams illustrating process steps associated with enrollment and authorization according to the present invention.
FIG. 5 is a flowchart illustrating method steps associated with enrolling an individual in accordance with a biometric authentication system according to the present invention.
FIG. 6 is a flowchart illustrating method steps associated with authenticating an individual in accordance with an illustrative embodiment of a biometric authentication system according to the present invention.
FIGS. 7 a and 7 b illustrate process steps associated with enrollment and authorization in accordance with an alternative biometric authentication system according to the present invention.
FIG. 8 is a flowchart illustrating method steps associated with enrolling an individual in accordance with an alternative biometric authentication system according to the present invention.
FIG. 9 is a flowchart illustrating method steps associated with authenticating an individual in accordance with an alternative biometric authentication system according to the present invention.
FIGS. 10 a and 10 b illustrate process steps associated with enrollment and authorization according to another alternative embodiment of the present invention.
FIG. 11 illustrates process steps associated with enrollment in accordance with another alternative embodiment of a biometric authentication system according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As used herein, the term “biometric” means any physiological characteristics containing information which is unique for an individual. Example biometrics are a person's fingerprint or irises.
In prior art biometric systems, individuals seeking enrollments are prompted by the system to provide a personal identifier and a biometric sample from which a corresponding biometric record is created and stored as part of the biometric database.
During verification, any individual from the general population seeking access to the general database is prompted by the system to supply a personal identifier which is used to find a matching biometric record. If a matching record is found, the system further prompts the individual for a current biometric sample. The current biometric sample is compared to the stored biometric sample contained as part of the matched record to determine the degree of statistical equivalence. If the equivalence score exceeds some threshold, the individual will be considered authorized to access the general database.
Referring now to FIGS. 1 and 2, which illustrate the detailed process steps of enrollment and verification in accordance with the prior art. It is to be appreciated that once all individuals have been enrolled, the biometric database is considered to be fully constructed. As previously generally described, during enrollment each individual 270 seeking enrollment supplies personal identification data 272 and a biometric sample 274 . The biometric sample 274 may include, for example, a fingerprint, iris, or retinal pattern. It will be obvious to those skilled in the art that the biometric sample may be any one of a number of standard bio-characteristics. The personal identifier is preferably, a name or other non-secret identifier, to be later used during verification as an index to find a matching database record. For each individual 272 wishing to enroll, a single biometric record 278 is created including his or her created biometric model 276 along with the provided identifier 272 . The biometric record is stored in the database 280 along with similarly created biometric records.
Having created the biometric database at the enrollment step, any individual from the general population seeking access to the general database must first be verified (i.e. authorized to gain access to the general database) by the system. It is to be appreciated that only previously enrolled individuals may potentially be authorized by the system at a verification session. The biometric database facilitates the verification process.
A verification session is said to occur each time any individual seeks access to the contents of the general database. The process of verifying an individual so as to authorize his or her access to the general database includes: prompting the individual for a personal identifier 282 to be used as a retrieval index to find a database record 284 with a matching personal identifier. Failure to find a matching identifier will result in declaring the individual unauthorized thereby terminating the verification session. If, however, a matching biometric record 284 is found, the individual 270 is further prompted to provide a current biometric sample 286 . For example, an individual may be prompted to provide a handwriting, speech, or fingerprint sample. Note that the provided sample must be of the same type as that requested during enrollment. A statistical equivalence test 288 is performed comparing the individuals provided biometric sample 286 with the biometric model 284 contained as part of the retrieved matching record and a threshold score is generated from the comparison. Based on the threshold score an accept/reject decision 290 is made to determine whether the individual is determined to be who he claims to be.
It is to be appreciated that the conventional biometric system illustrated in FIGS. 1 and 2, is vulnerable to attacks. Specifically, if the database was stolen by a prospective attacker, the attacker would be able to choose the most closely matching statistical model in the database and claim to be that user. This vulnerability is a direct consequence of storing the biometric data in unencrypted form.
Referring now to FIG. 3, which illustrates a block diagram of a biometric authentication system in accordance with the teachings of the present invention. Each individual 310 seeking enrollment is prompted to provide enrollment data including a biometric sample, a personal identifier and encryption key generation data. An encrypted biometric record 330 is created for each enrolled individual and stored as part of the biometric database 340 .
Once all users have been enrolled, the encrypted database is used at subsequent verification sessions to verify the authenticity of any individual who desires access to the general database 360 . The details of which will be provided below. It is to be appreciated that the present invention is usable with any general database, and is not, in any way, limited to use with or dependent on any details (e.g. contents) or methodologies of a particular database configuration. It should also be appreciated that the elements shown throughout the figures may be implemented in various forms of hardware, software, or combinations thereof.
FIG. 4 a shows illustrative steps associated with enrolling a plurality of individuals in the encrypted biometric database 340 in accordance with an embodiment of the present invention. It should be appreciated that a separate and distinct encrypted biometric record is created for each individual wishing to enroll. FIG. 4 a describes the enrollment process for a single individual. Specifically, block 10 illustrates three inputs supplied by an individual wishing to enroll; a biometric sample (S) 12 , a password (P) 14 , and a personal identifier (I) 16 . The personal identifier (I) may, for example, be the individuals name or an equivalent identifying string. Alternate embodiments may forego the identifier (I) input whereby the system would, instead, perform an exhaustive search using the password (P) as an index against every record in the database seeking a successful decryption.
The three inputs are preferably entered into the system as speech patterns via microphone means. Other embodiments, however, may consider alternate means. For example, with specific reference to the biometric sample (S) input means may include fingerprint readers, hand geometry readers, retinal scanners, DNA readers, dynamic signature readers , and other biometric input apparatus known in the art. Further, while FIG. 4 a describes the biometric sample (S) 12 being provided as a separate and distinct input, it is to be appreciated that the sample may be derived as a by-product of an individuals responses to other system prompts. For example, the password input response may be used to implicitly derive the biometric sample (S). The capability to implicitly derive the biometric sample holds true for the present embodiment and for all other contemplated embodiments discussed herein.
At block 18 a biometric model (T=f(S)) is created from the biometric sample (S). At block 17 , An encryption key (k) is created from the password (P) input. The encryption key (k) is provided as input to a symmetric key encryption algorithm, at block 20 to encrypt the biometric model (T). The particular encryption algorithm selected is not critical for purposes of the present invention, however, it is preferred that the algorithm be a secret key (symmetric), such as data encryption standard (DES) and not a public key algorithm.
Referring now to FIG. 4 b , once the biometric model has been encrypted, the encryption key (k) is discarded by the system. That is, it is not stored for later use, but rather re-generated, at block 31 , during verification from a user supplied input, password (P′) at block 30 .
Further, as is well known in the art, encryption systems that use a password to encrypt data typically employ “salt”, which is the addition of some random information that is added to the material to be encrypted. This serves to prevent identical information, possibly from different users, from encrypting to the same result. Both the salt and the resulting encrypted message are stored together. With respect to all embodiments discussed herein, the optional addition of “salt”, wherever appropriate, is within the scope of the present invention.
Referring again to FIG. 4 a , a single biometric record is stored for each individual at block 22 . The record includes a personal identifier input (I), stored as plaintext, and an encrypted biometric model (E k (T)). It is to be appreciated that the present invention is not limited to storing only the data elements defined by the various embodiments. The record may be comprised of whatever additional encrypted or unencrypted information the system designer deems necessary, which may be more or less information than that described herein.
Referring now to FIG. 4 b , a block diagram illustrates the process steps associated with a verification session. The focus of verification is to verify the identity of any individual desiring access to the general database. Verification presumes the prior creation of an encrypted biometric database. The block/flow diagram steps illustrated at FIG. 4 b are performed each time an individual's identity must be verified by the system to either grant or deny him or her access to the database.
In block 26 an individual seeking access to the database is prompted for a personal identifier (I). The system will attempt to match the personal identifier (I) with one of the personal identifiers (I) stored in plaintext as a component of each encrypted biometric record. If no matching record is found the individual cannot be verified and his authorization status will be declared as “failed”. If, however, a matching record is found, an encrypted biometric record with matching personal identifier (I) will be retrieved. At block 30 , the individual is then further prompted to provide a password (P′). The system uses the password (P′) to create decryption key (k′) at block 31 . The encrypted biometric record will be successfully decrypted only if the password (P′) is identical to the password (P), and thus the identical key used to initially encrypt the record.
The decryption key (k′), block 31 , is provided as input to a standard decryption algorithm at block 38 . The particular decryption algorithm is not critical for purposes of the present invention, and as such, any decryption algorithm known in the art may be used. It is only required that the decryption algorithm be a secret key and not a public key algorithm. The retrieved encrypted biometric record at block 33 is provided as input to the decryption algorithm, along with the decryption key (k′) where an attempt is made to decrypt the retrieved biometric record. If the decryption is unsuccessful, the individual cannot be verified and his or her authorization status will be declared as “failed”, thereby terminating the verification session. Otherwise, if the decryption of the encrypted biometric record is successful, a decrypted biometric model (T) is extracted from the decrypted biometric record at block 40 . In block 32 , an individual is further prompted to provide a current biometric sample (S′). The provided biometric sample (S′) must be of the same type requested at enrollment (See block 12 at FIG. 4 a ). At block 42 , the provided biometric sample (S′) is compared with the decrypted biometric model (T) for statistical equivalence and a statistical equivalence score is generated therefrom. The higher the computed score the higher the statistical equivalence. At block 44 , if the score is above some predetermined accept/reject threshold the individuals authorization status is declared as “failed”. Otherwise, an acceptable score will result in authorizing the individual 26 access to the database.
FIG. 5 is a flowchart illustrating the method steps associated with enrollment in accordance with the first embodiment. The method steps described at FIG. 5 correspond to the process blocks illustrated in FIG. 4 a . At step 52 an individual is prompted for a biometric sample (S). From the provided sample, the system constructs a biometric model, T=f(S), at step 54 . At step 56 , an individual is prompted for a personal identifier (I). At step 58 , an individual is prompted for a password (P). At step 60 , an encryption key (k) is created from the provided password (P). At step 62 , the encryption key (k) is used in conjunction with a standard secret key algorithm to encrypt the biometric model (E k (T)). At step 64 , a biometric record is created including; the encrypted biometric model, the personal identifier in plaintext, {I,E k (T)}. At step 66 , the enrollment session is considered complete for that individual 26 . Step 67 is a decision step to determine if there are other individuals wishing to be enrolled in the system. If so, the process returns to step 52 , otherwise the database is considered as fully constructed. It is to be appreciated that although the process step as illustrated in FIG. 5 is explained for enrollment of a single user, the system according to the present invention is capable of enrolling multiple users at the same time, or preferably, by interleaving enrollment sessions and authentication sessions.
FIG. 6 is a flowchart illustrating the method steps associated with verification in accordance with the first embodiment. The method steps described at FIG. 6 correspond to the block diagram illustrated in FIG. 4 b . At step 74 an individual 26 is prompted by the system for a personal identifier (I). At step 76 , the system will attempt to match the provided identifier with personal identifiers stored as part of each biometric record. Step 78 is a decision step to determine whether biometric record was found with a matching personal identifier. If not, the authorization session terminates at step 79 where the individual cannot be verified and his authorization status is declared as “failed”. Otherwise, if a matching biometric record is found, the encrypted biometric model, E k (T), will be retrieved. At step 82 , an individual is further prompted by the system to provide a password (P′). At step 84 , the system will create a decryption key (k′) from the password (P′). At step 86 , the decryption key (k′) is used in conjunction with a standard decryption algorithm to attempt to decrypt the retrieved biometric record. Step 88 is a decision step to determine whether the decryption was successful. If not, the verification status terminates at step 89 , with the authorization status being declared as “failed”. Otherwise, the retrieved biometric model is successfully decrypted and extracted from the record. At step 90 , the individual is further prompted to provide a current biometric sample (S′). The sample type must correspond to the sample provided at enrollment. At step 92 , the provided sample is compared with the decrypted biometric model (T) for statistical equivalence. A statistical equivalence score is generated from the comparison. The lower the computed score the higher the statistical equivalence. Step 93 is a decision step to determine if the computed score is acceptable. If not, the process terminates at step 91 , where the users authorization status is declared as “failed”. If, however, an acceptable score will result in granting the individual access to the database at step 94 . Step 96 is a decision step to determine whether the individual has finished accessing the database, if not the process loops until such time.
As explained in FIG. 5 for enrollment of users, the illustrative system according to the present invention is capable of verifying multiple users by interleaving enrollment sessions.
If the individual changes his password, a new encryption key will be created at step 98 . The database record will then be re-encrypted using the newly created encryption key in conjunction with a standard encryption algorithm at step 100 . The process terminates at step 102 .
It is readily apparent to one skilled in the art that biometric systems are vulnerable to a “playback” attack where intruders record and playback a valid user's authentication data. According to another illustrative embodiment of the present invention, a key is derived from a randomly chosen subset of answers obtained as a result of conducting a challenge question/answer session with the individual. The details of which will be provided below.
Referring to FIG. 7 a , a block/flow diagram is shown of an enrollment process according to another embodiment of the present invention. An individual wishing to enroll in the database (block 750 ) provides inputs including a biometric sample (S) and an identifier (I). In process block 762 a biometric model, T=f(S), is created from the biometric sample (S). In process block 757 the individual is prompted with a series of challenge questions, {q1,q2, . . . ,qn}. The challenge questions are a series of system prompts, preferably regarding personal information. For example, the individual may be prompted to provide answers to questions directed to personal information concerning that individual's zip code, telephone number or birth date. At block 758 , the answers to the challenge questions are recorded by the system, {a1,a2, . . . ,an}. In block 759 , a random number generator generates m random values, where m is some positive integer value less than the total number of challenge questions (Q1-Qn) posed to the user at block 757 . The m random numbers generated at block 759 are supplied to block 760 to form a challenge list, {i1,i2, . . . im}. The challenge list is supplied to block 766 along with the challenge answers, provided by block 758 , to generate the encryption key (k). At block 766 , the encryption key (k) is generated by concatenating those challenge answers from block 758 whose index match the elements in the challenge list. For example, assume that the m randomly generated integers that comprise the challenge list consist of 4 elements { 2 , 4 , 7 , 9 ). In actual operation, the number of integers in the challenge list can be any number m where(m<n). For the present example, challenge answers with index 2 , 4 , 7 , and 9 would be concatenated to form the encryption key, k=a2¦a4¦a7¦a9.
Prior to forming the encryption key (k), the concatenated answers are preferably first hashed using any well known hashing algorithm. The hashed result then becomes the encryption key (k) which is used to encrypt both the biometric model (T) and the full set of answers {a1,a2, . . . an}. At block 764 , the biometric model (T) is encrypted using the generated encryption key as input to an encryption algorithm. The particular encryption algorithm is not critical for the purposes of the present application, therefore any known encryption algorithm in the art may be used at block 764 . The biometric model and the full set of answers are combined and encrypted E k ((a1,a2, . . . an), T) as part of the biometric record at block 769 . The biometric record is therefore comprised of the personal identifier and challenge list in plaintext, along with the encrypted answers and biometric model;
{I, {i1, . . . ,im},E k ({a1,a2, . . . an}, T)}
A single instance of the full set of challenge questions {q1,q2, . . . qn} can be preferably stored in a separate part of the database in unencrypted form to conserve memory. It is to be appreciated that storing the challenge questions in unencrypted form will not compromise the integrity of the database.
Referring now to FIG. 7 b , a system block diagram is illustrated describing the process steps for an authorization session in accordance with the present embodiment. An individual seeking authorization at block 770 is prompted to provide a personal identifier (I) at block 772 . The provided personal identifier is used to find a matching record in the database. If a matching biometric record is found, two items from the matching record will be retrieved. The first item retrieved, at block 782 , is the challenge list. The second item, the encrypted biometric model and challenge answers, is retrieved at block 784 . At block 776 , the system initiates a challenge question/answer session with the individual seeking authorization by asking those challenge questions from enrollment whose index match the elements of the retrieved challenge list. For example, if the retrieved challenge list consists of elements (1,5,6) then the system would challenge the individual with challenge questions x 1,5 and 6. At block 776 , the system then creates a decryption key (k′) by concatenating the individual's responses to the challenge questions. At block 786 , the generated decryption key (k′) is provided as input to a standard decryption algorithm in an attempt to decrypt the retrieved encrypted biometric model (T). It is important to note that if the individual provides a single incorrect answer the resulting decryption key will not successfully decrypt the record thereby resulting in the users authorization status being declared as failedY. If, however, the individual provides all correct responses to the challenge questions the record will be successfully decrypted at block 788 . The individual will then be further prompted to provide a current biometric sample (S) at block 778 . The current biometric sample (S) is then compared with the decrypted biometric model (T) at block 790 for statistical equivalence and a statistical equivalence score is generated therefrom. The higher the computed score the higher the statistical equivalence. At block 792 , if the score is more than some predetermined accept/reject threshold the individuals authorization status is declared as “failed”. Otherwise, an acceptable score will result in the individual being verified and as such granting that individual access to the database. Prior to re-storing the record in the database, a new encryption key is generated for the purpose of re-encrypting the retrieved record. The new encryption key is created by generating a new challenge list by randomly generating a new set of m integers and forming a challenge list therefrom. It is to be appreciated that each time a record is retrieved, the record will be re-encrypted with a new encryption key prior to restoring that record in the biometric database. In addition, a new challenge list will replace the old challenge list and also stored as part of the re-encrypted record.
FIG. 8 is a flowchart illustrating the method steps associated with enrolling a user in the database in accordance with the present embodiment. At step 812 an individual who wishes to be enrolled is prompted to provide a current biometric sample (S). At step 814 a biometric model or template (T) is constructed from the provided biometric sample (S). At step 816 an individual is further prompted for a personal identifier (I). At step 818 , an individual is further prompted with a series of challenge questions, {q1,q2, . . . ,qn} as described above. The answers to the challenge questions {a1,a2, . . . an) are recorded by the system. At step 820 , a challenge list is created. The challenge list is a randomly generated list of m integers, where m is less than the number of challenge questions, where each element of the challenge list is an index to one of the challenge questions {a1,a2, . . . an) posed to the user at block 818 . At step 822 , an encryption key is created by concatenating those answers to challenge questions whose index matches an element of the challenge list. At step 824 , the created encryption key is used to encrypt both the biometric model (T) and the full set of challenge answers. The encryption is performed using any standard secret key encryption algorithm (e.g. DES). At step 826 , an encrypted biometric database record is then created including an encrypted biometric model along with the encrypted challenge answers. In addition, the record further includes the personal identifier (I) and the challenge list {i1,i2, . . . ,in) in plain text. Step 830 is a determination step to ascertain whether there are additional individuals to be enrolled in the database. If so, the process loops back to step 812 to enroll another individual. Otherwise, the process is considered complete at step 832 .
In an alternate embodiment, should the system declare the individual as unauthorized due to an insufficient match in the biometric, the additional knowledge contained in the database from the current challenge and answer portion could be used to establish another challenge and response session based on the questions not yet asked, and this can be used to bypass or update the biometric model once sufficient information is received to verify the target's identity. If, however, the answers in the challenge set are incorrect, the record cannot be decrypted and further questions cannot be asked.
FIG. 9 is a flowchart illustrating the method steps associated with authorizing an individual in accordance with the present embodiment. At step 842 an individual is prompted for a personal identifier (I). At step 844 , the system will attempt to retrieve a biometric record from the database with a personal identifier (I) that matches the personal identifier (I) provided by the individual seeking verification. Step 846 is a decision step to determine if the match was successful. If not, the individual cannot be verified and his or her authorization status is considered as “failed”. The verification session terminates at step 864 . Otherwise, if a matching record is found, the challenge list, stored as plaintext, is extracted from the record. At step 850 , the system initiates a challenge question/answer session with the individual. That is, the system prompts the individual with challenge questions whose index matches one of the elements of the challenge list. For example, if the extracted challenge list consists of elements (1,5,6) then the system would challenge the individual with challenge questions 1,5 and 6. At step 852 , the system then creates a decryption key by concatenating the answers provided by the user. It is to be appreciated that any one incorrect response at step 852 will result in the creation of a decryption key different from that used to encrypt the record at enrollment thereby resulting in disallowing the individual's authorization to access the database. At step 854 , the decryption key is used in an attempt to decrypt the encrypted portion of the retrieved record. Step 856 is a decision step to determine whether the decryption was successful. If not, at step 864 , the individual cannot be verified and his authorization status is considered “failed”. The verification session then terminates at step 874 . Otherwise, at step 858 , the individual is prompted to provide a current biometric sample (S). At step 860 , the current biometric sample (S) is compared with the decrypted biometric model for statistical equivalence. The lower the computed score the higher the statistical equivalence. At decision block 862 , if the score is less than some predetermined accept/reject threshold the individual is disqualified on the statistical grounds at step 864 , and the process terminates at step 864 . Otherwise at step 866 , the individual is authorized and granted access to the database. Step 868 is a decision step to determine if the individual has finished accessing the database. The process loops until such time. Prior to re-storing the record in the database, a new encryption key is generated at step 870 . The new encryption key is created by randomly selecting a different random set of questions from the set of challenge questions thereby forming a new challenge list. The previously provided answers whose index match the elements of the new challenge list are then concatenated to create a new encryption key for the purpose of re-encrypting the retrieved record prior to restoring it in the database.
According to another embodiment of the present invention, tolerance is given to mistakes in answering the challenge questions. In this embodiment an m out of n question threshold test is established whereby if an individual answers any m questions correctly out of a list of n challenge questions the encryption key can be re-generated from the correctly answered questions. This differs from the previous embodiment whereby an individual was required to answer each and every challenge question correctly, and failing to do so resulted in a defective decryption key. That is, a decryption key that is not identical to the encryption key used to encrypt the record.
The motivation for such the (m,n) threshold test of the present embodiment arises from the fact that an individual for one reason or another may have failed to correctly recall certain personal information, or information may have changed from the point in time it was first stored in the system at the enrollment period. This embodiment considers these and similar situations to give the individual an additional opportunity to successfully satisfy the challenge and answer session.
Referring to FIG. 10 a , a block/flow diagram is shown of the enrollment process according to the present embodiment of the present invention. In block 1000 , an individual wishing to enroll in the database is shown. The individual provides as input a biometric sample (S) and a personal identifier (I) 1120 . In process block 1040 a biometric model, T=f(S), is created from the provided biometric sample (S). In process block 1100 the individual is prompted with a series of challenge questions, {q1,q2, . . . ,qn}, similar to that described in the previous embodiment. The answers to the challenge questions are recorded by the system, {a1,a2, . . . an} at block 1260 . The challenge answers are encrypted at block 1060 and included as part of the biometric record at block 1200 . In block 1220 , a random number generator generates m values, where m is some positive integer value less than the total number of questions posed to the user at block 1100 , (m<n). The m random numbers generated at block 1220 are supplied to block 1240 to form a challenge list, {i 1 ,i 2 , . . . i m }. Each member of the challenge list is an index to one of the challenge questions posed to the user at block 1100 . The challenge list is both stored in unencrypted form as part of the biometric record at block 1200 , and further supplied to block 1180 to select answers those challenge answers from block 1260 whose index corresponds to the elements of the challenge list. For example, if the user answered ten challenge questions, and assuming that the random number generator generated m=3 values {3,5,6}, then challenge answers {3,5,6} would be combined at block 1180 .
In block 1140 , a random encryption key (k) is generated and provided as input to the encryption algorithm at block 1060 , and further provided at block 1160 . Block 1160 describes a process whereby the randomly generated encryption key (k) is broken into n-shares. The n-shares of the key will then be provided as input to block 1180 where each individual share of the key will be combined with one of the n challenge questions. The challenge answers are preferably combined with the n-shares of the key by an exclusive-or operation, however, other embodiments may define the method of combining the shares by any means familiar to those of ordinary skill in the art.
At block 1040 , the biometric model (S) is encrypted T=f(S), using any encryption algorithm, well known in the art. The encryption algorithm generates an encrypted biometric model, E k (T), is generated at block 1080 and stored as part of the biometric record at block 1200 . Referring now to FIG. 10 b , a system block diagram is illustrated describing the process steps associated with verification in accordance with the present embodiment. The individual seeking verification at block 130 provides an identifier (I) at block 132 . At block 140 the biometric database will be searched to find a matching record using the identifier (I) input as an index. If a matching biometric record is found, two items from the matching record will be retrieved. Block 142 describes the first retrieved item, the challenge list. The challenge list is provided as input to block 134 where the system initiates a challenge/response session with the individual seeking authorization. At block 134 , the individual will be asked challenge questions whose index correspond to the elements of the challenge list. At block 148 , the individual's responses to the challenge questions are combined using exclusive-or with the m-shares of the encryption key. At block 148 the “A” and “B” inputs from blocks 146 and 136 respectively, are then combined to form decryption key (k′). It is to be appreciated that if the individual answers less than m questions correctly, the resulting decryption key (k′) will not be capable of successfully decrypting the record.
In the situation where the user answers at least m of n questions correctly, the full decryption key (k′) can be re-generated and will be used to successfully extract the decrypted biometric model (T) at block 150 . At block 154 , the decrypted biometric model will then be compared with the current biometric sample (S) provided by the user at block 138 for statistical equivalence and a statistical equivalence score is generated therefrom. The lower the computed score the higher the statistical equivalence. At block 158 , if the score is more than some predetermined accept/reject threshold the individuals authorization status is declared as “failed”. Otherwise, an acceptable score will result in granting the individual 130 access to the general database.
Prior to re-storing the record in the database, a new encryption key and/or new challenge list is generated for the purpose of re-encrypting the retrieved record prior to restoring it in the database.
Alternatively, the biometric, or portions thereof, is utilized as part of the challenge question/answer portion of an authorization session. In other words, some or all of the questions/answers can be derived from the biometric. By their nature, biometric measures are statistical and thus prone to errors during measurement. In addition certain parameters which comprise the biometric inevitably change with time while other biometric parameters remain relatively constant over time. Therefore, utilizing those parameters which are not susceptible to variation with the thresholding challenge and response scheme can be comprised of questions directed to that variation. For example, typical questions might include; 1) How large is your hand 2) How many whirls do you have in your fingerprint 3) Is your voice more like person A or person B. Note that the series of biometric oriented questions does not subsume the biometric equivalence test performed at block 156 of the previous embodiment. Rather, the nature of the biometric questions posed in the challenge question/answer portion would typically be of a less detailed nature and much smaller in overall scope than that performed by the succeeding biometric equivalence test.
As an alternative to using individual information such as password or challenge answers to encrypt the database record, as described heretofore above, a randomly chosen key can be used instead to encrypt the records. These keys will preferably contain a large number of bits, larger than the number of bits attainable by using user supplied information (e.g., passwords, challenge answers) thereby providing security advantages as a result. These large keys may then be stored in a separate database in encrypted form, using user supplied information (e.g., passwords, challenge answers) to encrypt the keys. It is to be appreciated that the present embodiment creates a layer of indirection that is advantageous in that only the large keys need to be re-encrypted at the conclusion of each authorization session rather than the entire database record.
Referring now to FIG. 11, in block 160 , an individual wishing to enroll in the database is shown. The individual provides as input a biometric sample (S) 166 , and an identifier (I) 168 . In process block 176 a biometric model, T=f(S), is created from the provided biometric sample (S). In process block 162 the individual is prompted with a series of challenge questions, {q1,q2, . . . ,qn}, similar to that described in the previous embodiments. The answers to the challenge questions are recorded by the system, {a1,a2, . . . ,an} at block 170 . The challenge answers are provided as output to both blocks 178 and 175 . At block 178 the challenge answers are encrypted and included as part of the biometric record at block 186 . At block 175 , the challenge answers are provided from block 174 .
The challenge list at block 174 is created in a manner similar to that described above. A random number generator, block 164 , generates m values, where m is some positive integer value less than the total number of questions posed to the user at block 162 , (i.e. “n”). The m randomly generated numbers are supplied to block 174 to form a challenge list, {i 1 ,i 2 , . . . i m }. As previously stated, each member of the challenge list is used as an index to one of the questions posed to the user at block 162 .
At block 175 , the challenge answers are concatenated using the challenge list as previously described to create encryption key k 2 . This key is then provided as input to the encryption algorithm at block 180 where it will be used to encrypt a larger randomly generated encryption key, k 1 at block 172 .
Subsequent to encrypting key k 1 with key k 2 , the encrypted key k 1 is preferably stored in a separate database, database 2 along with the challenge list. It is to be appreciated that the large random key, k 1 , is created once and never updated. By contrast, encryption key, k 2 , can be updated by choosing a new challenge list after each successful authorization session.
Although illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be affected therein by one skilled in the art without departing from the scope or spirit of the invention.
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A method of performing biometric authentication of a person's identity including a biometric template prior to storing it in a biometric database. The encryption algorithm encrypts the biometric template using a pass-phrase, known only to the individual, to generate the cryptographic key used to store and retrieve the biometric template. When an individual wishes to access a secured resource, he must be authenticated by providing an identifier which is used to retrieve the appropriate record. He must also provide the correct password to allow the system to decrypt the model.
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TECHNICAL FIELD
The present invention relates to a construction machine.
BACKGROUND ART
In the past, there has been proposed a so-called hybrid construction machine that generates power by the drive of an engine, stores the generated power in an electrical storage device, and assists the drive of the engine using the stored power. For example, a generator, an electrical storage device, and an inverter, which controls charge and power supply between these, are closely disposed in a centralized configuration in a construction machine disclosed in the following PTL 1, so that the lengths of wires connecting electrical devices are short.
CITATION LIST
Patent Literature
[PTL 1] JP-A-2004-169466
SUMMARY OF INVENTION
Technical Problem
However, actually, there is a case where the respective electrical devices cannot be closely disposed in a centralized configuration. For this reason, it is hoped that wires for connecting electrical devices, which cannot be closely disposed in a centralized configuration as described above, can be safely disposed.
Accordingly, an object of the invention is to provide a construction machine where the safety of wires is improved.
Solution to Problem
A construction machine of the invention includes an engine, power generation means for generating power by the drive of the engine, storage means for storing the power generated by the power generation means, and electric drive means that is driven by the power from the storage means. High voltage cables, which connect the power generation means or the electric drive means to the storage means and through which power is supplied, are wired along a side surface of a frame structural member that protrudes in a vertical direction.
According to the construction machine of the invention, since the high voltage cables are wired along the side surface of the frame structural member protruding in the vertical direction, the frame structural member becomes an upright wall, so that the high voltage cables are adequately protected. Accordingly, for example, even when the construction machine collides with an obstruction or the like, the high voltage cables are adequately protected by the frame structural member. As a result, safety is improved.
Here, the high voltage cables, which are wired along the side surface of the frame structural member, may be specifically high voltage cables between the power generation means and an inverter that is connected to the storage means and controls the power generation means or high voltage cables between the electric drive means and an inverter that is connected to the storage means and controls the electric drive means.
Further, the frame structural member may be an A-frame that supports a boom for work so as to allow the boom for work to be capable of moving up and down, and the high voltage cables may be wired along an inner side surface of the A-frame. When this structure is employed, the high voltage cables are adequately protected by the A-frame having high rigidity, so that it is possible to improve safety. In addition, for example, even when the construction machine collides with an obstruction or the like, the A-frame is separated from a collision portion since it is disposed at a central portion. Accordingly, the high voltage cables are more adequately protected.
Moreover, the frame structural member may be a side frame that forms an end portion of a base frame and forms a closed cross-sectional space, and the high voltage cables may be wired so as to pass through the side frame. Since the high voltage cables pass through the side frame that has high rigidity and forms a closed cross-section when this structure is employed, the high voltage cables are adequately protected, so that safety can be improved. Further, since the side frame surrounding the high voltage cables blocks electromagnetic waves as described above, electromagnetic shielding performance can be improved.
Advantageous Effects of Invention
According to the construction machine of the invention, it is possible to adequately protect high voltage cables and to improve safety.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view showing the appearance of a construction machine according to a first embodiment of the invention.
FIG. 2 is a block diagram showing the internal structure of an electrical system, a hydraulic system, and the like of the construction machine shown in FIG. 1 .
FIG. 3 is a circuit diagram showing the internal structure of storage means shown in FIG. 2 .
FIG. 4 is a perspective view showing a house portion of a revolving body shown in FIG. 1 .
FIG. 5 is a cross-sectional view showing a state where a capacitor box of storage means is installed in the house portion.
FIG. 6 is a perspective view showing wires of high voltage cables, which connect a revolving electric motor to an inverter circuit thereof, together with a base frame, an A-frame, and components in a right front portion of the house portion, and is a perspective view as seen from the rear upper side of a left portion of a vehicle.
FIG. 7 is a perspective view of FIG. 6 as seen from the rear upper side of a right portion of a vehicle.
FIG. 8 is a plan view of FIGS. 6 and 7 .
FIG. 9 is a perspective view showing wires of high voltage cables, which connect an electric generator to an inverter circuit thereof, together with a base frame, an A-frame, and components in a right front portion of the house portion, and is a perspective view as seen from the rear upper side of a left portion of a vehicle.
FIG. 10 is a perspective view of FIG. 9 as seen from the rear upper side of a right portion of a vehicle.
FIG. 11 is a plan view of FIGS. 9 and 10 .
FIG. 12 is a view taken along line XII-XII of FIG. 11 .
FIG. 13 is a perspective view showing main portions of a construction machine according to a second embodiment of the invention, is a perspective view showing wires of high voltage cables, which connect an electric generator to an inverter circuit thereof, together with a base frame, A-frames, and components in a right front portion of a house portion, and is a perspective view as seen from the rear upper side of a left portion of a vehicle.
FIG. 14 is a perspective view of FIG. 13 as seen from the rear upper side of a right portion of a vehicle.
FIG. 15 is a plan view of FIGS. 13 and 14 .
FIG. 16 is a block diagram showing the internal structure of an electrical system, a hydraulic system, and the like of a construction machine according to another embodiment.
DESCRIPTION OF EMBODIMENTS
Preferred embodiments of a construction machine according to the invention will be described below with reference to the drawings. Meanwhile, the same elements in the description of the drawings are denoted by the same reference numerals, and repeated description thereof will be omitted.
FIG. 1 is a perspective view showing the appearance of a construction machine according to a first embodiment of the invention. The construction machine of this embodiment is a so-called hybrid construction machine, and a lifting magnet vehicle as an example of the construction machine is shown.
As shown in FIG. 1 , a lifting magnet vehicle 1 includes a traveling mechanism 2 that includes caterpillar tracks and a revolving body 4 that is rotatably mounted on the traveling mechanism 2 with a revolving mechanism 3 interposed therebetween. A boom 5 for work, an arm 6 link-connected to an end of the boom 5 , and a lifting magnet 7 link-connected to an end of the arm 6 are mounted on the revolving body 4 . The lifting magnet 7 is apiece of equipment that attracts a load G such as steel material by a magnetic force so as to catch the load. The boom 5 , the arm 6 , and the lifting magnet 7 are hydraulically driven by a boom cylinder 8 , an arm cylinder 9 , and a bucket cylinder 10 , respectively.
Further, the revolving body 4 is provided with an operator's cab 4 a and a house portion 4 b . The operator's cab 4 a accommodates an operator who adjusts the position of the lifting magnet 7 and performs an exitation operation and a release operation of the lifting magnet. The house portion 4 b accommodates a power source, that is, an engine 11 (see FIG. 2 ) that is a power source for generating hydraulic pressure, and the like. The engine 11 is formed of, for example, a diesel engine.
FIG. 2 is a block diagram showing the internal structure of an electrical system, a hydraulic system, and the like of the construction machine shown in FIG. 1 , and the structure is a so-called parallel type. Meanwhile, in FIG. 2 , systems mechanically transmitting power are shown by double lines, a hydraulic system is shown by a thick solid line, a control system is shown by a broken line, and an electrical system is shown by a thin solid line. Further, FIG. 3 is a diagram showing the internal structure of storage means 120 shown in FIG. 2 .
As shown in FIG. 2 , the lifting magnet vehicle 1 includes an electric generator (power generation means) 12 and a transmission 13 , and rotating shafts of the engine 11 and the electric generator 12 are connected together to an input shaft of the transmission 13 , so that the engine 11 and the electric generator 12 are connected to each other. When a load of the engine 11 is large, the electric generator 12 assists the driving force of the engine 11 by driving the engine 11 as a work element and the driving force of the electric generator 12 is transmitted to a main pump 14 through an output shaft of the transmission 13 . Meanwhile, when the load of the engine 11 is small, the driving force of the engine 11 is transmitted to the electric generator 12 through the transmission 13 . Accordingly, the electric generator 12 generates power.
The electric generator 12 is formed of, for example, an IPM (Interior Permanent Magnetic) motor where magnets are embedded in a rotor. Switching between the drive and power generation of the electric generator 12 is performed by a controller 30 , which controls the drive of the electrical system of the lifting magnet vehicle 1 , according to the load of the engine 11 and the like.
The main pump 14 and a pilot pump 15 are connected to the output shaft of the transmission 13 , and a control valve 17 is connected to the main pump 14 through a high-pressure hydraulic line 16 . The control valve 17 is a unit that controls the hydraulic system of the lifting magnet vehicle 1 . In addition to left and right hydraulic motors 2 a and 2 b that drive the traveling mechanism 2 shown in FIG. 1 , the boom cylinder 8 , the arm cylinder 9 , and the bucket cylinder 10 are connected to the control valve 17 through hydraulic lines, and the control valve 17 controls hydraulic pressure, which is supplied to these cylinders and motors, according to driver's operation input.
An output end of an inverter circuit (inverter) 18 A is connected to an electrical terminal of the electric generator 12 . The storage means 120 is connected to an input end of the inverter circuit 18 A. As shown in FIG. 3 , the storage means 120 includes a DC bus 110 that is a DC bus bar, a step-up/down converter 100 , and a capacitor 19 . That is, an input end of the inverter circuit 18 A is connected to an input end of the step-up/down converter 100 through the DC bus 110 . The capacitor 19 is connected to an output end of the step-up/down converter 100 . Here, the capacitor 19 includes a plurality of cells. Meanwhile, a battery may be used instead of the capacitor.
Returning to FIG. 2 , the inverter circuit 18 A controls the operation of the electric generator 12 on the basis of an instruction from the controller 30 . That is, when electrically operating (assisting) the electric generator 12 , the inverter circuit 18 A supplies required power to the electric generator 12 from the capacitor 19 and the step-up/down converter 100 through the DC bus 110 . Further, when the electric generator 12 is operated so as to generate power, power generated by the electric generator 12 is stored in the capacitor 19 through the DC bus 110 and the step-up/down converter 100 . Meanwhile, switching between the step-up operation and step-down operation of the step-up/down converter 100 is controlled by the controller 30 on the basis of a voltage value of the DC bus, a voltage value of the capacitor, and a current value of the capacitor. Accordingly, it is possible to maintain the DC bus 110 in a state where the DC bus is charged at a predetermined constant voltage value.
Furthermore, the lifting magnet 7 shown in FIG. 1 is connected to the DC bus 110 of the storage means 120 through an inverter circuit 20 B. The lifting magnet 7 includes an electromagnet that generates a magnetic force for magnetically attracting metal materials, and is supplied with power from the DC bus 110 through the inverter circuit 20 B. The inverter circuit 20 B supplies required power to the lifting magnet 7 from the DC bus 110 when turning on the electromagnet on the basis of an instruction from the controller 30 . Moreover, the inverter circuit 20 B supplies regenerated power to the DC bus 110 when turning off the electromagnet.
In addition, an inverter circuit (inverter) 20 A is connected to the storage means 120 . A revolving electric motor (AC electric motor; electric drive means) 21 as an electric motor for work is connected to one end of the inverter circuit 20 A, and the other end of the inverter circuit 20 A is connected to the DC bus 110 of the storage means 120 . The revolving electric motor 21 is a power source of the revolving mechanism 3 shown in FIG. 1 that revolves the revolving body 4 . A resolver 22 , a mechanical brake 23 , and a revolving reduction gear 24 are connected to a rotating shaft 21 A of the revolving electric motor 21 .
When the revolving electric motor 21 performs a power running operation, the torque of a rotational driving force of the revolving electric motor 21 is amplified at the revolving reduction gear 24 . Accordingly, the acceleration and deceleration of the revolving body 4 are controlled and the revolving body 4 is operated so as to rotate. Further, rotation speed is increased at the revolving reduction gear 24 by the inertial rotation of the revolving body 4 and is transmitted to the revolving electric motor 21 , so that the regenerated power is generated. The revolving electric motor 21 is AC-driven according to a PWM (Pulse Width Modulation) control signal by the inverter circuit 20 A. For example, a magnet embedded type IPM motor is preferred as the revolving electric motor 21 .
The resolver 22 is a sensor that detects the rotational position and the rotation angle of the rotating shaft 21 A of the revolving electric motor 21 , and detects the rotation angle and the rotating direction of the rotating shaft 21 A by being mechanically connected to the revolving electric motor 21 . The resolver 22 derives the rotation angle and the rotating direction of the revolving mechanism 3 by detecting the rotation angle of the rotating shaft 21 A. The mechanical brake 23 is a braking device that generates a mechanical braking force, and mechanically stops the rotating shaft 21 A of the revolving electric motor 21 according to an instruction from the controller 30 . The revolving reduction gear 24 is a reduction gear that reduces the rotating speed of the rotating shaft 21 A of the revolving electric motor 21 and mechanically transmits the rotating speed to the revolving mechanism 3 .
Meanwhile, since the electric generator 12 , the revolving electric motor 21 , and the lifting magnet 7 are connected to the DC bus 110 through the inverter circuits 18 A, 20 A, and 20 B, the power generated by the electric generator 12 may be directly supplied to the lifting magnet 7 or the revolving electric motor 21 , the power regenerated by the lifting magnet 7 may be supplied to the electric generator 12 or the revolving electric motor 21 , and the power regenerated by the revolving electric motor 21 may be supplied to the electric generator 12 or the lifting magnet 7 .
An operating device 26 is connected to the pilot pump 15 through a pilot line 25 . The operating device 26 is an operating device that operates the revolving electric motor 21 , the traveling mechanism 2 , the boom 5 , the arm 6 , and the lifting magnet 7 . The operating device 26 is operated by an operator. The control valve 17 is connected to the operating device 26 through a hydraulic line 27 , and a pressure sensor 29 is connected to the operating device 26 through a hydraulic line 28 . The operating device 26 converts hydraulic pressure (primary-side hydraulic pressure), which is supplied through the pilot line 25 , into hydraulic pressure (secondary-side hydraulic pressure), which corresponds to the amount of work performed by an operator, and outputs the converted hydraulic pressure. The secondary-side hydraulic pressure, which is output from the operating device 26 , is supplied to the control valve 17 through the hydraulic line 27 and is detected by the pressure sensor 29 .
When an operation for revolving the revolving mechanism 3 is input to the operating device 26 , the pressure sensor 29 detects the amount of operation as the change of hydraulic pressure in the hydraulic line 28 . The pressure sensor 29 outputs an electrical signal that represents hydraulic pressure in the hydraulic line 28 . This electrical signal is input to the controller 30 , and is used to control the drive of the revolving electric motor 21 .
The controller 30 forms a control circuit of this embodiment. The controller 30 is formed of a processing unit that includes a CPU and an internal memory. The CPU executes a drive control program stored in the internal memory, so that the controller 30 is realized. Further, a power supply of the controller 30 is a battery (for example, 24V in-vehicle battery) that is separate from the capacitor 19 . The controller 30 converts a signal, which represents the amount of operation required for revolving the revolving mechanism 3 , among signals input from the pressure sensor 29 into a speed instruction, and controls the drive of the revolving electric motor 21 . Further, the controller 30 controls the charge and discharge of the capacitor 19 that is performed by the control of the operation of the electric generator 12 (switching between an assist operation and a power generating operation), the control of the drive of the lifting magnet 7 (switching between excitation and demagnetization), and the control of the drive of the step-up/down converter 100 .
Here, the step-up/down converter 100 of this embodiment will be described in detail. As shown in FIG. 3 , the step-up/down converter 100 has a step-up/down switching control system, and includes a reactor 101 and transistors 100 B and 100 C. The transistor 100 B is a step-up switching element, and the transistor 100 C is a step-down switching element. The transistors 100 B and 100 C are formed of, for example, IGBTs (Insulated Gate Bipolar Transistors), and are connected in series to each other.
Specifically, a collector of the transistor 100 B and an emitter of the transistor 100 C are connected to each other, an emitter of the transistor 100 B is connected to a negative-side terminal of the capacitor 19 and a negative-side wire of the DC bus 110 , and a collector of the transistor 100 C is connected to a positive-side wire of the DC bus 110 . Further, one end of the reactor 101 is connected to the collector of the transistor 100 B and the emitter of the transistor 100 C, and the other end of the reactor 101 is connected to a positive-side terminal of the capacitor 19 . A PWM voltage is applied to gates of the transistors 100 B and 100 C from the controller 30 .
Meanwhile, a diode 100 b , which is a rectifying element, is connected in parallel in an opposite direction between the collector and the emitter of the transistor 100 B. Likewise, a diode 100 c is connected in parallel in an opposite direction between the collector and the emitter of the transistor 100 C. A smoothing capacitor 110 a of the DC bus 110 is connected between the collector of the transistor 100 C and the emitter of the transistor 100 B (that is, between the positive-side wire and the negative-side wire of the DC bus 110 ). The capacitor 110 a smoothes a voltage that is output from the step-up/down converter 100 , a voltage that is generated from the electric generator 12 , and a voltage that is regenerated from the revolving electric motor 21 .
In the step-up/down converter 100 having the above-mentioned structure, a PWM voltage is applied to the gate of the transistor 100 B according to an instruction from the controller 30 when DC power is supplied to the DC bus 110 from the capacitor 19 . Further, an induced electromotive force generated at the reactor 101 is transmitted through the diode 100 c according to the turning-on/off of the transistor 100 B, and this power is smoothed by the capacitor 110 a . Furthermore, when DC power is supplied to the capacitor 19 from the DC bus 110 , a PWM voltage is applied to a gate of the transistor 100 C according to an instruction from the controller 30 and current output from the transistor 100 C is smoothed by the reactor 101 .
Subsequently, the revolving body 4 will be described. FIG. 4 is a perspective view showing the house portion 4 b of the revolving body 4 . Hereinafter, in the description of the structure of the house portion 4 b , the front, the rear, the left, and the right means the front, the rear, the left, and the right of the lifting magnet vehicle 1 unless otherwise particularly mentioned. As shown in FIG. 4 , the house portion 4 b is formed so as to have a substantially U-shape in plan view, and is disposed so that an opened portion of the U-shape faces forward. Here, in the house portion 4 b , a right front portion (a left front portion shown in FIG. 4 ) of a vehicle is referred to as a right front portion Rf, a right rear portion (a left back portion shown in FIG. 4 ) is referred to as a right rear portion Rr, a left front portion (a right front portion shown in FIG. 4 ) is referred to as a left front portion Lf, a left rear portion (a right back portion shown in FIG. 4 ) is referred to as a left rear portion Lr, and a portion between the right front portion Rf and the left front portion Lf is referred to as a central portion C.
The operator's cab 4 a shown in FIG. 1 is provided so as to correspond to the left front portion Lf of the house portion 4 b , and a base end of the boom 5 is mounted on the central portion C so as to be capable of moving up and down. Further, the revolving body 4 including the house portion 4 b is rotated about an axis extending in a vertical direction, that is, is revolved to left and right in a revolving direction D by the revolving electric motor 21 (see FIG. 2 ) that is provided below the central portion C. The right front portion Rf is provided with steps 31 for maintenance and a handrail 32 .
The storage means 120 , the inverter circuits 18 A, 20 A, and 20 B, and the controller 30 , which are shown in FIG. 2 , are installed in the right front portion Rf. Opening portions are formed at the lower portions of the left and right surfaces of the right front portion Rf, respectively, and the capacitor 19 of the storage means 120 is installed between the right opening portion 34 (see FIG. 5 ) and the left opening portion 33 . That is, the left and right opening portions 34 and 33 are formed as vents through which air for cooling the capacitor 19 flows to the left and right.
FIG. 5 is a cross-sectional view of a capacitor 19 and the like installed in the lower portion of the right front portion Rf as seen from the front side. A base frame B, which includes a bottom frame Ba and an outer peripheral frame Bb, is shown in FIG. 5 . The bottom frame Ba is a frame member that forms the bottom of the house portion 4 b . The outer peripheral frame Bb is erected at the peripheral edge (the left side in FIG. 5 ) of the bottom frame Ba.
As shown in FIG. 5 , louvers 36 and 35 are provided at the right front portion Rf inside the right and left opening portions 34 and 33 , respectively. Further, a capacitor box 80 including the capacitor 19 is provided between the louvers 35 and 36 , and is installed on the bottom frame Ba with seats 155 and vibration-proof rubbers 156 interposed therebetween. A plurality of cells 41 is arranged side by side on upper and lower stages and assembled, so that the capacitor 19 is formed. The assembly of the cells 41 of the upper stage forms an upper-stage module 45 , and the assembly of the cells 41 of the lower stage forms a lower-stage module 45 . These modules 45 and 45 are surrounded and reinforced by an outer frame so as to allow air to flow to the left and right, so that the capacitor box 80 is formed.
An air intake duct 40 is connected to the right side (the left side in FIG. 5 ) of the capacitor box 80 , and louvers 38 are provided at the upstream end portion in the air intake duct 40 so as to face the louvers 36 . Further, fans 43 and 43 , which make cooling air flow to the right from the left in FIG. 5 , are provided at the left (right in FIG. 5 ) end portion of the capacitor box 80 so as to correspond to the cells 41 and 41 of the upper and lower stages, respectively. Furthermore, an exhaust duct 39 is connected to the left side (the right side in FIG. 5 ), and louvers 37 are provided at the downstream end portion in the exhaust duct 39 so as to face the louvers 35 .
The louvers 36 corresponding to the air intake side are inclined downward relative to the flow direction of cooling air that flows to the right from the left in FIG. 5 , and the louvers 38 provided in the air intake duct 40 on the downstream side of the louvers 36 are inclined upward so as to be opposite to the louvers 36 . In addition, the louvers 37 provided in the exhaust duct 39 are inclined downward relative to the flow direction of cooling air, and the louvers 35 , which correspond to the exhaust side and are provided on the downstream side of the louvers 37 , are inclined upward so as to be opposite to the louvers 37 . The capacitor box 80 is intended to be made waterproof by the above-mentioned structure of the louvers.
Further, since the capacitor box 80 is installed on the bottom frame Ba as described above, the position where the capacitor box is installed is lower than the right and left opening portions 34 and 33 . For this reason, the air intake duct 40 and the exhaust duct 39 have an asymmetric shape in the vertical direction. That is, the air intake duct 40 and the exhaust duct 39 have a shape that extends downward from both the louvers 38 and 37 toward the capacitor box 80 .
Furthermore, a partition wall 44 , which connects an upstream end portion formed between the upper-stage module 45 and the lower-stage module 45 to the downstream end portion of the louver 38 and partitions the inner space of the air intake duct 40 into upper and lower spaces, is provided in the air intake duct 40 . The partition wall 44 distributes the same amount of cooling air as the amount of cooling air, which is to be supplied to the upper-stage module 45 , to the lower-stage module 45 that is disposed so as to be shifted downward without exactly facing the louvers 38 arranged side by side in the vertical direction. The partition wall 44 is inclined downward relative to the flow direction of cooling air without being horizontal so that the flow rate of cooling air at a lower inlet is larger than the rate of cooling air at an upper inlet (an outlet of the louvers 38 ).
Meanwhile, the capacitor box 80 , the air intake duct 40 , the exhaust duct 39 , the opening portion 34 , the opening portion 33 , and the like are installed at the right front portion Rf here, but may be installed at the left front portion Lf below the operator's cab 4 a.
Further, coolers, such as a radiator for an engine, an oil cooler, an intercooler, a fuel cooler, a radiator for a hybrid system (a radiator for hybrid), and a heat exchanger for an air conditioner of the operator's cab 4 a (a capacitor for an air conditioner) (none of which are shown), are installed in the left rear portion Lr of FIG. 4 .
Furthermore, the engine 11 , the transmission 13 , the electric generator 12 , the main pump 14 , and the like shown in FIG. 2 are installed from the left rear portion Lr to the right rear portion Rr, that is, below an engine hood H forming a top panel. A fan (not shown) is connected to the engine 11 . Accordingly, the fan is rotated by the rotation of the engine 11 , so that air flows into the left rear portion Lr from a vent 46 formed at the left side of the left front portion Lf. As a result, the above-mentioned respective coolers installed in the left rear portion Lr are cooled.
So-called A-frames 47 that are frames where the boom 5 is supported and interposed so as to be capable of moving up and down, and a boom cylinder frame 48 that is a frame on which the base end of the boom cylinder 8 is mounted are provided at the central portion C.
Next, a structure related to wires of high voltage cables of the electric generator 12 and the revolving electric motor 21 will be described in detail.
FIG. 6 is a perspective view showing wires of high voltage cables 63 , which connect the revolving electric motor 21 to the inverter circuit 20 A thereof, together with the base frame B, the A-frames 47 , and components in the right front portion Rf of the house portion, and is a perspective view as seen from the rear upper side of the left portion of the vehicle; FIG. 7 is a perspective view of FIG. 6 as seen from the rear upper side of the right portion of the vehicle; FIG. 8 is a plan view of FIGS. 6 and 7 ; FIG. 9 is a perspective view showing wires of high voltage cables 53 , which connect the electric generator 12 to the inverter circuit 18 A thereof, together with the base frame B, the A-frames 47 , and components in the right front portion Rf of the house portion, and is a perspective view as seen from the rear upper side of the left portion of the vehicle; FIG. 10 is a perspective view of FIG. 9 as seen from the rear upper side of the right portion of the vehicle; FIG. 11 is a plan view of FIGS. 9 and 10 ; and FIG. 12 is a view taken along line XII-XII of FIG. 11 .
As shown in FIGS. 6 and 7 , the capacitor box 80 to which the air intake duct 40 and the exhaust duct 39 are connected, the inverter circuits 18 A, 20 A, and 20 B, and the controller 30 are mounted on the bottom frame Ba in the right front portion Rf of the house portion from the lower side to the upper side.
Further, a pump chamber (not shown) is formed in the house portion 4 b on the base frame B at the right rear portion Rr and the transmission 13 , the electric generator 12 , and the main pump 14 are provided in the pump chamber.
Furthermore, the A-frames (frame structural members) 47 and 47 , which support the boom 5 , are formed at the central portion C so as to protrude in the vertical direction and face each other, and the revolving electric motor 21 is provided near the rear portion of the boom 5 at the middle position interposed between the A-frames 47 and 47 so as to be substantially erected on the bottom frame Ba.
Moreover, outer peripheral frames (side frames; frame structural members) Bb forming the base frame B are provided at both left and right end portions of the base frame B so as to extend in a longitudinal direction. As shown in FIG. 12 , the outer peripheral frame Bb is formed in the shape of a rectangular tube that extends in the vertical direction, and a closed cross-sectional space S having a substantially rectangular cross-section is formed in the outer peripheral frame Bb.
Here, as shown in FIGS. 6 to 8 , the high voltage cables 63 , which connect the revolving electric motor 21 to the inverter circuit 20 A thereof and through which power is supplied, are wired along the inner side surface of the A-frame 47 .
Specifically, an opening 88 a through which the high voltage cables 63 corresponding to three phases (U, V, and W) pass is formed at the lower portion of the A-frame 47 facing the capacitor box 80 at a position close to the capacitor box 80 . The high voltage cables 63 extending from the revolving electric motor 21 are laid along the inner surface of the lower portion of the A-frame 47 that protrudes in the vertical direction on the side close to the capacitor box 80 , are led to the outside of the A-frame 47 through the opening 88 a , and are connected to three-phase terminals 64 of the inverter circuit 20 A, respectively.
Further, as shown in FIGS. 9 to 12 , the high voltage cables 53 , which connect the electric generator 12 to the inverter circuit 18 A thereof and through which power is supplied, are wired so as to pass through the outer peripheral frame Bb.
Specifically, openings 89 a and 89 b through which the high voltage cables 53 corresponding to three phases (U, V, and W) pass are formed at the outer peripheral frame Bb, which faces the electric generator 12 and the capacitor box 80 , at a position corresponding to the side of the electric generator 12 and a position close to the capacitor box 80 , respectively. The high voltage cables 53 extending from the electric generator 12 are introduced into the outer peripheral frame Bb through the opening 89 a , pass through the closed cross-sectional space S formed in the outer peripheral frame, are laid along the side surfaces of inner and outer walls of the outer peripheral frame Bb protruding in the vertical direction, are led to the outside of the outer peripheral frame Bb through the opening 89 b , and are connected to three-phase terminals 54 of the inverter circuit 18 A, respectively.
Since the high voltage cables 53 and 63 are wired along the side surfaces of the frame structural members Bb and 47 protruding in the vertical direction in this embodiment as described above, the frame structural members Bb and 47 become upright walls, so that the high voltage cables 53 and 63 are adequately protected. Accordingly, for example, even when the lifting magnet vehicle 1 collides with an obstruction or the like, the high voltage cables 53 and 63 are adequately protected by the frame structural members Bb and 47 . As a result, safety is improved.
Further, since the high voltage cables 63 forming the frame structural member are wired along the inner side surface of the A-frame 47 , the high voltage cables 63 are adequately protected by the A-frame 47 having high rigidity. Accordingly, safety is improved. In addition, even when the lifting magnet vehicle 1 collides with an obstruction or the like, the A-frame 47 is separated from a collision portion since being disposed at the central portion. Accordingly, the high voltage cables 63 are more adequately protected.
Moreover, since the high voltage cables 53 forming the frame structural member pass through the outer peripheral frame Bb that has high rigidity and forms a closed cross-section, the high voltage cables 53 are adequately protected, so that safety is improved. Further, the outer peripheral frame Bb surrounding the high voltage cables 53 is made of metal, so that the outer peripheral frame Bb blocks electromagnetic waves. Accordingly, electromagnetic shielding performance is also improved.
In addition, the high voltage cables 53 and 63 can be wired separately from a control harness having a low voltage (for example, 24 V) connected to the controller 30 or the like, it is possible to reduce noise that is generated on the harness by the high voltage cables 53 and 63 .
Meanwhile, a waterproof cap (not shown) is provided at portions of the high voltage cables 63 penetrating a frame of the revolving electric motor 21 and a waterproof cap (not shown) is provided at portions of the high voltage cables 53 penetrating a frame of the electric generator 12 so that the frames are sufficiently intended to be made waterproof. For example, a waterproof cap, which is made of a fluororesin and has heat resistance, may be used as these waterproof caps.
FIG. 13 is a perspective view showing main portions of a construction machine according to a second embodiment of the invention; is a perspective view showing wires of high voltage cables 53 , which connect an electric generator 12 to an inverter circuit 18 A thereof, together with a base frame B, A-frames 47 , and components in a right front portion Rf of a house portion; and is a perspective view as seen from the rear upper side of a left portion of a vehicle. FIG. 14 is a perspective view of FIG. 13 as seen from the rear upper side of a right portion of a vehicle, and FIG. 15 is a plan view of FIGS. 13 and 14 .
This second embodiment is different from the first embodiment in that the wires of high voltage cables 53 are wired along the inner side surface of the A-frame 47 .
Specifically, an opening 88 b through which the high voltage cables 53 pass is formed at the lower portion of the A-frame 47 facing the electric generator 12 at a position corresponding to the side of the electric generator 12 . The high voltage cables 53 extending from the electric generator 12 are led to the inside of the A-frame 47 facing the electric generator 12 through the opening 88 b , are laid along the inner surface of the lower portion of the A-frame 47 , are led to the outside of the A-frame 47 through the above-mentioned opening 88 a , and are connected to terminals 54 of the inverter circuit 18 A, respectively.
It goes without saying that the same operation and effect as the operation and effect of the high voltage cables 63 described in the first embodiment are obtained even in this second embodiment.
Meanwhile, although not described here, high voltage cables 63 , which connect a revolving electric motor 21 to an inverter circuit 20 A, may be wired so as to pass through an outer peripheral frame Bb.
Further, in the above-mentioned first and second embodiments, the high voltage cables 53 between the electric generator 12 and the inverter circuit 18 A thereof or the high voltage cables 63 between the revolving electric motor 21 and the inverter circuit 20 A thereof are wired along the inner side surface of the A-frame 47 or are wired so as to pass through the outer peripheral frame Bb. However, in the cases of an electric generator with an inverter and a revolving electric motor with an inverter that are obtained by attaching the inverter circuits 18 A and 20 A to the electric generator 12 and the revolving electric motor 21 , respectively, high voltage cables connecting the inverter circuit 18 A to the storage means 120 and high voltage cables connecting the inverter circuit 20 A to the storage means 120 are wired along the inner side surface of the A-frame 47 or are wired so as to pass through the outer peripheral frame Bb.
FIG. 16 is a block diagram showing the internal structure of an electrical system, a hydraulic system, and the like of a construction machine according to another embodiment.
A structure shown in FIG. 16 is a so-called series type, is separately provided with an electric motor 140 for a pump and an inverter 18 D instead of the structure, which connects the transmission 13 to the main pump 14 , in the parallel type structure shown in FIG. 2 ; converts the entire power of the engine 11 into electrical energy once; and drives various drive elements.
Specifically, the inverter 18 D is electrically connected to the DC bus 110 (see FIG. 3 ) of the storage means 120 and is controlled by the controller 30 . Further, an output end of the inverter 18 D is connected to the electric motor 140 for a pump, and the electric motor 140 for a pump is driven and controlled by the inverter 18 D. Furthermore, power, which is generated by the main pump 14 in the electric motor 140 for a pump, is supplied to the storage means 120 through the inverter 18 D as regenerated energy.
The invention has been specifically described above with reference to the embodiments thereof, but the invention is not limited to the above-mentioned embodiments. For example, in the above-mentioned embodiments, the invention has been applied to a lifting magnet type hybrid construction machine as a particularly preferred example. However, the invention may be applied to other construction machines such as a shovel, a wheel loader, or a crane.
INDUSTRIAL APPLICABILITY
According to the invention, it is possible to improve the safety of wires in a construction machine.
REFERENCE SIGNS LIST
1 : lifting magnet vehicle (construction machine)
5 : boom
11 : engine
12 : electric generator (power generation means)
18 A, 20 A: inverter
21 : revolving electric motor (electric drive means)
47 : A-frame (frame structural member)
53 , 63 : high voltage cable
120 : storage means
B: base frame
Bb: outer peripheral frame (side frame; frame structural member)
S: closed cross-sectional space
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A construction machine with improved safety can include a high voltage cable for supplying power. The high voltage cable connects a storage devices to an electric drive that drives using power from a power generation device, which generates power using the drive of an engine, or from the storage device, which stores the power generated by the power generation device, is wired along the sides of a frame structural member that protrudes in a vertical direction. The frame structural member serves as an upright wall to adequately protect the high voltage cable. In cases in which, for example, the construction machine strikes an obstruction, or the like, the high voltage cable is adequately protected by the frame structural member.
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FIELD OF THE INVENTION
[0001] The teachings of this invention relate generally to computer vision and computer graphics and, more specifically, the teachings of this invention relate to techniques for acquiring silhouettes from an image.
BACKGROUND OF THE INVENTION
[0002] A number of different techniques have been developed to compute shapes from silhouettes or contours in the field of computer imaging.
[0003] The teachings herein address the problem of acquiring a numerical description of the shape of an object. Given a numerical description of the object's shape it is possible, using well-known computer graphics algorithms, to generate images of the object from different points of view and under different lighting conditions. One important application of such synthetic imagery is in e-commerce, where the seller of an object allows potential customers to inspect a virtual copy of an object interactively using a computer. Numerical representations of objects can be used for other purposes, such as in CAD (computer-aided design) systems as a starting point for the design of new objects.
[0004] A class of popular methods for acquiring a numerical representation of an object's shape is known as shape from silhouette, also referred to by similar names such as shape from occluding contour or shape from boundaries. Shape from silhouette algorithms use an image of an object captured by a camera, or any other imaging device. Using the known position of the camera, and the silhouette of the object in the image (i.e. the curve that marks the boundary in the image between the object and the background), an estimate of the numerical shape can be made. A very crude estimate of shape can be obtained from a single image. An improved estimate is obtained using a number of silhouettes from images of the object in different positions relative to the camera.
[0005] Many algorithms have been devised to compute a numerical description of the three dimensional shape of an object from silhouettes. One class of algorithms is known as volumetric or space carving, as originally described by Martin and Aggrawal (Worthy N. Martin and J. K Agrawal, “Volumetric Descriptions of Objects from Multiple Views”, IEEE Transactions on Pattern Analysis and Machine Intelligence, Vol. PAMI-5, No. 2, March 1983, pp. 150-158.) In this technique a volume of small boxes is numerically defined that completely encloses the object. For each image the boxes are projected onto an image plane. If the projection of a box falls outside of the object silhouette, it is marked as “outside” and is eliminated from a current estimate of the object shape. As each silhouette image is considered more of the boxes are eliminated, or “carved away” from the initial volume. The boxes remaining after all of the silhouette images have been examined is the estimate of the object's shape. A smooth representation of the surface of the object can then be obtained by any well-known isosurface algorithm.
[0006] An alternative class of algorithms for extracting shape from silhouettes uses the variation of contour shape in successive images. An example is described by Zheng (Jiang Yu Zheng, “Acquiring 3-D Models from Sequences of Contours”, IEEE Transactions on Pattern Analysis and Machine Intelligence, Vol. 16, No. 2, February 1994, pp. 163-178.) In this method, many silhouette images are obtained as the object is rotated in front of the camera. An estimate of 3D location of points on the object's surface is obtained from the location of silhouettes in the image relative to the projection of the axis of rotation, and the rate of change of these positions with respect to angular change.
[0007] There are fundamental limitations on the accuracy of the shape that can be recovered by shape from silhouettes, as discussed by Laurentini (Aldo Laurentini, “How Far 3D Shapes Can Be Understood from 2D Silhouettes”, IEEE Transactions on Pattern Analysis and Machine Intelligence, Vol. 17, No. 2, February 1995, pp. 188-195.). For example, object concavities will not appear in silhouettes, and so will not be captured. To provide the illusion of concavities, and to add color to the model, capture systems generally acquire color images of the object from known camera positions. These color images can be related to the captured geometry by the well-known computer graphics technique known as projective texture mapping. Geometries (generally in the form of triangular meshes) with texture maps can be displayed with hardware and software available on typical personal computers.
[0008] A basic operation required by either class of the shape from silhouette algorithms is the accurate extraction of the boundary between the object and the background. This is an example of the classic image segmentation problem from the field of image processing. Systems for extracting shape attempt to simplify the segmentation by designing a suitable backdrop. An example of such a design is illustrated in Jones and Oakely (M. Jones and J. P. Oakley, “Efficient representation of object shape for silhouette intersection”, IEEE Proc.-Vis. Image Signal Process, Vol. 142, No. 6, December 1995, pp. 359-364.) The backdrop for the object is painted a uniform color ( in the case of Jones and Oakely “Chromakey Blue”). The silhouette is defined as the boundary of the image regions that are the uniform background color.
[0009] An alternative approach uses a large flat diffuse light source in place of the colored backdrop. The silhouette is defined as the boundary of the bright image regions, with the object itself generally appearing dark.
[0010] Shape from silhouettes, particularly with the addition of color textures, is a popular technique because it can be implemented inexpensively. The major cost of the system resides in the camera and in a mechanism to control the position of the object, such as a turntable. The implementation with volume carving is particularly attractive for applications because the method guarantees a closed surface.
[0011] An alternative and related method for capturing object shape is “shape from shadows”, as described in U.S. Pat. Nos: 4,792,696 and 4,873,651. These methods are similar to shape from silhouettes, since a sharp shadow is the silhouette projected from a point light source. In both of these patents the camera is placed on the same side of the object as the direction of light incident on the object, and images are taken of the shadows cast by the object. In both of these patents it is assumed that the surface is a height field. That is, the object sits on a reference plane with locations on the plane specified by (x,y) Cartesian coordinates. The shape of the object is given by a third coordinate z that is descriptive of the height of the object surface above the reference plane. With this assumption, the shape of the object surface is inferred from where shadows begin and end, and from knowledge of the light source direction.
[0012] U.S. Pat. No.: 4,604,807 employs a shadow that is observed using a camera on the opposite side of the object from the light source. In this patent the shadow is formed by pressing a relatively flat object, e.g., a person's foot, onto a translucent panel. The shadow is observed from the opposite side to obtain a numerical description of the two dimensional area of the foot, and is not used to estimate the three dimensional shape of the foot.
[0013] In an article by Leibe et al. (B. Leibe, T. Starner, W. Ribarsky, Z. Wartell, D. Krum, J. Weeks, B. Singletary and L. Godges, “Toward Spontaneous Interaction with the Perceptive Workbench”, IEEE Computer Graphics and Applications, November/December 2000, pp. 54-65.) a system is described that observes shadows cast by objects on a translucent table with a camera located underneath the table. The system can produce only a crude estimate of shape, because the object cannot be repositioned in a calibrated manner.
[0014] All of the prior art techniques known to the inventors assume that an accurate silhouette can be extracted from the image. However, if an accurate silhouette cannot be extracted, then the shape of the object will be inaccurate.
[0015] The segmentation approach fails if the object is shiny, transparent, or is same color as the background. Segmentation can also fail even with the use of a large diffused light source.
[0016] A number of other problems are encountered with the prior art techniques for finding object silhouettes. First consider the approach of using a background of known color. The silhouette is detected where the backdrop color ends in the image. This method fails for glossy objects that reflect some of the background color in the direction of the camera, and for objects which transmit light. This method also fails when camera characteristics cause “bleeding” of color from one region of the image to another. The method can also fail if inter-reflections on the object cast color from the background onto the object. The method also fails if the object happens to be the same color as the backdrop.
[0017] Some methods attempt to avoid these problems by taking an image of the backdrop alone and then an image of the object in front of the background, and then taking the difference between the two images. However, this approach fails for very shiny objects. It also fails when any shadow is cast by the object onto the backdrop.
[0018] The approach of using a large diffuse light source seeks to avoid the problem of the object possibly being the same color as the background. However, this technique also fails for shiny surfaces, light transmitting surfaces, and for surfaces in which self-interreflections transmit light from the backdrop onto the object. This approach also prevents the simultaneous acquisition of color images to be used as texture maps, since the bright background causes most of the object to appear very dark in the image. Having to acquire the color images separately extends the length of time required to obtain the numerical description of the object.
[0019] Both of the backdrop approaches allow only one silhouette to be obtained for each position of the object. For simple systems employing a device with one degree of freedom to provide accurate positioning, such as a turntable, one position of the object on the turntable may not be adequate to obtain a view of the entire object surface. The object is placed once, a series of images is obtained for one rotation of the device. The object is placed in a different position relative to the turntable, and another series is obtained. This process may need to be repeated many times, and the geometries recovered by each rotation must be registered to one another by an additional geometric processing step.
[0020] The methods that employ shadows have been in part motivated by the problem of segmentation from the backdrop when shiny objects are being scanned. However, for the shadow methods, with the camera in the same direction as the direction of incident light, the problem remains of separating the image of the object and the image of its shadow. Such segmentation is difficult for objects with a dark or partially dark surface, and is impossible for black objects. The shadow methods are also limited by the height field assumption for 3-D shape recovery. Objects with even moderately complex topologies, e.g., a coffee mug with a handle, cannot be measured with such techniques without substantial error.
[0021] The method described in U.S. Pat. No.: 4,604,807 employs optics and geometry that require that the object being measured rest against the translucent panel, and that the object shape is almost flat. The apparatus can only measure 2-D areas, and cannot be used to capture silhouettes of objects of arbitrary shape for 3-D shape recovery.
[0022] The system described by Leibe et al. requires the object to be scanned to sit on a fixed translucent surface. Although the shape of some objects can be estimated from a sparse set of views spanning the full space of directions around the object, the system described by Leibe et al. is limited to shadows that can be cast from light sources above the translucent surface. The goal of the Leibe et al. system is to produce crude shape representations only, and the design does not permit the calibrated repositioning of an object, nor does it include a way to obtain additional information, such as shape from photometric data, to improve the estimate of shape and to include concavities. The system includes a side camera above the translucent surface, but obtaining silhouettes from this camera presents all of the problems of traditional silhouette extraction, and cannot, for example, be used for shiny objects.
OBJECTS AND ADVANTAGES OF THE INVENTION
[0023] It is a first object and advantage of this invention to provide an improved system and method to obtain 3-D shapes from one or more images.
[0024] It is a further object and advantage of this invention to provide a system and method for deriving the surface shape of an object from shadow images of the object obtained from behind a translucent panel that is interposed between an image capture device, referred to for convenience as a camera, and the object, where the object is interposed between the front of the translucent panel and one or more point light sources.
SUMMARY OF THE INVENTION
[0025] The foregoing and other problems are overcome and the foregoing objects and advantages are realized by methods and apparatus in accordance with embodiments of this invention.
[0026] Disclosed herein are embodiments of apparatus for obtaining the silhouette of an object in a form suitable for use by a shape from silhouette algorithm for obtaining a numerical description of the object's three dimensional shape. Also disclosed are methods for processing the output of the apparatus into a numerical description of the object that is suitable for interactive display on a computer graphics system.
[0027] More particularly, disclosed herein are methods and apparatus for obtaining the shape of an object by observing silhouettes of the object. At least one light source, preferably a point light source, is placed in front of the object, thereby casting a shadow of the object on a translucent panel that is placed behind the object. An imaging device, referred to for convenience as a camera, captures an image of the shadow from behind the translucent panel. The silhouette or shadow contour is obtained from the image of the shadow as the region of the shadow that is substantially darker than the region outside of the shadow. This is true for any opaque object regardless of its surface finish or shape. By using a point light source, rather than a large diffuse light source, the quantity of light reflected by the object in the direction of the translucent panel is orders of magnitude smaller than light that impinges on the panel directly from the point source, thereby enhancing the contrast between the object's shadow and the illumination from the light source. A further benefit obtained by the use of the point light source is that the object need not be in contact with the translucent panel to obtain a shadow having sharp edges. The full object silhouette is obtained since nothing (including the object itself) is in the path between the camera and the translucent panel. The full silhouette obtained can be processed by any suitable shape from silhouette algorithm, and thus the to be imaged are not limited in topological type. Unlike systems with large diffuse lights as backgrounds, which make the object appear black, a color image of the object can optionally be obtained simultaneously with the shadow image by using another camera, such as a color camera, that is placed on the same side of the object as the light source. Unlike conventional silhouette systems, multiple silhouettes can be captured for one object position, reducing the number of rotations needed on a turntable system, and reducing the post-processing needed to register geometries obtained from multiple different positions.
[0028] In accordance with the teachings herein, a system and method is disclosed for obtaining a three dimensional image of an object. The method includes the steps of (a) shining light from at least one light source on to the object from a first direction to create a first shadow cast by the object on a first surface of a translucent panel, where the object is disposed between a light source and the first surface of the translucent panel and has a first pose; (b) obtaining a first digital image of the first shadow from a second, opposite surface of the translucent panel; (c) changing the pose of the object and obtaining additional digital images of additional shadows cast by the object for different object poses; and (d) processing the first and the additional digital images to create a three dimensional image of the object. The step of processing preferably employs a space carving process. The step of processing operates to identify a boundary of the image of the shadow in each of the first and additional digital images, where the boundary is identified in a given one of the digital images by applying a pixel thresholding process to determine whether a given pixel is located within the image of the shadow or outside of the image of the shadow. The step of processing further defines a virtual volume as a list of volume elements, projects individual ones of the volume elements onto the plane of the image of the shadow, and retains only those volume elements in the list that lie within the image of the shadow or on the identified boundary. The step of processing then further applies an isosurface extraction algorithm to the list of surviving volume elements to obtain a numerical description of the shape of the surface of the object.
[0029] The step of shining light on to the object can also be done from a second, or third, or fourth, etc., direction to create an additional shadow or shadows cast by the object on the first surface of the translucent panel. The resulting shadow image(s) are processed in the same manner as the first shadow. A plurality of light sources each having a different color can be used, as can array of light sources that are operated in sequence. A single light source may be translated with respect to the object to shine light on the object from a plurality of different directions.
[0030] Further in accordance with these teachings the method may include additional steps of obtaining a digital image of the object for each object pose; processing the digital images of the object to derive surface normals and color maps; and applying the surface normals and color maps to the surface of the three dimensional image of the object.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above set forth and other features of the invention are made more apparent in the ensuing Detailed Description of the Invention when read in conjunction with the attached Drawings, wherein:
[0032] [0032]FIG. 1 depicts a presently preferred embodiment of a system for obtaining the shape of an object by observing silhouettes of the object..
[0033] [0033]FIGS. 2 a and 2 b are diagrams depicting ideal properties of the light source and the translucent panel shown in FIG. 1, wherein FIG. 2 a illustrates an ideal light scattering distribution for the translucent panel, and FIG. 2 b shows an ideal light emission distribution for the light source.
[0034] [0034]FIG. 3 shows an exemplary shadow image produced by the acquisition system of FIG. 1.
[0035] [0035]FIG. 4 is a logic flow diagram of the processing of the shadow image of FIG. 3.
[0036] [0036]FIG. 5 shows an image of a contour found in the shadow image after processing.
[0037] [0037]FIG. 6 is a logic flow diagram of the processing of the images with contours into a shape approximation in the form of a set of volume elements, also referred to as boxes.
[0038] [0038]FIG. 7 is a logic flow diagram of the processing of the set of boxes computed in accordance with FIG. 6 into a surface.
[0039] [0039]FIG. 8 is a block diagram of a second embodiment of the image acquisition system in accordance with these teachings, wherein three color light sources are used in lieu of the single light source of FIG. 1.
[0040] [0040]FIG. 9 is a block diagram of a third embodiment of the image acquisition system, wherein an array of light sources replaces the single light source of FIG. 1.
[0041] [0041]FIG. 10 is a logic flow diagram of the image processing associated with the output from the third embodiment of this invention shown in FIG. 9, wherein detail and color are added to the surface.
DETAILED DESCRIPTION OF THE INVENTION
[0042] A presently preferred first embodiment of image acquisition apparatus is depicted in FIG. 1. A point light source 140 is placed in front of an object 120 that is to be imaged, thereby casting a shadow 125 on a translucent panel 100 . In the preferred embodiment, to measure an object 120 of maximum linear dimension H, the light source has a diameter of about 0.025 H, and is located a distance about 5 H from the object 120 . The light source 140 has a nearly uniform intensity output 300 in the direction of the object 120 , as is diagramed in FIG. 2 b. Referring also to FIG. 2 a, the translucent panel 100 is preferably a thin sheet of partially light transmissive material, for example a less than 1 mm thick sheet of diffusely transmitting material. The panel 100 is thin to eliminate significant scattering in the plane of the panel 100 , to thereby avoid blurring of the image of the object's shadow 125 , and has a forward scattering distribution 210 that is nearly uniform for light 200 incident on the panel 100 . The translucent panel 100 is preferably non-colored or color neutral. A sheet of white writing paper with no water marking may be used, with the sheet of paper being sandwiched between thin (3 mm or less) plates of transparent glass for support. Other types of translucent panels may also be used, such as a sheet of certain polymer materials, frosted glass, and other materials that are only partially transmissive to impinging light. The translucent panel 100 is located a distance of about 2H from the object 120 , and has dimensions of at least about 1.5H by 1.5H.
[0043] The object 120 to be measured is placed on a device that has a calibrated position. In FIG. 1 this device is embodied as a turntable 130 which is controlled by a computer 150 . A camera 110 (a black and white, or a color camera) is placed behind the translucent panel 100 , and is preferably also controlled by the computer 150 (although manual control of the turntable and/or camera could be used as well.) In the preferred embodiment the camera 110 has a 32 degree field of view (wider angles are preferably avoided to eliminate potential distortion effects in the camera optics), and is located a distance of about 5H from the second, rear surface of the translucent panel 100 .
[0044] The positions of the camera 110 , translucent panel 100 and the light source 140 are calibrated with respect to a coordinate system defined on the turntable 130 (or other positioning device) in its initial position. Any well-known calibration or measurement techniques for obtaining camera parameters and measuring object locations may be used. Assuming that the positions are suitably calibrated, the object 120 need not be located at the center of the turntable 130 , the light source 140 need not lie on the optical axis of the camera 110 , and the optical axis of the camera 110 need not be perpendicular to the plane of the translucent plate 100 .
[0045] What is important to the operation of the imaging system is that: (a) the light from source 140 is incident on the front of the object 120 (i.e. light source 140 is in front of the object 120 , or the direction of light from the source 140 , if behind the object 120 , is redirected to be incident from the front of the object 120 by the use of a mirror or mirrors), (b) the object 120 is in front of the translucent panel 100 , and the panel 100 is in front of the camera 110 .
[0046] For each rotation increment of the turntable 130 the object 120 , and hence its shadow 125 , assumes a different pose with respect to the image plane of the camera 112 . The rotation increment of the turntable 130 , and hence the number of poses attained by the object 120 , may be a function of the surface complexity of the object 120 , as the more complex is the surface shape the more shadow images will be required to capture the surface shape. That is, the rotation increment of the turntable 130 may be larger when the object 120 is a coffee cup as compared to the rotation increment when the object 120 is a decorative vase.
[0047] As an example, if the object 120 is a coffee mug with a handle, the rotation increment of the turntable 130 may be about 30 degrees.
[0048] An image is taken by the camera 110 with respect to each pose of the object 120 . The images that are acquired by the system, such as the exemplary object shadow image 350 shown in FIG. 3, are processed using the method shown in FIG. 4. In a loop 400 for each shadow image, each pixel is identified as being inside or outside the shadow in process 410 . Any suitable pixel thresholding analysis may be used in process 410 , such as the well-known k-means algorithm for unsupervised identification of clusters of values. The boundary of the shadow 125 is then found in process 420 with, preferably, sub-pixel accuracy using any image edge detector, such as the well-known Sobel edge detector. The exemplary shadow image 450 in FIG. 5 shows the results of processing image 350 with the method shown in FIG. 4.
[0049] Any suitable method may be employed for obtaining an estimated shape from silhouettes may be used to estimate the object shape from the derived object contours, such as the contour shown in the image 450 . The preferred embodiment shown in FIG. 6 uses a volume carving approach. In step 500 a virtual array of volume elements (such as, but not limited to, boxes) of dimension h×k×l are defined, where h,k and l are 0.01 H or less, in the coordinate system defined on the turntable 130 , such that the extent of the array encompasses the full object 120 . Initially all vertices on all volume elements are assigned a signed-distance value (i.e., negative for inside the object 120 , positive for outside the object 120 ) of −0.01H. This indicates initially that all vertices are inside the object 120 . For the loop 510 over each image acquired, the volume elements in list 520 are projected along lines emanating from the light source 140 position and ending on the plane of the translucent panel 100 using processes 530 . A test 540 is performed to determine if the volume element (box) is projected into the shadow region. If the result of test 540 is no, another test 550 is performed to see if the box is projected on the boundary of the shadow region. If the result of test 550 is yes, a process 555 computes a new signed-distance that is assigned to each vertex of the volume element equal to the distance of the projection of the vertex to the shadow boundary. If the result of the test in process 550 is no, the volume element is marked “out” in step 560 , given a signed distance value of 0.01H, and is eliminated from list of volume elements for the processing of subsequent images.
[0050] The further processing of the list of boxes (or volume elements) 600 is shown in FIG. 7. The numerical description of the object shape 620 is extracted by using any well-known isosurface algorithm 610 to find the surface that passes through the volume at signed-distance values of zero.
[0051] [0051]FIG. 8 shows a second embodiment of the image acquisition system, wherein components that are also found in FIG. 1 are numbered accordingly. A plurality of radiation sources (in this case three sources 142 , 144 and 146 ), each with a narrow, but not necessarily visible, spectral distribution are used in place of the single point light source 140 . In the preferred system, point lights with red 142 , green 144 and blue 146 filters are used. The sources 142 , 144 and 146 are arranged in this embodiment in a triangular shape, with each light source being placed at a vertex of the triangle, and separated from adjacent sources by about 2H. The size of the light sources is again 0.025H, and the plane of the triangularly-disposed light sources is located about 5H from the object 120 . The camera 112 that is used is capable of sensing radiation in each of the spectral bands. For point light sources with visible red 142 , green 144 and blue 146 filters a commodity digital camera 112 can be used. Each time the turntable 130 is moved a color image is obtained, with three separate shadows for the red, green and blue sources. The N images are processed as before (i.e., as in FIGS. 4, 6 and 7 ), with a total of 3N images being processed, and with each of the color images being separated into three grey-scale images.
[0052] [0052]FIG. 9 shows a third embodiment of the system, wherein components that are also found in FIG. 1 are numbered accordingly. In this embodiment an array 160 of M light sources (in this case M=9) is used in place of the single light source 140 . The light sources 161 , 162 , 163 , 164 , 165 , 166 , 167 , 168 , 169 are mounted on a frame 180 , with a distance 2H between adjacent light sources, and the plane of the array 160 of light sources is located about 5H from the object 120 . A color camera 170 is placed in front of the object 120 adjacent to light source 169 (i.e., at about the center of the array 160 . As each light source ( 161 , 162 , 163 , 164 , 165 , 166 , 167 , 168 , 169 ) is illuminated in turn, both cameras ( 170 and 110 ) acquire an image. A series of M shadow images and M color images are thus obtained for each position of the turntable 130 . The shadow images are processed as before (i.e., as in FIGS. 4, 6 and 7 ). This embodiment thus uses photometric stereo techniques to obtain additional shape information, and assumes the use of the visible spectrum of light.
[0053] Alternatively, the array of M light sources 160 can be replaced by a single point source and a mechanism to translate the point light source to different known positions. For example, person or a machine may move a single light with a tracking system and record the light position each time an image is acquired. A single light source can also be made to impinge on the object 120 from many different directions by reflecting against a mirror that is controlled to move into a series of known positions.
[0054] The processing of the M color images obtained by the camera 170 is shown in FIG. 10. Using the numerical surface description 620 obtained in FIG. 7, in step 630 the M color images are processed by means of a photometric stereo technique, preferably one described in Rushmeier et al. “Acquiring Input for Rendering at Appropriate Levels of Detail: Digitizing a Pieta”, Proceedings of the 9th Eurographics Rendering Workshop, Vienna, Austria, June 1998, and in Rushmeier and Bernardini, “Computing Consistent Normals and Colors from Photometric Data”, Proceedings of 3DIM ‘99, Ottawa, Canada, October, 1999, incorporated by reference herein, to produce detailed maps of color and surface normals for the object 120 . In step 640 the color and surface normal maps are projected on to the estimated shape of the object 120 and combined into a single non-redundant map of normals and colors by the methods described in Bernardini et al., “High-Quality Texture Synthesis from Multiple Scans”, IBM Research Division Report, RC21656, Feb. 1, 2000, incorporated by reference herein. The result is a model 650 that contains of a numerical description of shape and a map of detailed colors and normals. The resultant model 650 is suitable for display using software available on most commodity personal computers.
[0055] Other techniques for deriving surface color and normals maps could be employed as well.
[0056] Note should be made that the color camera 170 , and the associated processing shown in FIG. 10, could be incorporated as well into the system embodiments shown in FIGS. 1 and 8.
[0057] While the invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the scope and spirit of the invention.
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Disclosed are methods and apparatus for obtaining the shape of an object by observing silhouettes of the object. At least one point light source is placed in front of the object, thereby casting a shadow of the object on a translucent panel that is placed behind the object. A camera, or other imaging device, captures an image of the shadow from behind the translucent panel. The object's full silhouette is obtained from the image of the shadow as the region of the shadow is substantially darker than the region outside of the shadow. The full silhouette thus obtained may be processed by any suitable shape from silhouette algorithm, and thus objects are not limited in topological type. A color image of the object can optionally be obtained simultaneously with the shadow image using a camera placed on the same side of the object as the light source. Multiple silhouettes can be captured for one object position, reducing the number of rotations needed on a turntable system, and reducing the post-processing needed to register geometries obtained from multiple different positions.
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FIELD OF THE INVENTION
This invention relates to wireless communications networks, and in particular to a method of self-configuration of such a network.
BACKGROUND
A cellular communications network includes multiple base stations. In order for the network to provide the best possible coverage for users, it is necessary for the radio configuration of each base station to take into consideration the radio configurations of nearby base stations. For example, the downlink power with which each base station transmits signals needs to take into account the downlink powers used by nearby base stations, in order to ensure that there is adequate network coverage, without causing problems due to interference.
Traditionally, the radio configuration of cellular networks is manually planned, and explicitly provisioned from the network to a macrolayer NodeB. As a development of this, as disclosed in GB-2447439A, standalone femtocell base stations can instead be provisioned with a range of possible values for their radio configuration, and can then choose an optimal configuration autonomously. In addition, GB-2472597 discloses a femtocell base station that is intended to form part of a group of base stations that can be deployed in an enterprise such as a large office, a shopping mall, a campus, or the like. In this solution, small groups of femtocell base stations that are connected to the same local area network (LAN) may autonomously reach a collective radio configuration by broadcasting their own selected configuration to all their peers, and then adjusting their own configuration based on the configurations of their peers that they receive.
However, this has the limitation that the femtocells must all be connected to the same local area network, so that they can communicate by broadcasting (or multicasting their configuration information messages). Moreover, in the case of a large deployment of small cells, there is the disadvantage that every femtocell basestation must handle signalling traffic from every other femtocell basestation.
SUMMARY
According to an aspect of the present invention, there is provided a method of configuring an access point, the method comprising:
transmitting operational context information for the access point according to a publish-subscribe messaging pattern; receiving information identifying at least one other access point meeting proximity criteria; subscribing to publish-subscribe messages from the or each other access point identified in said information; and setting radio configuration information for the access point in view of the received messages from the or each other access point.
According to a second aspect of the present invention, there is provided an access point, configured to operate in accordance with the method of the first aspect
According to a third aspect of the present invention, there is provided a computer program product, comprising computer readable code for causing a processor to operate in accordance with the method of the first aspect.
According to a fourth aspect of the present invention, there is provided a network node for a telecommunications network, the network node being configured:
to receive information from each of a plurality of access points, to determine on the basis of said information which of said access points have coverage areas that overlap, and, for each pair of access points with overlapping coverage areas, to notify the access points of the overlap.
This has the advantage that large numbers of small cells can be deployed without requiring the mobile network operator to incur the large operational expenditure that would be involved in extensive network planning, and without requiring each basestation to process messages from every other basestation.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, and to show how it may be put into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 illustrates a wireless communications network in accordance with an embodiment of the invention;
FIG. 2 illustrates a cellular base station in accordance with an embodiment of the invention;
FIG. 3 is a flow chart illustrating a method in accordance with the invention;
FIG. 4 schematically illustrates the operation of the cellular base station in accordance with the method of FIG. 3 ; and
FIG. 5 is a flow chart illustrating the operation of the Geospatial Radio Coverage Registry.
DETAILED DESCRIPTION
FIG. 1 illustrates the general form of a part of a wireless communications network 10 . At this level of generality, the network 10 is conventional, and so it is described here only to the extent required for an understanding of the present invention.
The invention is described here with reference to a cellular wireless communications network, for example a Universal Mobile Telecommunications System (UMTS) Terrestrial Radio Access Network (UTRAN). However, it will be appreciated that the invention is applicable to other types of network.
The network 10 includes multiple access points, for example in the form of cellular base stations. Each access points is a radio transmit/receive station, having a specific location, and transmitting at a specific power in a specific part of the radio spectrum. Depending on the cellular radio technology that is used by the network, the spectrum might be divided by frequency, timeslot and/or code.
FIG. 1 shows an access point 12 , which has the potential to provide coverage in a cell, namely an area bounded by the line 14 . Each access point serves a cell in this way. The exact size of each cell will be determined by the presence of any obstacles such as tall buildings and the like. However, in general terms the size of the cell can be regarded as a function of the transmit power with which the access point broadcasts its signals.
A network operator will typically install a number of base stations that is sufficient to provide coverage throughout the intended coverage area. These base stations each serve relatively large cells. There is a limit to the number of calls that can be handled by an access point any time, and so additional access points can then be deployed in areas of high user density.
For example, FIG. 1 shows a base station 16 serving a cell 18 . If the network operator is able to predict that there will be a high level of traffic at a particular location within the cell 18 , for example at a railway station, then an additional base station 20 can be installed to serve a cell 22 that covers that location.
A user equipment (UE) device, such as the mobile phone 24 , obtains network service by radio contact with an access point. For example, FIG. 1 shows the mobile phone 24 being within the cell 14 , but also being within a cell 26 being served by an access point 28 . Thus, the UE could make radio contact with the access point 12 or the access point 28 , and the protocols used by the Radio Access Network define mechanisms that determine which access point should serve the UE. In general terms, the access point that is best able to serve the UE is the access point that has the strongest signal. Service to a UE is maintained by changing the serving access point as the user equipment moves within the region.
In larger areas of high user density, multiple small cells can be deployed, either at the instigation of the mobile network operator, or of the management of a campus, shopping mall, large office building, or the like. Thus, FIG. 1 shows three access points 30 , 32 , 34 , serving respective small cells 36 , 38 , 40 , within the cell 14 .
In order to provide service to UEs throughout a region, the access points must have transmit power and spectrum configurations which maximise coverage while avoiding interference. There are typically a small number of available spectrum choices, so coverage areas must be adjusted such that no coverage areas with the same spectrum assignment overlap.
FIG. 2 is a block schematic diagram, illustrating in general terms the form of an access point in accordance with an embodiment of the invention.
Thus, FIG. 2 shows an access point 50 , which is generally conventional, and thus is described here only so far as is necessary for an understanding of the present invention. The access point 50 has an antenna 52 , connected to transceiver (TRX) circuitry 54 , which performs the required modulation and demodulation of the radio frequency signals for the cellular communications protocol used by the access point.
The TRX circuitry is connected to a processor 56 , which performs the required control functions for the access point, including a location detection block 60 and a radio configuration block 62 . The processor 56 is also connected to a network interface 58 , which allows the access point 50 to connect over an IP network such as a local area network (LAN) and into a wide area network (WAN). The processor 56 runs software for performing the various procedures described herein.
FIG. 3 is a flow chart, illustrating a procedure performed in accordance with an aspect of the present invention. In one illustrative embodiment, described purely by way of example, the procedure is performed in a femtocell access point (also known as a Home NodeBs in 3GPP standards). More specifically, the procedure of FIG. 3 relates to a situation in which a group of femtocells is deployed to cover an area. This may be an area in a larger commercial building or outdoors. However, the configuration process described herein is sufficiently scalable that the procedure is equally applicable to a very large deployment of small cells, for example across a city or region.
Costs are reduced when planning, managing and operating a group of femtocells as a network if they can autonomously and collectively configure how they share the available radio spectrum, and can autonomously provide inter-femtocell mobility to UE devices. As is conventional, the femtocell access points of the group are all connected to a public Wide Area Network (WAN), specifically the internet, enabling communication between each access point and other resources that are accessible over the internet.
Specifically, FIG. 3 illustrates a procedure performed when there is an existing group of femtocells operating as a network, and a new access point is added to the network, in order that it can come into service and provide connectivity to mobile UEs. It should be noted that the actual sequence of steps in a concrete implementation may vary as access points are independent computational units exchanging asynchronous messages. FIG. 4 illustrates the access point 50 establishing a connection to the centralized functions 110 of the mobile network.
The process begins with step 80 , when the access point is first powered on. In step 80 , the access point receives a common configuration from a network management function (shown as block 112 in FIG. 4 ), which typically will be centralized, so that it provisions multiple groups of access points throughout the network. For reasons of efficiency, it is preferable that exactly the same initial configuration data is provisioned to every access point. The initial configuration data might be provided on the access point 50 at manufacture, or the access point 50 might instead be provided with a URL identifying a suitable server from which the initial configuration data might be downloaded to the access point 80 on start up.
In one example, the initial configuration data includes constraints, within which the autonomous radio configuration algorithms on the access point 50 must make their dynamic selections. In addition, the initial configuration data in this example includes values to be looked up later (i.e. DNS lookups).
In step 82 , the access point publishes values defining its operational context. The values are published using a publish-subscribe mechanism, whereby the access point 50 makes no attempt to identify specific receivers of the information, but simply publishes the information to a publish-subscribe server 114 , which is hosted on the public internet, accessible by all of the access points over the IP network, as shown in FIG. 4 , and which provides message broker, forwarding and repeater functionality. While publishing the information, an access point characterizes the message into one of several available classes. For example, in this case, the message might be allocated to a class of messages that all provide updates to the operational context of an access point.
Publish-subscribe, or PubSub, is an accepted design pattern within the Internet development community, most notably implemented as a extension of the XMPP protocol (http://xmpp.org/extensions/xep-0060.html). PubSub improves scalability of information exchange by decoupling the relationship between senders and receivers. With PubSub, the publisher of information does not know about the subscribers that will receive the message, and the subscribers register their interest in certain classes of message ahead of time. The publisher sends a message to the PubSub service, and the PubSub service distributes a copy of the message to each interested subscriber.
Thus, the messaging traffic volumes scale approximately linearly with the number of access points, rather than exponentially, as messages from access points are routed only to the other access points that are interested, and not to every other peer.
The set of values defining the operational context of the access point is extensible. For example, in this embodiment, the access point 50 includes a location detection block 60 . For example, the location detection block 60 might receive input signals from a GPS, or other satellite positioning system, receiver, and calculate the location of the access point from the received signals. Alternatively, the location detection block 60 might control the transceiver circuitry 54 of the access point 50 to detect signals from other access points or from other radio sources, and can then determine the location of the access point by triangulation in the received signals.
As another example, the operational context of the access point might include the maximum power at which it is physically capable of transmitting. The operational context might also include the assigned IP network address or addresses of the access point. In addition, if the access point is part of a group of access points within an enterprise, for example, this group identity might also be part of the operational contect that can be shared with other access points.
In step 84 , the access point takes measurements of its radio environment. For example, the access point 50 detects signals from neighbouring access points, and from any macrocells that are able to provide coverage at that location. Having detected the signals, the access point 50 is able to identify the cells transmitting those signals by the Cell-ID that they broadcast, and is also able to detect the strengths of such signals. This information forms the radio environment context within which the access point 50 is operating.
In step 86 , the access point publishes the information defining the radio environment context to the publish-subscribe site 114 as shown in FIG. 4 .
When information is published to the publish-subscribe site 114 , the publish-subscribe service propagates the information defining the access point's operational context and/or radio environment context as events to those of its peers (shown as 116 , 118 etc in FIG. 4 ) that have subscribed. As described in more detail below, the peer access points 116 , 118 , . . . then make any necessary adjustments to their configuration so as to accommodate the addition of the new access point.
In step 88 , the access point 50 subscribes through the publish-subscribe site 114 to those peer access points in its proximity that are close enough that it may need either to negotiate non-interfering radio configurations with those access points, or to exchange mobility control signalling with those access points to effect the handover of a UE.
Then, in step 90 , the access point receives (as events from the publish-subscribe service 114 ) the operational context and radio configuration last published by each of the peers to which it has subscribed.
In step 92 , the access point 50 determines its own radio configuration by means of its autonomous radio configuration block 62 shown in FIG. 2 . More specifically, it applies an algorithm which combines the constraints from its initial configuration data with the configurations of its peers that it received in step 90 , and the measurement data relating to the radio environment that it obtained in step 84 . Based on these inputs, the access point decides upon a part of the radio spectrum and a transmit power to use. As noted above, the access point might be able to select an operating frequency and/or a scrambling code and/or a timeslot for its transmissions, depending on the radio access method used in the network.
Then, in step 94 , the access point 50 publishes (to the publish-subscribe service 114 ) values defining its radio configuration. The PubSub service then propagates these values as events to those of the peer access points that have subscribed, enabling them to make any adjustments to their configuration as necessary to accommodate the addition of the new access point.
The access point has now completed all of the PubSub interactions required for it to enter service in step 96 . Specifically, the access point 50 provides service to UEs within its radio coverage area, and interacts with centralized mobile network functions to authenticate UEs and to place calls to and from the PSTN through the PSTN interworking function 122 of the network. As part of this service, the access point 50 will typically receive measurement reports from any UEs connected thereto. If these measurement reports suggest that a handover might be required, the access point 50 is able to engage in direct communication with peer access points over the LAN, or other IP network, to effect the handover.
While in service, the access point 50 continually determines in step 98 whether it has received any events from the PubSub service containing updated operational context or radio configuration from peers to which it is subscribed. On receipt of such an event, the process returns to step 92 , in which the access point repeats the determination of its radio configuration, in order to resolve any potential for radio interference which has been introduced. If any change is made, the access point 50 publishes the new radio configuration in step 94 as described above.
Thus, the access point 50 is able to obtain the information that it requires to set its configuration, in a manner that is highly scalable, remaining efficient even if there are a large number of access points in the group.
In step 88 , it was mentioned that the access point must determine which subset of the whole collection of its peers are neighbours whose operational context and radio configuration it requires. There are at least two ways in which this can be done. As a first example, the network management function 112 may provision a neighbour list in step 80 , based on information as to the location in which each access point is intended to be deployed, and a manual determination as to which access points are then potential neighbours. The publish-subscribe service 114 can then operate such that each access point receives the radio configuration update messages from its designated neighbours.
As a second example, an adjunct of the PubSub service can act as a Geospatial Radio Coverage Registry, subscribing to all access points to receive information about their locations and their maximum transmit powers (published in step 82 ).
FIG. 5 is a flow chart, illustrating the operation of the Geospatial Radio Coverage Registry. In step 130 , the Geospatial Radio Coverage Registry subscribes to each access point. It has access to a database that stores details of all of the access points, and so it is able to ensure that it subscribes to any access point that is added to the network. In step 132 , the Geospatial Radio Coverage Registry receives the initial operational context message from each access point, specifically identifying the location of that access point and the maximum power with which it can transmit. Based on this information, in step 134 the Geospatial Radio Coverage Registry is able to determine the potential coverage areas of each access point.
In its simplest embodiment, the Geospatial Radio Coverage Registry determines that the coverage areas of two access points overlap based on a simple calculation of a maximum distance over which the access point can transmit, derived from the maximum power with which it can transmit. Combining this with the location of that access point provides a potential coverage area, and it is straightforward to determine when the potential coverage areas of two access points overlap.
In an alternative embodiment, the Geospatial Radio Coverage Registry determines the coverage area of each access point based on a more detailed calculation that takes account of the terrain in which the access point is situated.
For example, the presence of a hill or a tall building might mean that the coverage area of an access point is less than the potential coverage area that its maximum transmit power would suggest. Alternatively, if the access point is located at the top of a hill its coverage area might actually be larger than its maximum transmit power would suggest. Thus, in step 134 , the determination of the potential coverage areas can be performed in an accurate manner that takes account of these factors, or can be performed in a less accurate manner relying only on the location of the access point, and its transmit power.
In either case, the Geospatial Radio Coverage Registry, is then able in step 136 to identify when the potential coverage areas of two access points overlap, and hence that the two access points are capable of transmitting signals that can be detected at the same point.
When it is determined in step 136 that the coverage areas of two access points overlap, the Geospatial Radio Coverage Registry can identify that the two access points should receive radio configuration update messages from each other. Each access point subscribes to the Geospatial Radio Coverage Registry on initialisation, and so, when the Geospatial Radio Coverage Registry identifies that two access points should receive radio configuration update messages from each other, it notifies each of the access points that it should subscribe to messages from the other, and the subscriptions are updated in step 138 .
In other embodiments, the Geospatial Radio Coverage Registry can identify that the two access points should receive radio configuration update messages from each other when an alternative proximity criterion is met.
For example, when an access point has the capability to detect signals transmitted on system downlink frequencies by other access points, it can list those access points whose transmissions it can detect, as its neighbours. In one embodiment, the Geospatial Radio Coverage Registry can identify that the two access points should receive radio configuration update messages from each other when they are neighbours according to this definition, or when they have at least one neighbour in common.
Thereafter, each access point receives events relating to any radio configuration updates from any of the peer access points in its proximity that might affect its own radio configuration. Thus, in step 92 , the access point 50 determines its radio configuration.
In one embodiment the access point makes a deterministic decision in isolation on the basis of the constraints it received in step 80 , together with the configurations of peers it received in step 90 and its measured radio environment. It makes its best effort to avoid choosing a configuration which conflicts with a neighbour's settings and might cause interference, but, if such a conflict is unavoidable, the access point will go ahead, and will leave the peer to resolve the situation when it subsequently receives an event notifying it of the new configuration and reconsiders its own radio configuration in the light of that.
This may cause several access points to need to alter their configurations as the effects pass to the neighbours of the neighbours of the first access point.
As an alternative, the access point can determine its configuration as described above but, if it determines that it cannot avoid a conflicting configuration, it exchanges direct messages with the affected peer to resolve the conflict before proceeding. Again, there may be knock-on conflicts with neighbours of that peer, in which case all affected peers can negotiate a mutually satisfactory set of radio configurations before finalising them in parallel.
It can be difficult to design sequential or parallel algorithms executed at each access point which guarantee to converge at a stable and near-optimal radio configuration for the network. Therefore, as an alternative to the above, a specialised client of the PubSub service may act as a controller to co-ordinate radio configuration decisions. For example, this client may determine, based on the location of an access point, that it is only able to operate on certain frequencies, so that any conflicts are localised. This may be implemented as a function of the Geospatial Radio Coverage Registry or as an additional specialised client of the PubSub service.
It has been mentioned above that, in some situations, it is useful for there to be direct IP communication paths between access points. However, access points are often behind Network address translation (NATs).
In order to allow IP packet routing between access points in this case, the assigned IP network addresses published (to the PubSub service) may be routable from other peers, in which case they are sufficient. For example, this would apply if, within the centralized mobile network functions 110 , there is a security gateway or IP relay assigning mutually-routable addresses to the access points.
As an alternative, NAT traversal technology can be used to determine routes between access points on a pairwise basis as needed, for example the Jingle extension of the XMPP protocol (http://xmpp.org/extensions/xep-0166.html).
The process described above was concerned with the situation where a new access point is added to the network. However, there are other situations in which the use of the PubSub service provides advantages.
As one example, once they are in service, access points may undertake relatively frequent collaborative radio transmit power reconfiguration to resolve dynamic issues with UE service. For example, when too many UEs are attached to one access point that access point may shrink its coverage area while its neighbours expand theirs, so that they can take some of the UEs from the congested access point, providing better service overall. As another example, UE mobility between access points depends upon zones of overlapping coverage in order to allow handovers to be made successfully. If two access points experience repeated dropped calls on handover between them, then one or both may increase their transmit power in an effort to expand the region of overlapping coverage.
When it is determined for one of these reasons (or any other reason) that an access point should alter its transmit power, changes are propagated between peers using the mechanism described above, whereby each access point publishes its changed transmit power, and any other access point that has subscribed to that event will receive the message. As an alternative, the decision making process to determine new transmit power values may be made between access points sequentially, in parallel or with assistance from a mediator.
In addition, access points may use the publish-subscribe mechanism to publish data for consumption by specialist subscribers which are not peer access points. For example, technicians can monitor the status of each access point, in order to be able to detect any problems with the network. For example, the technicians can monitor the numbers of UEs being served by each access point, and can receive faults and alarms, statistics about dropped calls, and warnings if the radio configuration algorithms can only make choices that risk causing interference. In addition, the technicians can receive statistics about user paths through the network of access points. In the case of shopping malls or the like, this information can be used not only to improve the cellular radio network, but can also be used for planning the layout of the mall itself.
Thus, it is described how the publish-subscribe mechanism can be applied to enable a group of cellular access points to self-configure and hence provide autonomous UE mobility.
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A cellular communications network includes multiple base stations. In order for the network to provide the best possible coverage for users, it is necessary for the radio configuration of each base station to take into consideration the radio configurations of nearby base stations. Operational context information for the access point is transmitted according to a publish-subscribe messaging pattern. Information is received identifying at least one other access point meeting proximity criteria. The access point subscribes to publish-subscribe messages from the or each other access point identified in said information, and sets its radio configuration information in view of the received messages from the or each other access point.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electrical connector assembly, and particularly to an electrical connector assembly used for interconnecting an Integrated Circuit chip (hereinafter abbreviated as IC chip) and a Printed Circuit Board (hereinafter abbreviated as PCB).
[0003] 2. Description of the Prior Art
[0004] As the “Test and Burn-in Socket Developments” (Connector Specifier, February 2001) discloses, a trend has been more and more clear that the IC chip is becoming minisize and an electrical connector used for interconnecting the IC chip and the PCB intends to become “light, thin and small”. Such an electrical connector assembly usually comprises a mounting portion, an insulative housing and a plurality of contacts received in the insulative housing. The mounting portion fixes the insulative housing and the IC chip with the PCB thereby establishing an electrical connection between the IC chip and the PCB. Those electrical connector assemblies are described in the U.S. Pat. No. 5,481,435, U.S. Pat. No. 5,251,107 and U.S. Pat. No. 5,184,285.
[0005] Referring to FIG. 18 , a conventional electrical connector assembly 9 comprises an insulative housing 90 , a plurality of contacts 91 received in the insulative housing 90 and a mounting portion 92 fixed with the insulative housing 90 . An IC chip (not shown) is received in the insulative housing 90 and is formed with a plurality of pins. Each pin of the IC chip connects one contact 91 . The PCB 8 forms a plurality of soldering pads (not shown) corresponding to the contacts 91 . Because distance between the adjacent contacts 91 is changeless, the distance between adjacent soldering pads of the PCB 8 must equal to the distance between the pins of the IC chip.
[0006] However, the IC chip is mini in size, the distance between the adjacent pins will be very small. In another hand, the soldering pads should space each other for a certain distance as a reason of anti-interference, so it will be very different for the PCB to arrange the soldering pads.
[0007] Hence, an improved electrical connector assembly is required to overcome the disadvantages of the prior art.
BRIEF SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide an improved electrical connector with a transfer member, which can solve a problem resulted by the miniaturization of the IC chip.
[0009] An electrical connector in accordance with the present invention comprises a first connector, a second connector and a transfer member interconnecting the first connector and the second connector. The first connector includes a first housing and a plurality of first contacts received in the first housing. The second connector has a second housing and a plurality of second contacts received in the second housing. The transfer member disposes between the first connector and the second connector and comprises a first interface and a second interface. The first interface defines a plurality of first receiving holes receiving the first contacts therein. The second interface forms a plurality of golden fingers electrically connecting the second contacts. Each first receiving hole correspondingly electrically connects one golden finger, and a distance between the adjacent first receiving holes is smaller than the distance between the adjacent golden fingers.
[0010] To compare with the conventional invention, the merit of the present invention is the transfer member. The first connector connects an IC chip, and the distance between adjacent pins of the IC chip equals to the distance between the adjacent first contacts. Because of the minisize of the IC chip, this distance is very small. In another hand, the distance between the adjacent second contacts of the second connector is the same as the distance of adjacent soldering portions of the PCB. As a requirement of anti-interference, this distance should be wider than the distance between the adjacent first contacts. Because the distance between the adjacent golden fingers formed on the second interface is wider than the distance between the adjacent first receiving holes defined on the first interface, the IC chip with a narrow distance between the adjacent pins may be connected to the PCB.
[0011] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description of a preferred embodiment when taken in conjunction with the accompanying drawings.
BREIF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an assembled view of an electrical connector assembly in accordance with the present invention;
[0013] FIG. 2 is an assembled view of a first contact and a first housing of a first connector;
[0014] FIG. 3 is an assembled view of a first assembly member, the first contact and the first housing of the first connector;
[0015] FIG. 4 is a perspective view of a second assembly member of the first connector;
[0016] FIG. 5 is another perspective view of the second assembly member showing a bottom surface;
[0017] FIG. 6 is an assembled view of the first contact, the first housing, the first assembly member and the second assembly member;
[0018] FIG. 7 is a perspective view of a third assembly member of the first connector;
[0019] FIG. 8 is an assembled view of the first contact, the first housing, the first assembly member, the second assembly member and the third assembly member;
[0020] FIG. 9 is a perspective view of a forth assembly member of the first connector;
[0021] FIG. 10 is another perspective view of the forth assembly member showing a bottom surface;
[0022] FIG. 11 is an assembly view of the first contact, the first housing, the first assembly member, the second assembly member, the third assembly member, the forth assembly member and a locking member of the first connector;
[0023] FIG. 12 is a perspective view of a fifth assembly member of the first connector;
[0024] FIG. 13 is an assembled view of the first connector;
[0025] FIG. 14 is a perspective view of a transfer member showing a first interface of the electrical connector assembly;
[0026] FIG. 15 is another perspective view of the transfer member showing a second interface;
[0027] FIG. 16 is an assembled view of the first connector and the transfer member; and
[0028] FIG. 17 is a perspective view of a second connector of the electrical connector assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Referring to FIGS. 1, 13 , 14 , 15 and 17 , an electrical connector assembly 1 used for interconnecting an IC chip (not shown) and a PCB (not shown), comprises a first connector 2 , a second connector 3 and a transfer member 4 interconnecting the first connector 2 and the second connector 3 . The first connector 2 comprises a first housing 20 , a plurality of first contacts 21 received in the first housing 20 , a first assembly member 22 , a second assembly member 23 , a third assembly member 24 , a forth assembly member 25 , a fifth assembly member 27 and a locking member 26 . The second connector 4 comprises a second housing 40 and a plurality of second contacts 41 . The transfer member 3 defines a first interface 30 and a second interface 31 . The first interface 30 engages with the first connector 2 . The second interface 31 is defined opposite to the first interface 30 and engages with the second connector 4 . The transfer member 3 has a plurality of receiving holes 300 defining through the first interface 30 and the second interface 31 corresponding to the contact 21 . The second interface 31 is formed with a plurality of golden fingers 310 arranged in two rows in longitudinal direction. Each receiving hole 300 connects one golden finger 310 with a wire (not labeled).
[0030] Referring to FIGS. 2 and 3 , the first housing 20 of the first connector 2 is formed with a lengthwise configuration, and defines a plurality of slits 200 . Each of the slits 200 receives one contact 21 therein. The contact 21 comprises a first contacting portion 210 for contacting a pin of the IC chip, a first soldering portion 211 soldering with the receiving hole 300 , and a first connecting portion 212 interconnecting the first contacting portion 210 and the first soldering portion 211 . The first assembly member 22 comprises a base 220 and a pair of first positioning post 221 symmetrically projecting from the base 220 . In assembly, a pair of first assembly members 22 is placed parallelly with each other. The first housing 20 mounts on the bases 220 and interconnects two first positioning posts 221 of different first assembly member 22 .
[0031] Referring to FIGS. 4, 5 and 6 , the second assembly member 23 substantially is a frame. A pair of positioning portions 230 is formed at ends of the second assembly member 23 in a longitudinal direction. Two pairs of first positioning bores 231 and third positioning bores 233 are symmetrically defined on the positioning portions 230 . A pair of second positioning bores 232 is defined through the positioning portion 230 , and a pair of positioning posts 234 is vertically projecting upwardly from positioning portion 230 . A pair of the diagonal third positioning bores 233 each receives a spring (not labeled). The positioning portion 230 comprises a first abutting wall 235 abutting the first assembly member 22 and a lower second abutting wall 236 . A pair of first recessing portions 238 is defined at the opposite edges of the first abutting wall 235 . A pair of second recessing portions 237 is defined at the opposite edges of the second abutting wall 236 . In assembly, the second assembly member 23 engages with the first housing 20 , first contact 21 and the first assembly member 22 . A pair of first recessing portions 238 of different positioning portions 230 engages with first housing 20 . The first abutting walls 235 abut against the bases 220 , and each of the first positioning posts 221 engages with one first positioning bore 231 .
[0032] Referring to FIGS. 7 and 8 , the third assembly member 24 is formed with a plurality of grooves 241 arranged in two rows in a longitudinal direction. A pair of first engaging bore 242 is defined on the third assembly member 24 according to the second positioning posts 234 . Four clasping arms 244 project downwardly at corner portions of a lower surface of the third assembly member 24 . Two pairs of second engaging bores 243 are defined at the lower surface of the third assembly member 24 corresponding to the third positioning bores 233 of the second assembly member 23 . In assembly, the third assembly member 24 engages with an assembled member shown in FIG. 6 . The third assembly member 24 mounts on the second assembly member 23 , and the grooves 241 each receive one first contact 21 therein. The first engaging bores 242 engage with the second positioning posts 234 , thus the four second engaging bores 243 are opened against the third positioning bore 233 . Two of the second engaging bores 243 corresponding the diagonal third positioning bores 233 receives free end of the springs. The four clasping arms 244 engage with the second recessing portions 237 of the second assembly member 23 and clasp the third assembly member 24 with the second assembly member 23 , thus the third assembly member 24 is capable of moving downwardly towards the second assembly member 23 . pair of supporting portions 250 respectively extends towards each other from a bottom portion of an inner sidewall of the forth assembly member 25 . A pair of third positioning posts 2500 respectively vertically project from middle portions of the supporting portions 250 . A first engaging wall 251 is defined adjacent to the transfer member 3 at a lower surface of the forth assembly member 25 . A second engaging wall 252 is defined opposite to the first engaging wall 251 at an upper surface of the forth assembly member 25 . A plurality of first receiving holes 253 is defined at corner portions of the first engaging wall 251 . A pair of first engaging posts 254 symmetrically and downwardly projects from the first engaging wall 251 in a longitudinal direction. Every two second receiving holes 255 are defined at a corner portion of the second engaging wall 252 , and a second engaging post 256 upwardly projects from each corner portion. The forth assembly member 25 also defines a pair third recessing portions 258 at longitudinal ends thereof. A pair of third receiving holes 257 is defined at opposite inner walls of each third recessing portion 258 . The locking members 26 have configurations of mirror imaged Z shape, and engage with the forth assembly member 25 . A lower end 261 of the mirror imaged Z-shaped locking member 26 engages the third receiving portion 257 . The locking member 26 defines a pair of forth receiving holes (not labeled) corresponding to the third receiving holes 257 and a forth recessing portion 260 at a free end of the lower end 261 . A first bolt 28 passes through the third receiving holes 257 and the forth receiving holes thereby securing the locking member 26 with the forth assembly member 25 . In assembly, the assembled member in FIG. 8 is inserted into the cavity of forth assembly member 25 in an up-to-down direction, of which the second abutting wall 236 abuts the supporting portion 250 , and the third positioning posts 2500 respectively couple with the second positioning bore 232 . A higher end 262 of the locking member 26 abuts a top surface of the third assembly member 24 . A plurality of springs is received in the second receiving hole 255 .
[0033] Referring to FIGS. 12 and 13 , the fifth assembly member 27 comprises a third engaging wall 270 defined at a lower surface and a forth engaging wall defined at a top surface thereof. Four first coupling arms 272 vertically and downwardly project from corner portions of the third engaging wall 270 . A pair of first tabs 273 respectively extends downwardly from a middle portion of longitudinal side edges of the third engaging wall 270 . A plurality of third receiving holes 274 is defined on the third engaging wall 270 corresponding to the second receiving holes 255 of the forth assembly member 25 . Four forth positioning bores 275 are defined through the third engaging wall 270 corresponding to the second engaging posts 256 . Each first coupling arm 272 defines a first coupling hole 276 therethrough at a latitudinal direction. In assembly, the third receiving hole 274 corresponds to the second receiving hole 255 and receives free ends of spring therein. The forth positioning bore 275 couple with the second engaging post 256 . The first coupling arms 272 abuts the latitudinal sidewall of the forth assembly member 25 . Because of the springs received in the second receiving holes 255 and the third receiving holes 274 , the fifth assembly member 27 is capable of pressed down towards the forth assembly member 25 . When an external force is exerted on the fifth assembly member 27 , the spring is caused to distort, the fifth assembly member 27 is pressed on the forth assembly member 25 . A second bolt 29 is inserted through each pair of first coupling holes 276 , and is mounted below the lower ends 261 and is received in the forth recessing portion 260 of the locking member 26 . When the external force is removed, the fifth assembly member 27 restores itself under a restore force of the springs. In a restore operation, as the second bolts 29 couple with first coupling arms 272 and the forth recessing portions 260 , the second bolt 29 is taken along by the fifth assembly member 27 and causes the lower end 261 been raised. Because the locking member 26 couples with the first bolt 28 and is able to pivot around the first bolt 28 , as a principle of leverage, the higher end 262 moves downwardly and presses third assembly member 24 .
[0034] Referring to FIGS. 14, 15 and 16 , the transfer member 3 is a plan plate with a circuit. The transfer member 3 comprises a first interface 30 connecting with the first connector 2 and a second interface 31 connecting with the second connector 3 . A plurality of first conductive holes 300 is defined through the transfer member 3 corresponding the first soldering portions 211 . A plurality of golden fingers 301 is arranged in two rows in longitudinal direction, each golden finger 301 electrically connects a conductive holes 300 . A distance between adjacent golden fingers 301 is twice widths of the distance between the adjacent conductive holes 300 . A plurality of first engaging holes 32 is defined corresponding to the first receiving holes 253 , and a pair of second engaging holes 33 is defined corresponding to the first engaging post 254 . Four first positioning holes 34 are defined at corner portions of the transfer member 3 . In assembly, the first engaging posts 254 couples with the second engaging holes 33 . The first contacts 21 are respectively received in the corresponding conductive holes 300 , and solder with the conductive holes 300 . A plurality of screws is used to couple the first engaging holes 32 with the first receiving holes 253 .
[0035] Referring to FIG. 17 , the second connector 4 is a flat frame. The second connector 4 comprises a second housing 40 and a plurality of second contacts 41 received in the second housing 40 . The second contacts are arranged in two rows in a longitudinal direction corresponding to the golden fingers 301 . Each second contact 41 comprises a second contacting portion 410 at an upper portion and a second soldering portion at a lower portion 411 . Four second positioning holes 401 are defined corresponding to the first positioning holes 34 of the transfer member 3 . In assembly, the transfer member 3 secures with the second connector 4 by bolting the first positioning hole 34 with the second positioning hole 401 .
[0036] When the IC chip (not labeled) is put in, the steps are given out hereinbelow. First, an external force is exerted on the higher ends 262 of locking member 26 to raise it, as a principle of leverage, the lower ends 261 are caused to move down thereby pressing the second bolts 29 and causing the fifth assembly member 27 moving down. Because of the first bolt 28 , the higher ends 262 respectively pivot around the corresponding first bolts 28 , and the third assembly member is exposed upwardly. Thus, the IC chip is easily to put in.
[0037] After the IC chip is put in, the external force is removed. As a restore force of the springs received in the second receiving holes 255 and third receiving holes 274 , the fifth assembly member 27 restore to a normal status. With a pressure of the second bolt 29 , the lower ends 261 pivot around the first bolt 28 and the higher ends 262 are caused to press the IC chip. Mentioned hereinabove, there are springs received in the third positioning bores 233 and second engaging bores 243 . These springs are pressed to distort and the third assembly member 24 is lowed. So, the first contacting portions 210 of the first contacts 21 expose from the grooves 241 of the third assembly member 24 and electrically connect with IC chip thereby connecting with a PCB through the transfer member 3 and the second contacts 41 .
[0038] It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not be limited to the details given herein.
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An electrical connector assembly includes a first connector ( 2 ), a second connector ( 4 ) and a transfer member ( 3 ). The first connector has a first housing ( 20 ) and a number of first contacts ( 21 ) received in the first housing. An Integrated Circuit chip (not shown) electrically connects with the first contacts. The second connector has a second housing ( 40 ) and a number of second contacts ( 41 ) received in the second housing. The transfer member is disposed between the first connector and the second connector. The transfer member includes a first interface ( 30 ) and a second interface ( 31 ). The first interface is formed with a number of first conductive portions ( 300 ) connecting the first contacts. The second interface provides a number of second conductive portions ( 301 ) electrically connecting the second contacts. Each first conductive portion correspondingly electrically connects one second conductive portion, and a distance between the adjacent first conductive portions is smaller than the distance between the adjacent second conductive portions.
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FIELD OF THE INVENTION
The field of this invention relates to installation of lengthy assemblies into a live well while providing a dual shut-off capability in a technique which does not require lengthy surface-mounted lubricators.
BACKGROUND OF THE INVENTION
In many applications, downhole assemblies which are quite lengthy need to be inserted into live wells. One technique that has been used in the past to accomplish this is to assemble a very tall lubricator. A lubricator is an isolation device mounted at the surface, which allows, through sequential valve operation, the assurance of a chamber which is at least doubly isolated from wellbore pressure, so that lengthy downhole assemblies can be assembled therein. Once the lengthy assemblies are fully put into the lubricator, the lubricator is isolated at the top around tubing or wireline and opened at the bottom. The tubing or wireline is then used to advance the assembly into the live well. One of the drawbacks of such a technique is that lubricators, which are 40 to 100 feet long, must be erected on the rig to accommodate lengthy bottomhole assemblies. This is time-consuming and expensive and further presents additional safety hazards for personnel who must be present near the top end of the lubricator to facilitate the insertion of the downhole assembly into the lubricator.
Regulations require that at least two positive shut-offs be provided from the well pressures at the surface where the downhole assembly is put together. The subsurface safety valve, which is a standard item on all the wells, is one such barrier. In some situations where the dual barrier can be required is if an existing well needs to be perforated at another location. In the past, large lubricators have been built at the rig floor to accommodate a gun assembly which could be fairly lengthy.
One of the objectives of the present invention is to eliminate the need for building lengthy lubricators at the rig floor by employing a portion of the wellbore for assembly of lengthy downhole assemblies such as perforating guns. Thus, in accomplishing the objective, the present invention provides for a second barrier such as a plug in addition to the subsurface safety valve. This additional barrier can be manipulated out of the way to allow the additional downhole function to be performed and, at the same time, the plug can be repositioned so that the assembly, which has been put together in the wellbore, can be brought up above the subsurface safety valve. Once again, two isolation devices will exist to permit the disassembly of the lengthy downhole assembly still in the wellbore. Thereafter, the upper barrier can be removed from the wellbore to facilitate future operations.
The prior art illustrates numerous styles of subsurface valves primarily used for safety shut-off purposes. Some assemblies involve singular valves and others involve dual valves. Typical of such art are U.S. Pat. Nos. Reissue 25,471; 4,116,272; 4,253,525; 4,273,186; 4,311,197; 4,368,871; 4,378,850; 4,444,268; 4,448,254; 4,476,933; 4,522,370; 4,579,174; 4,595,060; 4,603,742; 4,618,000; 4,619,325; 4,624,317; 4,655,288; 4,665,991; 4,711,305; 4,846,281; 4,903,775; 4,415,036; 4,427,071; 4,531,587; 4,825,902; 4,856,558; 4,986,358; 5,201,371; 5,203,410; 5,213,125; 5,411,096; and 5,465,786. This subject has also been written about in the November 1995 issue of World Oil in an article by Tim Walker and Mark Hopmann, entitled "Underbalanced Completion Improved Well Safety and Productivity," and in an SPE, Paper No. 304 Q1 by Tim Walker and Mark Hopmann, entitled "Downhole Swab Valve Aids In Underbalanced Completion of North Sea Well." This SPE paper was presented in the 1995 meeting held in Aberdeen.
The prior art just described reveals various components of downhole safety valve systems which include flapper-type and ball-type valves. What has been lacking is a system that is versatile and reliable as the system that is the present invention which facilitates the assembly of long downhole assemblies in the wellbore. The new system is flexible and can be readily installed when using extended assemblies in conjunction with wireline coil tubing or work string assemblies.
SUMMARY OF THE INVENTION
The wellbore is adapted for use as a lubricator for assembly of lengthy installations. The subsurface safety valve is used in conjunction with a nipple inserted into the wellbore and held in position by a packer. A plug is part of the nipple assembly. Upon setting of the packer, two barriers downhole are created to facilitate assembly of tools such as a perforating gun in the wellbore behind two barriers. The tool, such as a perforating gun, has a running tool below it which engages the plug. When the assembly is made up in the wellbore, the plug is engaged by the running tool and released from the nipple. The plug can then be advanced through the open subsurface safety valve to the proper location for deployment of a perforating gun, for example. Upon completion of the downhole procedures, such as perforating, the tools are brought uphole and the plug is sealingly relatched in the nipple, thus recreating the necessary two barriers to permit opening the wellbore at the surface to remove the assembly of the downhole tools and the running tool. The plug can be reengaged as many times as necessary for installation of a variety of equipment. The nipple can then also be removed after the packer is released.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the wellbore, showing the installation of the nipple with the plug and the packer assembly on the nipple.
FIG. 2 is a view of FIG. 1, with the nipple assembly in position and the packer set, thus forming a second barrier above the subsurface safety valve.
FIG. 3 is a schematic view of a tool assembled in the wellbore above the two closed barriers.
FIG. 4 illustrates the release of the plug from the nipple and the passage of the tool through the nipple and the opened subsurface safety valve for the completion of the downhole operation.
FIG. 5 is a schematic representation showing the retrieval of the downhole tool through the subsurface safety valve until the plug catches in the nipple to recreate the two barriers to allow the assembly of the downhole tool assembly within the wellbore.
FIGS. 6a-6g illustrate the nipple assembly with the running tool in the run-in position.
FIGS. 7a-7g illustrate further advancement of the running tool to equalize pressure on the plug.
FIGS. 8a-8g illustrate further advancement of the running tool indicating a travel limit reached for the outer sleeve.
FIGS. 9a-9g illustrate further advancement of the running tool just prior to release of the plug latch.
FIGS. 10a-10g indicate further advancement of the running tool and collet assembly so as to retain the outer sleeve as the plug latch is about to be turned.
FIGS. 11a-11g illustrate the further advancement of the running tool and collet assembly, with the plug latch fully rotated and full setdown weight.
FIGS. 12a-12g illustrate the plug latch fully turned just prior to application of a pickup force on the running tool so as to facilitate advancement of the plug downhole.
FIGS. 13a-13g show the fully released position allowing the plug to move downhole.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The operation of the apparatus and method of the present invention is illustrated schematically in FIGS. 1-5. In FIG. 1, the wellbore 10 has a subsurface safety valve 12. A lubricator or snubbing unit 14 can be mounted on top of the wellbore 10. An assembly of a nipple 16, a plug 18, and a packer 20 are installed through the lubricator 14 with, for example, a wireline 22. The assembly further includes the necessary setting tool 24 to actuate the packer 20. The packer 20 and setting tool 24 are well-known in the art. As shown in FIG. 1, the assembly is suspended above the subsurface safety valve 12. As shown in FIG. 2, the packer 20 has been set against the wellbore 10 and the setting tool 24 removed with the wireline 22. The plug 18 is part of the assembly with the nipple 16 when it is run into the wellbore on the wireline 22. It should be noted that alternative techniques for getting the assembly of the packer 20, the nipple 16, and the plug 18 to the desired position can be employed without departing from the spirit of the invention. With the plug 18 now in position, where it seals off the passage 26, the pressure in the wellbore 10 can be relieved through the lubricator 14 which was used to install the nipple 16. The upper region of the wellbore 28 is now available for assembling the downhole assembly within the wellbore 10. It should also be noted that the nipple 16 can be installed at any given time and may not necessarily require a lubricator 14 for insertion into the wellbore depending on the timing of its installation and the actual wellbore conditions at the time of its installation.
With the upper region 28 now depressurized and isolated by subsurface safety valve 12 and plug 18, a downhole assembly such as a perforating gun 30 with a running tool 32 at the bottom of it can be run into the wellbore 10, as shown in FIG. 3. The running tool 32 latches into the plug 18 so that the plug 18 can ultimately be released from the nipple 16. Once the plug 18 is latched with the running tool 32 and the top of the wellbore 10 is closed off through a snubbing unit such as 14, the coiled tubing 34 is advanced into the wellbore 10, allowing the gun 30 and the plug 18 to move through passage 26 to the desired position in the wellbore, as shown in FIG. 4. In the situation as shown in FIG. 4 where a gun 30 is used, the gun is now in position for firing and it is fired with the plug 18 still appended to the running tool 32. At the completion of the perforating operation, the perforating gun and plug are retrieved uphole, as shown in FIG. 5. Eventually, the plug 18 reseats in the nipple 16 and the running tool 32 releases from the plug 18 to allow the gun 30 to be in the upper region 28 of the wellbore 10, with two positive closures below. Those closures are the subsurface safety valve 12, which is closed from the surface after the plug 18 passes through it, and the plug 18 seated in the nipple 16, which constitutes the other downhole barrier. At that point, the upper region 28 is again depressurized from the surface and the gun assembly 30 is dismantled using the wellbore 10 as the lubricator yet again. Thereafter, the nipple assembly 16 can be removed with a known retrieving tool which is inserted into the wellbore 10 to release the packer 20 so that the nipple 16 with the plug 18 can also be removed from the wellbore.
Those skilled in the art will appreciate that other types of assemblies than the perforating gun 30 can be used with this technique. Other types of delivery systems for the assembly can be used than the coiled tubing illustrated in FIGS. 3-5 without departing from the spirit of the invention. This procedure can also be repeated several times for different reasons with the nipple assembly 16 being used at different elevations as the second barrier in conjunction with a preexisting downhole subsurface safety valve 12.
Referring now to FIGS. 6a-g, the major components of the plug 18 and nipple assembly 16 and the running tool 32 will be described more fully to explain in detail how the steps illustrated in FIGS. 1-5 are accomplished.
Referring now to FIGS. 6c-g, the nipple assembly 16 is shown in part. The upper end of the nipple assembly 16 has been removed for ease of view of the remaining portions of the assembly. However, for the purpose of completeness, the packer 20 is shown schematically in FIG. 6c. The nipple assembly 16 includes a top sub 36 connected to a body 38 at thread 40. Seal 42 seals the threaded connection at thread 40. Thread 44 is at the lower end of body 38. A test plug 46 can be used initially to test the sealing integrity of the nipple assembly 16. Once that test is complete, the plug 46 is removed from thread 44 and is replaced with an entry guide 48. Entry guide 48 has a taper 50 at its lower end. When the plug 18 is returned into the nipple assembly 16, the taper 50 helps to guide the plug 18 into the body 38. The entry guide 48 can be seen in FIG. 7g, while FIG. 6g shows the initial test plug 46 for pressure-testing at the surface. The nipple assembly 16 has a groove 54. The plug 18 has a rotating latch 56 which is biased into groove 54. Latch 56 pivots about pivot 58 and is biased counterclockwise to remain in groove 54 by a biasing member which is not shown.
The plug 18 comprises a top sub 60 which has a shoulder 62 which faces outwardly. The top sub 60 is engaged to the latch sub 64 at thread 66. Latch sub 64 is engaged to seal sleeve 68 at thread 70. Sleeve seal 68 is engaged to equalizing sleeve 72 at thread 74. Equalizing sleeve 72 is engaged to well-killing sub 76 at thread 78. Finally, cap 80 is secured to well-killing sub 76 at thread 82. The seal sleeve 68 shown in FIGS. 6d-e houses opposed chevron seals 84 to seal between surface 87 of the nipple assembly 16 and the plug 18 in both directions. Again, it should be recalled that the nipple assembly 16 is run into the wellbore with the entry guide 48 and is thus open at its bottom so that the pressure in the wellbore is communicated into an annular space 86. The plug assembly 18 is made of various components, as described, connected at various threaded locations and suitable seals are provided at the threaded connections to ensure the integrity of the plug 18.
Referring now to FIGS. 6f and g, the well-killing sub 76 has a port 88 that leads into variable volume cavity 90. Seals 92 and 94, in conjunction with piston 96 and well-killing sub 76, define the variable-volume cavity 90. In the run-in position illustrated in FIGS. 6f and g, the port 88 is covered by piston 96. The position of piston 96 is held in the position shown by virtue of shear ring 98. The shear ring 98 is assembled to the well-killing sub 76 via a sleeve 100 secured at thread 102. While a shear ring 98 is illustrated, shear pins can also be used as well as other devices that retain the piston 96 in position until a predetermined force in the variable-volume cavity 90 is exerted which causes the piston to move. Piston 96 has a shoulder 104 which ultimately catches on shoulder 106 of the well-killing sub 76 if the shear ring 98 is broken. The assembly just described is placed there for the reason that if a well-killing operation is necessary, flow through the plug 18 becomes important. Thus, if for any reason the plug 18 does not release from the nipple assembly 16 and pressure below it must be applied to kill the well if necessary, the piston 96 under those circumstances can be displaced to break the shear ring 98 to open the port 88 to allow flow through to below the plug assembly 18 to kill the well if required.
Another feature of the plug assembly 18 can be seen in FIG. 6e. A sleeve 108 straddles port 110 and seals 112 and 114 are found above and below the port 110 on sleeve 108. The sleeve 108 is ultimately displaced against spring 218, as seen in FIG. 7e, to equalize the pressure within the plug assembly 18 with the well pressure seen in annular space 86. As illustrated in FIG. 6e, the sleeve 108, once displaced by tapered surface 158, is poised to come back due to spring 218 which bears on top end 116 of well killing sub 76 if surface 158 is raised. This feature allows the assembly of the nipple 16 with plug 18 and packer 20 to be relocated in the well after packer 20 is released.
The outer sleeve 118 has a top sub 120 connected to a body 122 at thread 124. Bottom sub 126 is connected to body 122 at thread 128. Bottom sub 126 has a window 130 which during run-in as shown in FIG. 6d is aligned with a recess 132 adjacent to shoulder 62 of the top sub 60 of the plug assembly 18. A dog or dogs 134 straddle the window 130 and the recess 132. A bias on the dogs to that position is provided and not shown.
The nipple assembly 16 further comprises a recess 136, which has a sloping surface 138 which ultimately catches the dogs 134, as shown in FIG. 8d, thus precluding further relative movement between the outer sleeve 118 and the nipple assembly 16. The spring 140 bears against surface 142 of body 122 on one end and the top end 144 of top sub 60 at the other end. Those skilled in the art can see that a downward force applied to the outer sleeve 118 will compress the spring 140 as the outer sleeve 118 moves relatively to the plug assembly 18 which is held in place by pivoting latch 56. The packer 20 holds in place the nipple assembly 16.
The motion that initiates the compression of spring 140 is created by movement of the running tool 146 in conjunction with collet assembly 148. The running tool 146 (also shown as 32 in FIGS. 1-5) has a top sub 150 with a thread 152 to which the downhole assembly, such as the gun 30 shown in FIG. 3, can be attached. The running tool 146 is then composed of a body 154, which is connected at thread 156 to sub 150. Body 154 has a tapered surface 158 at its lower end as seen in FIG. 6e. The tapered surface 158 is used to displace the sleeve 108 for equalization using port 110 as previously described. The body 154 also has a tapered shoulder 160, which engages a mating shoulder 162 on the collet assembly 148. Thus, when weight is set down on the running tool 146, it pushes with it the collet assembly 148 due to the interaction of shoulders 160 and 162. The running tool body 154 has a recess 164 with an adjacent shoulder 166. The collet assembly 148 has a series of collet heads 168, each of which has an exterior surface 170, an interior surface 172, an inner shoulder 174, and an outer shoulder 176. Outer shoulder 176 is ramped along shoulder 178 of top sub 120 on the outer sleeve assembly 118. This interaction can be seen by examining FIG. 9b. Alternatively, when a pickup force is applied, the shoulder 166 on the running tool 146 catches the interior shoulder 174 on the collet heads 168 so that the running tool 146 moves in tandem with the collet assembly 148 as will be described below.
The collet assembly 148 has a shoulder 180 which engages with a shoulder 182 of the outer sleeve 118 in the run in position shown in FIG. 6b. Accordingly, when the running tool 146 is run in the well 10, shoulder 160 drives shoulder 162 as between the running tool 146 and the collet assembly 148. That force is in turn transmitted through the collet assembly 148 to the outer sleeve 118 through the engagement of shoulders 180 and 182. As a result of further advancement of the running tool 146, the sleeve 108 is displaced, allowing equalization through the plug assembly 18 through the passage 110. At the same time, the spring 140 is compressed. The reason this occurs is that the latch 56 prevents downward movement of the plug 18, while the running tool 146 and the collet assembly 148 move downhole in tandem due to the interaction of shoulders 160 and 162. With shoulder 180 pushing down on shoulder 182, the outer sleeve 118 is displaced with respect to the plug assembly 18. As a result, as best seen by comparing FIG. 6d with FIG. 7d, the window 130 has shifted from its initial alignment with recess 132. As a result, the dogs 134 have been ramped on taper 184 and the dogs 134 have moved into recess 136. Additionally, shoulder 186 has moved away from shoulder 62. Those skilled in the art will appreciate that shoulder 186 of the outer sleeve 118 retains the plug assembly 18 by virtue of the orientation of inwardly facing shoulder 186 and outwardly facing shoulder 62. Thus, for advancement of the plug assembly 18 out of the nipple assembly 16, the shoulder 186 will catch the shoulder 62 to retain the plug assembly 18. This procedure occurs much later.
Now reverting back to the initial steps involving a set down weight on the running tool 146, the spring 140 is compressed until the window 130 progresses sufficiently so that the dogs 134 become trapped in window 130 against sloping surface 138 and are held there by surface 188 of top sub 60 which is part of the plug assembly 18. That position is reached in FIG. 8d. It should be noted that at the time of the relative movement of the outer sleeve 118 with respect to the nipple assembly 16, the plug 18 is still latched, through latch 56, to the nipple assembly 16 at groove 54.
The collet assembly 148 is built sufficiently flexible so that a continuation of applied downward force on the running tool 146 will allow the sloping surface 180 to ride inwardly on sloping surface 182, as has been seen in comparing FIGS. 6b-9b. By the time sufficient force has been exerted on the running tool 146 to reach the position of 9b, the first of two raised surfaces 190 and 192 has cleared the sloping surface 182 of the outer sleeve 118. At that time, as shown in FIG. 9b, the running tool 146 has an external shoulder 194 adjacent a projection 196. As shown in FIG. 9b, when the shoulder 180 of the collet assembly 148 clears the shoulder 182, the projection 196 on the running tool 146 extends into groove 198 of the collet assembly 148. At that time, the interengagement between the projection 196 on the running tool 146 and the depression 198 on the collet assembly 148 allows the collet assembly to flex inwardly to accommodate further downward tandem movement of the running tool 146 with collet assembly 148.
While this is occurring, the collet heads 168 of the collet assembly 148 s have been ramped out of recess 202 on the outer sleeve 118 due to the interaction between shoulders 176 and 178. This is best shown in FIG. 9b where the collet heads 168 become trapped in recess 164 as surface 170 becomes supported by surface 204 of top sub 120. In the view shown in FIG. 9b, the collet heads 168 are trapped to recess 164 of the running tool 146. However, tandem movement of the running tool 146 and the collet assembly 148 continues.
Downward motion of the running tool 146 moving in tandem with collet assembly 148 continues beyond the position shown in FIG. 9b until ultimately recess 206 presents itself over lug 209 on the outer sleeve 118, as shown in FIG. 10b. At the same time, groove 198 presents itself opposite projection 196 on the running tool 146. In this transition position, the outer sleeve 118 is trapped to the collet assembly 148 such that the spring 140 cannot push the outer sleeve 118 upwardly. Friction in seals 84 is such that its force exceeds the force of spring 140. However, the combined assembly of the running tool 146 and the collet assembly 148 can still progress downwardly to present tapered surface 208 against the tapered surface 182. As further set down weight is applied to the running tool 146, the collet assembly 148 moves with it and tapered shoulder 208 rides up to shoulder 182 until surface 192 of the collet assembly 148 clears pass the lug 209. The position illustrating surface 192 as it is about to pass lug 209 is shown in FIG. 11b.
It should be noted that as the running tool 146 is pushed downwardly in tandem with collet assembly 148, the shoulder 210 on the collet assembly 148 has been moving closer to shoulder 212 on the outer sleeve 118. Additionally, the lower end 214 of the collet assembly 148 has been moving downwardly into the vicinity of the latch 56 so that by the time the position shown in FIG. 11d is reached, the latch 56 has been rotated clockwise to free the plug 18 from the nipple assembly 16. At this time, as shown in FIG. 11d, the outer sleeve 118 cannot move downwardly because the dogs 134 are still trapping the outer sleeve 118 against the nipple assembly 16 by virtue of engagement with sloping surface 138. The addition of set down weight on the running tool 146 now allows surface 214 on the collet assembly 148 to pass by lug 209 and enter recess 216. At this time, the collet assembly 148 prevents spring 140 from moving the outer sleeve 118 upwardly due to the close proximity of shoulders 210 and 212. When shoulders 210 and 212 connect, the weight indicator at the surface indicates that no further downward movement is achievable. At this point, the rotatable latch 56 has been turned out of groove 54. The spring 140 is selected to be of a strength which will not at this time drive the plug assembly 18 downwardly so as to bring shoulder 62 closer to shoulder 186 on the outer sleeve 118. This is because of friction in seals 84 resists such force. Such movement, when it does occur, results in a return of the dogs 134 to the position shown in FIG. 6d. However, such movement does not yet occur because after fully setting down weight on the running tool 146, so that no further weight indication is seen at the surface, an upward force is applied to the running tool 146 so as to engage shoulder 166 on the running tool with the shoulder 174 on the collet assembly 148. In addition, surface 214 on the upward pull to the running tool 146 is in engagement with lug 209 on the outer sleeve 118 and, therefore, brings up the outer sleeve 118 to bring shoulder 186 into contact with shoulder 62. The angle of contact between surface 214 and lug 209 is such that an upward pull on running tool 146 will not make surface 214 climb over lug 209. This upward pull then in turn brings up dogs 134 opposite recess 132. Thus, in the view shown in FIG. 13d, the dogs 134 have moved into alignment with recess 132, thus allowing the outer sleeve 118 to progress downwardly when the running tool 146 is then again lowered. The dogs 134 no longer are retained by the sloping surface 138 on the nipple assembly 16 on the subsequent trip down.
Thus, the sequence of motions is a set down weight on the running tool 146 which bottoms the outer sleeve 118 on sloping surface 138 of the nipple assembly 16. Further downward movement traps the collet assembly 148 to the running tool 146 at collet heads 186. Continuing downward movement results in flexing of the collet assembly 148 until ultimately surface 214 gets behind lug 209 which is about the time that the lower end 215 of the collet assembly 148 has contacted the pivoting latch 56 to force it out of groove 54. At this point, the chevron seals 84 in the plug 18 hold the plug in position with respect to the nipple 16, while at the same time the dogs 134 have trapped the outer sleeve 118 against any further downward movement with respect to the nipple 16. The subsequent pickup force has the purpose of unlocking the outer sleeve 118 from its locked position against the nipple 16 by virtue of dogs 134 being locked against sloping surface 138. The pickup force on the running tool 146 moves the dogs 134 opposite recess 132 on top sub 60 so that the outer sleeve 118 is no longer trapped by sloping surface 138. A subsequent downward movement allows the running tool 146 with the collet assembly 148 and the outer sleeve 118, which retains the plug 18, at surface 186, to all move downwardly through the nipple 16. To facilitate this downward movement, the running tool 146 holds the sleeve 108 against the bias of spring 218. As previously stated if for any reason the well needs to be killed, pressure is built up internally to the plug 18 through the running tool 146 so as to allow applied pressure to reach into the annulus 86 through passage 88.
Thus, if the tool assembled at thread 152 as shown in FIG. 6a is a perforating gun such as 30 shown in FIG. 3, the gun can now be placed at the desired location and fired through the opened subsurface safety valve 12. While this is occurring, the plug 18 is retained to the running tool 146. In order to get the gun 30, or other bottomhole assembly, back out after the downhole operation, the running tool 146 is picked up from the surface. The assembly is picked up until the shoulder 220 on the plug 18 contacts shoulder 222 on the nipple 16. These two shoulders are easier to see in FIG. 7e where they have separated from each other due to some slack available of the latch 56 in groove 54. Further upward movement of the running tool 146 pulls the collet heads 168 upwardly as shoulder 166 of the running tool 146 engages shoulder 174 of the collet heads 168. Ultimately, an upward force is put on the running tool 146 to make surface 214 of the collet assembly 148 jump over the lug 209 of the outer sleeve 118. Ultimately, sufficient upward movement of the assembly of the running tool 146 and the collet assembly 148 occurs for the lower end 215 of the collet assembly 148 to clear the latch 56. At this time, the latch 56 can rotate back into groove 54 to again secure the plug 18. The collet assembly 148 reaches the point where the collet heads 168 again come into alignment with the recess 202 on the outer sleeve 118. This is again the position shown in FIGS. 6a-g. At this time, the running tool 146 can be withdrawn and the port 110 is once again resealed as spring 218 biases the sleeve 108 so that seats 112 and 114 cover the port 110. This process can be repeated and the plug 18 can be reengaged with the running tool 146 to allow a variety of different assemblies to be put together in the wellbore without removing the nipple 16 or the plug 18 from the wellbore. At this time, a known release tool can be introduced to release the packer 20 and, if desired, retrieve the entire assembly of the nipple 16 and plug 18. In retrieving the plug 18 with the nipple 16, the sleeve 108 can move to allow port 110 to open so as to avoid having to pull up a column of liquid inside the retrieval string to the surface by allowing equalization.
The system as described above can be used as a retrofit on existing wells. If planned for during the initial completion, wireline nipples can be installed in the tubing string so that the nipple assembly 16 can be run on wireline into a seal bore in a wireline nipple already in the tubing string, thus doing away with the need for a packer such as 20. The wireline nipple has the standard features of allowing a nipple assembly such as 16 to seal up within its seal bore and lock to the wireline nipple.
Although the lower barrier is preferably the subsurface safety valve 12, a plurality of nipple assemblies such as 16 can be used if the plug in the upper assembly can pass through the nipple in the lower assembly. To do this, the upper plug would have its own running tool which would engage the lower plug.
Yet another feature of the present invention is the fact that surface 228, which is the seal bore for the chevron seals 84, has a larger diameter than the surface 226 immediately above the groove 54. The fact that the surface 226 is of smaller diameter helps centralize the equipment such as gun 30 after it is fired, when it is brought back into the nipple assembly 16. For example, if a gun is used in conjunction with the running tool 146 after the gun is fired, it will have burrs sticking out of it which if it was not centralized could affect the integrity of the seal bore which is surface 228. Accordingly, the diameter of surface 226 is made smaller to act as a centralizer.
The configuration of the outer sleeve 118 along with the dogs 134 and the way it interacts with surface 138 of the nipple 16 allows, in the event of an inadvertent dropping of the gun 30 and the running tool 146, a transfer of the kinetic energy directly to the nipple assembly 16 and to the slips in the packer 20 via dogs 134, which in that situation will come out into recess 136 and trap the falling components transferring their load to the slips in the packer 20.
The feedback feature of the apparatus and method is useful in letting surface personnel know that the plug has been effectively latched and released. Thus, when no weight is indicated at the surface, the running tool 146 has progressed to the point where it has pushed against the collet assembly 148, and the outer sleeve 118 has bottomed due to dogs 134 engaging surface 138 on the nipple assembly 16. When this indication is received at the surface, a pickup force allows the dogs 134 to come out of recess 136 so that a further set down will allow the plug 18 to clear the nipple assembly 16.
Another significant testing feature of the apparatus allows for an independent integrity test of the subsurface safety valve 12 and the plug 18 reseated in the nipple assembly 16. Thus, when the plug 18 is brought clear of the subsurface safety valve 12 but not yet in sealing engagement with the nipple assembly 16, the subsurface safety valve 12 can be closed and the wellbore 10 bled off at the surface to determine if the subsurface safety valve 12 is holding. If it is in fact holding, the well is then closed at the surface and the subsurface safety valve is opened while the plug 18 is raised into the nipple assembly 16 into sealing engagement. The well is again bled off at the surface to see if it will hold pressure. If that occurs, then the surface personnel know that the plug 18 has now fully reseated in the nipple assembly 16 and is functioning as a barrier. Thereafter, the subsurface safety valve 12 is closed again to provide the two barriers necessary to disassemble the bottomhole assembly with the running tool 32 as shown in FIG. 1, or 146 as shown in FIGS. 6-13, in the upper region 28 of the wellbore 10.
The advantages of the apparatus and method are that it can be easily retrofit to an existing well and the components can be run into place quickly with only a short lubricator. There is no need for a lubricator stack to be assembled on the rig which could be a 100 feet tall or more. The design is very simple in the sense that it does not involve a multiplicity of control lines that must be run to operate designs which have used multiple valves downhole. The nipple assembly 16 is relocatable in a variety of locations within the wellbore above the subsurface safety valve 12. Therefore, it is a more flexible system allowing for variation of the depth in the wellbore 10 to be used as the lubricator. Additionally, the design which allows the running tool 146 to grab the plug assembly 18 is simple with few moving parts and, hence, is more reliable. Additionally, the nipple assembly is removable after the downhole operation is concluded so that it does not remain in the wellbore to create any type of constriction for further downhole operations or well production. The configuration of the system allows for independent pressure-testing of the barriers against well pressure to ensure that the sealing integrity is maintained.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention.
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The wellbore is adapted for use as a lubricator for assembly of lengthy installations. The subsurface safety valve is used in conjunction with a nipple inserted into the wellbore and held in position by a packer. A plug is part of the nipple assembly. Upon setting of the packer, two barriers downhole are created to facilitate assembly of tools such as a perforating gun in the wellbore behind two barriers. The tool, such as a perforating gun, has a running tool below it which engages the plug. When the assembly is made up in the wellbore, the plug is engaged by the running tool and released from the nipple. The plug can then be advanced through the open subsurface safety valve to the proper location for deployment of a perforating gun, for example. Upon completion of the downhole procedures, such as perforating, the tools are brought uphole and the plug is sealingly relatched in the nipple, thus recreating the necessary two barriers to permit opening the wellbore at the surface to remove the assembly of the downhole tools and the running tool. The plug can be reengaged as many times as necessary for installation of a variety of equipment. The nipple can then also be removed after the packer is released.
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RELATED APPLICATIONS
This application is a Divisional of U.S. application Ser. No. 10/704,120, filed Nov. 10, 2003, now U.S. Pat. No. 7,488,823, claiming benefit of U.S. Provisional Application No. 60/427,544, filed Nov. 20, 2002, the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to a series of cyanoguanidine quinazoline and cyanoamidine quinazoline derivatives that are useful in the treatment of hyperproliferative diseases, such as cancer and inflammation, in mammals. This invention also relates to a method of using such compounds in the treatment of hyperproliferative diseases in mammals, especially humans, and to pharmaceutical compositions containing such compounds.
BACKGROUND OF THE INVENTION
The type I receptor tyrosine kinase family consists of four closely related receptors: EFGR (ErbB1 or HER1), ErbB2 (HER2), ErbB3 (HER) and ErbB4 (HER4). These are transmembrane glycoprotein receptors which contain an extracellular ligand binding region and, with the exception of erbB3, an intracellular catalytically active tyrosine kinase domain. These receptors transmit extracellular signals through the cytosol to the nucleus. The extracellular signal is transmitted by ligand binding to the homomeric receptor, with the exception of erbB2, of which a high affinity soluble ligand has yet to be identified. After ligand binding the type I receptor tyrosine kinases either homodimerize or heterodimerize with another member of the subfamily of receptors. ErbB2 participates in this process by heteromerization. In fact, it has been shown that erbB2 is the preferred heterodimerization partner (Mehelsohn Oncogene 2000). Dimerization leads to activation by autophosphorylation of the intracellular domain. This autophosphorylation recruits other proteins and leads to a phosphorylation cascade that transmits the signal throughout the cell. The type I receptor tyrosine kinase family signals through the ras/raf/MEK/MAPK pathway as well as the PI3K/Akt pathway. These signaling pathways lead to both cell proliferation and cell survival through inhibition of apoptosis.
Several investigations have demonstrated the role of EGFR and ErbB2 in cancer. Squamous carcinomas of the head and neck, and lung express high levels of EGFR. Also, constitutively active EGFR has been found in gliomas, breast cancer and lung cancer (Salomon et al Crit. Rev Oncol Hematol 1995, 19, 183-232—on order Jun. 4, 2002). ErbB2 overexpression occurs in ˜30% of all breast cancer. It has been also implicated in other human cancers including colon, ovary, bladder, stomach, esophagus, lung, uterus and prostate. ErbB2 overexpression has also been correlated with poor prognosis in human cancer, including metastasis, and early relapse (ref—two Slamon refs from Science and Klapper review).
The type I tyrosine kinase receptor family has been an active area of anti-cancer research. Several inhibitors of the EGFR and the ErbB2 signaling pathway have demonstrated clinical efficacy in cancer treatment. Herceptin, a humanized version of anti-ErbB2 monoclonal antibody, was approved for use in breast cancer in the United States in 1998. Iressa and Tarceva are small molecule inhibitors of EGFR that are expected to be launched in 2002. In addition, several other antibodies and small molecules that target the interruption of the type I tyrosine kinase receptor signaling pathways are in clinical and preclinical development (Ciardiello et al).
Several issued patents and applications have appeared describing quinazoline based type I receptor tyrosine kinase inhibitors, including WO 00/44728, WO 01/98277, WO 98/02438, GB 2 345 486 A, WO 96/33980, and references contained therein, which are incorporated herein by reference.
SUMMARY OF THE INVENTION
This invention provides for cyanoguanidine and cyanoamidine substituted 4-anilino quinazolines of formula I, and pharmaceutically acceptable salts and prodrugs thereof, that are useful in the treatment of hyperproliferative diseases. Specifically, the present invention relates to compounds of formula I that act as EGFR and/or ErbB2 inhibitors. Also provided are formulations containing compounds of formula I and methods of using the compounds to treat a patient in need thereof. In addition, there are described processes for preparing the inhibitory compounds of formula I.
Accordingly, the present invention refers to compounds of the formula (I):
wherein at least one of the positions 6 or 7 of the quinazoline ring must be substituted by a group A, and the remaining positions on the quinazoline ring may be optionally substituted by up to three R 2 groups; wherein
X is N, CH or a C—CN group;
R 1 is independently an aryl or heteroaryl group, substituted by at least one R 6 group, and optionally substituted by up to three R 5 groups, where
R 5 is cyano, chlorine, fluorine, bromine, lower alkyl, trifluoromethyl, difluoromethyl, nitro or OR 9 ;
R 6 is hydrogen, cyano, chlorine, fluorine, bromine, trifluoromethyl, difluoromethyl, trifluoromethoxy, nitro, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl, where each C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl portion is optionally substituted with up to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(O)R 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —OR 9 , —S(O)R 13 , —SO 2 R 13 , aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, and where
R 7 and R 10 independently represent hydrogen or C 1-6 alkyl, or R 7 and R 10 together with the atom to which they are attached form a 4 to 10 membered carbocyclic, heteroaryl or heterocyclic ring, each of which is optionally substituted with up to three groups independently selected from halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, aryl, heteroaryl, arylalkyl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl;
R 8 represents trifluoromethyl, C 1 -C 10 alkyl, C 3 -C 10 cycloalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl, where each alkyl, cycloalkyl, aryl, heteroaryl and heterocyclyl portion is optionally substituted with one to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, aryl, heteroaryl, arylalkyl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl;
R 9 represents hydrogen, trifluoromethyl, C 1 -C 10 alkyl, (CH 2 ) n C 3 -C 10 cycloalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl, where each alkyl, cycloalkyl, aryl, heteroaryl and heterocyclyl portion is optionally substituted with up to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, aryl, heteroaryl, arylalkyl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl, where n=0 or 4, or R 7 and R 9 together with the atom to which they are attached form a 4 to 10 membered carbocyclic, heteroaryl or heterocyclic ring, each of which is optionally substituted with up to three groups independently selected from halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, aryl, heteroaryl, arylalkyl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl;
R 13 represents trifluoromethyl, difluoromethyl, C 1 -C 10 alkyl, C 3 -C 10 alkenyl, C 3 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl, where each of the above alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl portion of R 13 is optionally substituted with one to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(O)R 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —NR 10 C(NCN)NR 7 R 9 , —OR 9 , aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl; where R 7 , R 8 , R 9 and R 10 are the same as R 7 , R 8 , R 9 and R 10 defined above;
R 2 represents hydrogen, halogen, cyano, nitro, trifluoromethyl, difluoromethyl, trifluoromethoxy, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl portion is optionally substituted with up to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(OCR 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —NR 10 C(NCN)NR 7 R 9 , —OR 9 , —S(O)R 3 , —SO 2 R 13 , aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl, and where R 7 , R 8 , R 9 , R 10 and R 13 are the same as R 7 , R 8 , R 9 , R 10 and R 13 as defined above;
A is represented by the following formula (II):
wherein
T represents C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl; where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl portion is optionally substituted with up to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(O)R 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —NR 10 C(NCN)NR 7 R 9 , —OR 9 , —S(O)R 13 , —SO 2 R 13 , aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl, where R 7 , R 8 , R 9 , R 10 and R 13 are the same as R 7 , R 8 , R 9 , R 10 and R 13 as defined above; T may optionally contain one or more heteroatoms, which heteroatoms may be further substituted or oxidized; and m is an integer from 0 to 1;
L is a nitrogen atom or a CR 4 group where R 4 represents hydrogen, trifluoromethyl, difluoromethyl, trifluoromethoxy, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl or heterocyclylalkyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl portion is optionally substituted with up to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(OCR 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —NR 10 C(NCN)NR 7 R 9 , —OR 9 , —S(O)R 3 , —SO 2 R 13 , aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl; where R 7 , R 8 , R 9 , R 10 and R 13 are the same as R 7 , R 8 , R 9 , R 10 and R 13 defined above;
Q is selected from CR 3 R 11 R 12 or NR 11 R 12 , where R 3 is the same as R 2 defined above and R 11 and R 12 independently represent hydrogen, trifluoromethyl, difluoromethyl, trifluoromethoxy, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(O)R 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —OR 9 , —S(O)R 13 or —SO 2 R 3 , where each C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl portion may be optionally substituted with up to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(O)R 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —NR 10 C(NCN)NR 7 R 9 , —OR 9 , —S(O)R 13 , —SO 2 R 13 , aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl; where R 7 , R 8 , R 9 , R 10 and R 13 are the same as R 7 , R 8 , R 9 , R 10 and R 13 defined above, provided that (i) when Q is CR 3 R 11 R 12 not more than one group among R 3 , R 11 or R 12 may be simultaneously connected to C through a heteroatom, (ii) when Q is CR 3 R 11 R 12 , R 3 may not be cyano or halogen, (iii) when Q is NR 11 R 12 , not more than one group between R 11 and R 12 may be connected to N through a heteroatom, and (iv) when L is CR 4 , Q is NR 11 R 12 ; and
D represents hydrogen, trifluoromethyl, difluoromethyl, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl, —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 or —C(O)NR 7 R 9 , where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl portion is optionally substituted with up to five groups independently selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(O)R 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —NR 10 C(NCN)NR 7 R 9 , —OR 9 , —S(O)R 13 , —SO 2 R 13 , aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl and heterocyclylalkyl, and where R 7 , R 8 , R 9 , R 10 and R 13 are the same as R 7 , R 8 , R 9 , R 10 and R 13 defined above, provided that when L is N, (i) D is hydrogen or is selected so that L binds to a carbon atom or to a S(O) i group, where i is an integer from 1 to 2, and (ii) if m=1, T is selected so that L binds to a carbon atom or to a S(O) j group, where j is an integer from 1 to 2; or Q and D taken together form a 5-11 member ring containing 0-3 heteroatoms in addition to the nitrogen atoms which are part of the cyanoguanidine or cyanoamidine group, with no direct bonding between any two heteroatoms, except for a bond between N to S(O) k , where k is an integer from 1 to 2, the carbon atoms of the said ring optionally substituted with up to two groups selected from oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy, azido, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl, alkyl, alkenyl, alkynyl, cycloalkyl, —NR 7 SO 2 R 8 , —SO 2 NR 9 R 7 , —C(O)R 9 , —C(O)OR 9 , —OC(O)R 9 , —NR 7 C(O)OR 8 , —NR 7 C(O)R 9 , —C(O)NR 7 R 9 , —NR 7 R 9 , —NR 10 C(O)NR 7 R 9 , —NR 10 C(NCN)NR 7 R 9 , —OR 9 , —S(O)R 3 , and —SO 2 R 13 , where R 7 , R 8 , R 9 , R 10 and R 13 are the same as R 7 , R 8 , R 9 , R 10 and R 13 above, and each nitrogen atom of the said ring may be optionally and independently substituted with an R 4 group, where R 4 is the same as R 4 defined above.
Examples of preferred embodiments of R 1 include, but are not limited to:
In another aspect of the invention there is provided a method of treating hyperproliferative disease comprising administering to a mammal a therapeutically effective amount of a compound of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The novel compounds encompassed by the instant invention are those described by the general formula I set forth above, including enantiomers, diastereosisomers, tautomers, pharmaceutically acceptable salts, and prodrugs thereof.
Except as expressly defined otherwise, the following definition of terms is employed throughout this specification.
By “C 1 -C 10 alkyl”, “alkyl” and “lower alkyl” in the present invention is meant straight or branched chain alkyl groups having 1-10 carbon atoms, such as, methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, pentyl, 2-pentyl, isopentyl, neopentyl, hexyl, 2-hexyl, 3-hexyl, 3-methylpentyl, heptyl, octyl, and the like. Preferred alkyl radicals are C 1-6 alkyls. More preferred alkyl radicals are C 1-3 alkyls.
By “C 2 -C 10 alkenyl”, “lower alkenyl” and “alkenyl” means straight and branched hydrocarbon radicals having from 2 to 10 carbon atoms and at least one double bond and includes ethenyl, propenyl, 1-but-3-enyl, 1-pent-3-enyl, 1-hex-5-enyl and the like. The preferred alkenyls are lower alkenyl having 3-5 carbon atoms.
By “C 2 -C 10 alkynyl”, “lower alkynyl” and “alkynyl” means straight and branched hydrocarbon radicals having from 2 to 10 carbon atoms and at least one triple bond and includes ethynyl, propynyl, butynyl, pentyn-2-yl and the like. The preferred alkynyls are alkynyl having 3-5 carbon atoms.
By the term “halogen” in the present invention is meant fluorine, bromine, chlorine, and iodine.
By “aryl” is meant an aromatic carbocyclic group having a single ring (e.g., phenyl), multiple rings (e.g., biphenyl), or multiple condensed rings in which at least one is aromatic, (e.g., 1,2,3,4-tetrahydronaphthyl, naphthyl), which is optionally mono-, di-, or trisubstituted with, e.g., halogen, lower alkyl, lower alkoxy, trifluoromethyl, aryl, heteroaryl, and hydroxy.
By “heteroaryl” is meant one or more aromatic ring systems of 5-, 6-, or 7-membered rings which includes fused ring systems (at least one of which is aromatic) of 5-10 atoms containing at least one and up to four heteroatoms selected from nitrogen, oxygen, or sulfur. Examples of heteroaryl groups are pyridinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, tetrazolyl, furyl, thienyl, isoxazolyl, thiazolyl, oxazolyl, isothiazolyl, pyrrolyl, quinolinyl, isoquinolinyl, indolyl, benzimidazolyl, benzofuranyl, cinnolinyl, indazolyl, indolizinyl, phthalazinyl, pyridazinyl, triazinyl, isoindolyl, pteridinyl, purinyl, oxadiazolyl, triazolyl, thiadiazolyl, thiadiazolyl, furazanyl, benzofurazanyl, benzothiophenyl, benzothiazolyl, benzoxazolyl, quinazolinyl, quinoxalinyl, naphthyridinyl, and furopyridinyl. Spiro moieties are also included within the scope of this definition. Heteroaryl groups are optionally mono-, di-, or trisubstituted with, e.g., halogen, lower alkyl, lower alkoxy, haloalkyl, aryl, heteroaryl, and hydroxy.
As used herein, the terms “carbocycle”, “carbocyclyl”, “cycloalkyl” or “C 3 -C 10 cycloalkyl” refer to saturated carbocyclic radicals having three to ten carbon atoms. The cycloalkyl can be monocyclic, or a polycyclic fused system, and can be fused to an aromatic ring. Examples of such radicals include cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl. The cycloalkyl groups herein are unsubstituted or, as specified, substituted in one or more substitutable positions with various groups. For example, such cycloalkyl groups may be optionally substituted with, for example, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, halogen, hydroxy, cyano, nitro, amino, mono(C 1 -C 6 )alkylamino, di(C 1 -C 6 )alkylamino, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 1 -C 6 haloalkyl, C 1 -C 6 haloalkoxy, amino(C 1 -C 6 )alkyl, mono(C 1 -C 6 )alkylamino(C 1 -C 6 )alkyl or di(C 1 -C 6 )alkylamino(C 1 -C 6 )alkyl.
By “heterocycle” or “heterocyclyl” is meant one or more carbocyclic ring systems of 5-, 6-, or 7-membered rings which includes fused ring systems of 4-10 atoms containing at least one and up to four heteroatoms selected from nitrogen, oxygen, or sulfur, and with the proviso that the ring of the group does not contain two adjacent O or S atoms. A fused system can be a heterocycle fused to an aromatic group. Preferred heterocycles include, but are not limited to, pyrrolidinyl, tetrahydrofuranyl, dihydrofuranyl, tetrahydrothienyl, tetrahydropyranyl, dihydropyranyl, tetrahydrothiopyranyl, piperidino, morpholino, thiomorpholino, thioxanyl, piperazinyl, homopiperazinyl, azetidinyl, oxetanyl, thietanyl, homopiperidinyl, oxepanyl, thiepanyl, oxazepinyl, diazepinyl, thiazepinyl, 1,2,3,6-tetrahydropyridinyl, 2-pyrrolinyl, 3-pyrrolinyl, indolinyl, 2H-pyranyl, 4H-pyranyl, dioxanyl, 1,3-dioxolanyl, pyrazolinyl, dithianyl, dithiolanyl, dihydropyranyl, dihydrothienyl, dihydrofuranyl, pyrazolidinylimidazolinyl, imidazolidinyl, 3-azabicyco[3.1.0]hexanyl, 3-azabicyclo[4.1.0]heptanyl, azabicyclo[2.2.2]-hexanyl, 3H-indolyl and quinolizinyl. Spiro moieties are also included within the scope of this definition. The foregoing groups, as derived from the groups listed above, may be C-attached or N-attached where such is possible. For instance, a group derived from pyrrole may be pyrrol-1-yl(N-attached) or pyrrol-3-yl(C-attached). Further, a group derived from imidazole may be imidazol-1-yl(N-attached) or imidazol-3-yl(C-attached). An example of a heterocyclic group wherein 2 ring carbon atoms are substituted with oxo (═O) moieties is 1,1-dioxo-thiomorpholinyl. The heterocycle groups herein are unsubstituted or, as specified, substituted in one or more substitutable positions with various groups. For example, such heterocycle groups may be optionally substituted with, for example, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, halogen, hydroxy, cyano, nitro, amino, mono(C 1 -C 6 )alkylamino, di(C 1 -C 6 )alkylamino, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 1 -C 6 haloalkyl, C 1 -C 6 haloalkoxy, amino(C 1 -C 6 )alkyl, mono(C 1 -C 6 )alkylamino(C 1 -C 6 )alkyl or di(C 1 -C 6 )alkylamino(C 1 -C 6 )alkyl.
The term “arylalkyl” means an alkyl moiety (as defined above) substituted with one or more aryl moiety (also as defined above). The preferred aralkyl radicals are aryl-C 1-3 -alkyls. Examples include benzyl, phenylethyl, and the like.
The term “heteroarylalkyl” means an alkyl moiety (as defined above) substituted with a heteroaryl moiety (also as defined above). The preferred heteroarylalkyl radicals are 5- or 6-membered heteroaryl-C 1-3 -alkyl. Examples include oxazolemethyl, pyridylethyl and the like.
The term “Me” means methyl, “Et” means ethyl, “Bu” means butyl and “Ac” means acetyl.
The phrase “pharmaceutically acceptable salt(s)”, as used herein, unless otherwise indicated, includes salts of acidic and basic groups which may be present in the compounds of formula 1 or of the compounds made in accordance with the examples herein. The compounds of formula 1 that are basic in nature are capable of forming a wide variety of salts with various inorganic and organic acids. The acids that may be used to prepare pharmaceutically acceptable acid addition salts of such basic compounds of formula 1 as well as the compounds prepared in the examples are those that form non-toxic acid addition salts, i.e., salts containing pharmaceutically acceptable anions, such as the acetate, benzenesulfonate, benzoate, bicarbonate, bisulfate, bitartrate, borate, bromide, calcium, edetate, camsylate, carbonate, chloride, clavulanate, citrate, dihydrochloride, edetate, edislyate, estolate, esylate, ethylsuccinate, fumarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylsulfate, mucate, napsylate, nitrate, oleate, oxalate, pamoate (embonate), palimitate, pantothenate, phosphate/diphosphate, polygalacturonate, salicylate, stearate, subacetate, succinate, tannate, tartrate, teoclate, tosylate, triethiodode, and valerate salts. Since a single compound of the present invention may include more than one acidic or basic moieties, the compounds of the present invention may include mono, di or tri-salts in a single compound.
The phrase “pharmaceutically acceptable salt(s)”, as used herein, unless otherwise indicated, includes salts of acidic and basic groups which may be present in the compounds of formula 1. The compounds of formula I that are basic in nature are capable of forming a wide variety of salts with various inorganic and organic acids. The acids that may be used to prepare pharmaceutically acceptable acid addition salts of such basic compounds of formula 1 are those that form non-toxic acid addition salts, i.e., salts containing pharmaceutically acceptable anions, such as the acetate, benzenesulfonate, benzoate, bicarbonate, bisulfate, bitartrate, borate, bromide, calcium, edetate, camsylate, carbonate, chloride, clavulanate, citrate, dihydrochloride, edetate, edislyate, estolate, esylate, ethylsuccinate, fumarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylsulfate, mucate, napsylate, nitrate, oleate, oxalate, pamoate (embonate), palimitate, pantothenate, phosphate/diphosphate, polygalacturonate, salicylate, stearate, subacetate, succinate, tannate, tartrate, teoclate, tosylate, triethiodode, and valerate salts. Since a single compound of the present invention may include more than one acidic or basic moieties, the compounds of the present invention may include mono, di or tri-salts in a single compound.
Those compounds of the present invention that are acidic in nature are capable of forming basic salts with various pharmaceutically acceptable cations. Examples of such salts include the alkali metal or alkaline earth metal salts and, particularly, the calcium, magnesium, sodium and potassium salts of the compounds of the present invention.
Certain compounds of formula I may have asymmetric centers and therefore exist in different enantiomeric forms. All optical isomers and stereoisomers of the compounds of formula I, and mixtures thereof, are considered to be within the scope of the invention. With respect to the compounds of formula I, the invention includes the use of a racemate, one or more enantiomeric forms, one or more diastereomeric forms, or mixtures thereof. The compounds of formula I may also exist as tautomers. This invention relates to the use of all such tautomers and mixtures thereof.
The subject invention also includes isotopically-labeled compounds, which are identical to those recited in formula I, but for the fact that one or more atoms are replaced by an atom having an atomic mass or mass number different from the atomic mass or mass number usually found in nature. Examples of isotopes that can be incorporated into compounds of the invention include isotopes of hydrogen, carbon, nitrogen, oxygen, phosphorous, sulfur, fluorine and chloride, such as 2 H, 3 H, 13 C, 14 C, 15 N, 18 O, 17 O, 31 P, 32 P, 35 S, 18 F, and 36 Cl, respectively. Compounds of the present invention, prodrugs thereof, and pharmaceutically acceptable salts of said compounds or of said prodrugs which contain the aforementioned isotopes and/or other isotopes of other atoms are within the scope of this invention. Certain isotopically-labeled compounds of the present invention, for example those into which radioactive isotopes such as 3 H and 14 C are incorporated, are useful in drug and/or substrate tissue distribution assays. Tritiated, i.e., 3 H and carbon-14, i.e., 14 C, isotopes are particularly preferred for their ease of preparation and detectability. Further, substitution with heavier isotopes such as deuterium, i.e., 2 H, can afford certain therapeutic advantages resulting from greater metabolic stability, for example increased in vivo half-life or reduced dosage requirements and, hence, may be preferred in some circumstances. Isotopically labeled compound of formula I of this invention and prodrugs thereof can generally be prepared by carrying out procedures disclosed in the Schemes and/or in the Examples and Preparations below, by substituting a readily available isotopically labeled reagent for a non-isotopically labeled reagent.
This invention also encompasses pharmaceutical compositions containing and methods of treating proliferative disorders, or abnormal cell growth, by administering prodrugs of compounds of the formula I. Compounds of formula I having free amino, amido, hydroxy or carboxylic groups can be converted into prodrugs. Prodrugs include compounds wherein an amino acid residue, or a polypeptide chain of two or more (e.g., two, three or four) amino acid residues is covalently joined through an amide or ester bond to a free amino, hydroxy or carboxylic acid group of compounds of formula I. The amino acid residues include but are not limited to the 20 naturally occurring amino acids commonly designated by three letter symbols and also includes 4-hydroxyproline, hydroxylysine, demosine, isodemosine, 3-methylhistidine, norvaline, beta-alanine, gamma-aminobutyric acid, cirtulline, homocysteine, homoserine, ornithine and methionine sulfone. Additional types of prodrugs are also encompassed. For instance, free carboxyl groups can be derivatized as amides or alkyl esters. Free hydroxy groups may be derivatized using groups including but not limited to hemisuccinates, phosphate esters, dimethylaminoacetates, and phosphoryloxymethyloxycarbonyls, as outlined in Advanced Drug Delivery Reviews 1996, 19, 115. Carbamate prodrugs of hydroxy and amino groups are also included, as are carbonate prodrugs, sulfonate esters and sulfate esters of hydroxy groups. Derivatization of hydroxy groups as (acyloxy)methyl and (acyloxy)ethyl ethers wherein the acyl group may be an alkyl ester, optionally substituted with groups including but not limited to ether, amine and carboxylic acid functionalities, or where the acyl group is an amino acid ester as described above, are also encompassed. Prodrugs of this type are described in J. Med. Chem. 1996, 39, 10. Free amines can also be derivatized as amides, sulfonamides or phosphonamides. All of these prodrug moieties may incorporate groups including but not limited to ether, amine and carboxylic acid functionalities.
It is to be understood that in instances where two or more radicals are used in succession to define a substituent attached to a structure, the first named radical is considered to be terminal and the last named radical is considered to be attached to the structure in question. Thus, for example, the radical arylalkyl is attached to the structure in question by the alkyl group.
The compounds of the invention are administered either singly or in combination to a mammal to treat hyperproliferative disease, such as various types of cancer, e.g., cancer of the colon, ovary, bladder, stomach, lung, uterus, and prostate. The compound may be administered via any acceptable route, e.g., intra venous, oral, intra muscular, via suppository, etc. The compounds can be formulated as oral dosage forms, e.g., tablets, capsules, liquid suspension, etc, as suppositories, or may be prepared as a liquid for injection, for example. The skilled practitioner can select the appropriate route and dosage amount for treatment of the specific hyperproliferative disease to be treated.
The examples below are intended to illustrate embodiments of the invention, and are not intended to limit the scope of the specification or claims in any way.
Example 1
N-(3-{4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-N′-cyano-N″,N″-dimethylguanidine
Step A: 6-iodo-4-quinazolinone
A solution of 2-amino-5-iodobenzoic acid (14.2 g, 50 mmol) and formamidine acetate (6.75 g, 65 mmol) in ethanol (200 mL) was refluxed for 20 hours. After cooling to 0° C. the solid product was collected by filtration. Further drying in a vacuum provided 6-Iodo-4-quinazolinone (11 g, 81%) as a gray solid.
Step B: 4-chloro-6-iodoquinazoline
To a stirred solution of anhydrous dimethyl foramide (DMF) (3.20 ml) in 1,2-dichloroethane (DCE) (10 ml), cooled in an ice-water bath, is added dropwise under nitrogen a solution of oxalyl chloride (5.2 ml, 60 mmol) in DCE (25 ml). A white precipitate forms during the addition. After the end of addition the cold bath is removed and the reaction mixture is stirred at room temperature for 5 minutes. 6-Iodo-quinazolin-4-ol (5.0 g, 18 mmol) is added in portions via scoopula under nitrogen flow and the mixture is heated immediately to reflux. Heating is continued for 4.5 hours, followed by cooling to room temperature. The reaction mixture is poured into excess ice-water mixture (approximately 300 ml) and extracted with DCM (approximately 500 ml). The aqueous layer is further extracted with DCM (2×50 ml). The combined organic extracts are dried (Na 2 SO 4 ) and concentrated under reduced pressure to yield 5.2 g (99%) of desired product as a tan solid.
Step C: 2-chloro-1-(3-fluoro-benzyloxy)-4-nitro-benzene
Sodium hydride (60% dispersion in oil, 1.4 g, 33.5 mmol) is suspended in dry DMF (10 ml) under a nitrogen atmosphere and the resulting mixture is cooled in ice:water. To above suspension is added dropwise over 15 minutes (3-Fluoro-phenyl)-methanol (2.90 ml, 27 mmol). Next, to the cold reaction mixture is added dropwise over 20 minutes a solution of 2-chloro-1-fluoro-4-nitro-benzene (4.2 g, 24 mmol) in dry DMF (20 ml). Upon the end of addition the cold bath is removed and the reaction mixture is stirred for another 4 hours. The reaction mixture is poured into 300 ml of ice:water. The resultant solid is isolated by suction filtration, washed with water (500 ml), and air dried to yield 5.5 g (20 mmol, 83%) of the clean desired material as an yellow powder.
Step D: 3-chloro-4-(3-fluoro-benzyloxy)-phenylamine
2-Chloro-1-(3-fluoro-benzyloxy)-4-nitro-benzene (4.08 g, 14.5 mmol) is suspended in MeOH (50 ml) and treated wet 5% Pt/C (Degussa type, Aldrich, 1.5 g). The flask is flushed with hydrogen gas from a balloon and the reaction mixture is stirred under hydrogen atmosphere until reaction is judged complete by this-layer chromatography (approximately 2 hours). The reaction mixture is filtered through a Celite plug and the solvent is removed under reduced pressure. The crude product is redissolved in DCM, dried (MgSO 4 ) and concentrated to yield 3.1 g (12 mmol, 83%) of the desired product.
Step E: [3-chloro-4-(3-fluoro-benzyloxy)-phenyl]-(6-iodo-quinazolin-4-yl)-amine hydrochloride salt
3-Chloro-4-(3-fluoro-benzyloxy)-phenylamine (3.1 g, 12 mmol) and 4-chloro-6-iodo-quinazoline (3.28 g, 11.3 mmol) are dissolved in a 1:1 mixture of DCE:t-BuOH (56 ml). The reaction mixture is refluxed for 19 hours. The product is isolated by suction filtration through sintered glass, washed with excess DCM, and air dried to afford 3.8 g (7.0 mmol, 58%) of the clean desired material.
Step F: (3-{4-[3-chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-carbamic acid tert-butyl ester
A mixture of prop-2-ynyl-carbamic acid tert-butyl ester (978 mg, 6.31 mmol) and 3-chloro-4-(3-fluoro-benzyloxy)-phenylamine hydrochloride (3.11 g, 5.74 mmol), dichlorobis(tri-phenylphosphine) palladium (II) (210 mg, 0.299 mmol), copper iodide (57 mg, 0.3 mmol), and diisopropylamine (1.77 mL, 7.28 mmol) in anhydrous THF (40 mL) was stirred at room temperature for 5 hours. After concentration, the residue was dissolved in CH 2 Cl 2 (50 mL), washed with aqueous NH 4 Cl and brine, dried over sodium sulfate, and concentrated to give the crude product (3.07 g, 100%) as a light yellow solid which was then used without further purification.
Step G: [6-(3-amino-prop-1-ynyl)-quinazolin-4-yl]-[3-chloro-4-(3-fluoro-benzyloxy)-phenyl]-amine
To a suspension of (3-{4-[3-chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-carbamic acid tert-butyl ester (2.01 g, 3.78 mmol) in CH 2 Cl 2 (3 mL) was added trifluoroacetic acid (TFA) (3 mL) dropwise. The reaction was stirred at room temperature for 30 minutes. The reaction mixture was then diluted with CH 2 Cl 2 (30 mL) and aqueous saturated sodium bicarbonate. Phases were separated and the aqueous layer was extracted with CH 2 Cl 2 (30 mL). Organic layers were combined, dried over sodium sulfate and concentrated to give the crude product (1.648 g, 101%) as a yellow oil.
Step H: 1-(3-{4-[3-chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-2-phenyl-N-cyano-isourea
A mixture of [6-(3-amino-prop-1-ynyl)-quinazolin-4-yl]-[3-chloro-4-(3-fluoro-benzyloxy)-phenyl]-amine (520 mg, 1.2 mmol), diphenyl cyano-carbonimidate (315 mg, 1.32 mmol), and triethylamine (0.17 mL, 1.2 mmol) in isopropanol (10 mL) was stirred at room temperature for 15 hours. After concentration, the crude white residue (840 mg) was then used without further purification.
Step I: N-(3-{4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-N′-cyano-N″,N″-dimethylguanidine
A mixture of crude 1-(3-{4-[3-chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-2-phenyl-N-cyano-isourea (80 mg, 0.14 mmol), dimethylamine (0.25 mL, 2M in THF) in isopropanol (3 mL) was heated to 85° C. in a sealed tube. The reaction was cooled to room temperature after 3 hours. Solvent was removed via rotovap. The residue was then purified by FCC to give the final product (35 mg, 47%) as a light yellow solid. MS ESI (+) m/z 528 (M+1) detected; 1 H NMR (400 MHz, deuterated DMSO) 9.9 (s, 1H), 8.7 (s, 1H), 8.6 (s, 1H), 8.05 (s, 1H), 7.8 (m, 1H), 7.75 (m, 2H), 7.58 (br, 1H), 7.5 (m, 1H), 7.22-7.4 (m, 3H), 7.2 (m, 1H), 5.25 (s, 2H), 4.4 (m, 2H), 3.02 (s, 6H).
Example 2
N-(3-{4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-N′-cyano-N″-3-(2-hydroxy-ethyl)guanidine
A mixture of crude 1-(3-{4-[3-chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-2-phenyl-N-cyano-isourea (70 mg, 0.12 mmol) (from Step H, Example 1), 2-hydroxyethylamine hydrochloride (39 mg, 0.4 mmol) and triethylamine (0.07 mL, 0.5 mmol) in isopropanol (2 mL) was heated to 85° C. in a sealed tube. The reaction was cooled to room temperature after 3 hours. Solvent was removed via rotovap. The residue was then purified by FCC to give the final product (25 mg, 38%) as a light yellow solid. MS ESI (+) m/z 544 (M+1) detected; 1 H NMR (400 MHz, deuterated DMSO) 9.95 (s, 1H), 8.7 (s, 1H), 8.6 (s, 1H), 8.05 (s, 1H), 8.0 (s, 1H), 7.8 (m, 1H), 7.78 (m, 2H), 7.6 (br, 1H), 7.5 (m, 1H), 7.22-7.4 (m, 2H), 7.2 (m, 1H), 7.1 (m, 1H), 5.25 (s, 2H), 4.25 (m, 2H), 3.5 (m, 2H), 3.25 (m, 2H).
Example 3
N-cyano-N′-(3-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)guanidine
Step A: 2-methyl-5-(2-methyl-4-nitro-phenoxy)-pyridine
To a 500 mL flask equipped with addition funnel at 0° C. was added NaH (8.26 g, 95%, 327 mmol), followed by slow addition of DMF (100 mL). The mixture was stirred for 10 minutes. The addition funnel was then charged with 6-methyl-pyridin-3-ol (30.2 g, 277 mmol) and DMF (100 mL), and the solution in addition funnel was added to the flask dropwise over 45 minutes. The reaction mixture was stirred at 0° C. for another 30 minutes once the addition was finished. To the addition funnel was then added 4-fluoro-3-methyl-nitrobenzene (39.1 g, 252 mmol) and DMF (100 mL) and the resulting solution was added to the flask dropwise over 45 minutes. The cold bath was removed at the end of the addition and the reaction mixture was allowed to stir at room temperature for 15 hours. The red dark solution was cooled to 0° C. and water (100 mL) was added cautiously to the reaction mixture. The resulting solution was stirred for 30 minutes and solid product was purified by filtration and washed with cold water (500 mL). The wet solid was dried in vacuo to give product (49.8 g, 81%).
Step B: 3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamine
A mixture of 2-methyl-5-(2-methyl-4-nitro-phenoxy)-pyridine (11.5 g, 47.1 mmol) and palladium on carbon (300 mg, 10 wt. %, wet) in MeOH (200 mL) was flashed with hydrogen. A hydrogen balloon was then applied to the reaction mixture. The reaction was stirred for 2 hours and the solution was filtered through a pad of celite, and the pad was washed with MeOH (300 mL). Concentration of the solution gave crude product (8.8 g, 87%) as light yellow solid.
Step C: (6-iodo-quinazolin-4-yl)-[3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenyl]-amine hydrochloride
A mixture of 3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamine (4.96 g, 23.18 mmol), 4-Chloro-6-iodo-quinazoline 604 g, 22.06 mmol) in tBuOH (60 mL) and DCE (60 mL) was refluxed for 6 hours. The reaction was cooled to 0° C. and the solid product (8.44 g, 76%) was isolated by filtration and washed with cold CH 2 Cl 2 (50 mL).
Step D: (3-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-carbamic acid tert-butyl ester
A mixture of prop-2-ynyl-carbamic acid tert-butyl ester (2.65 g, 17.08 mmol) and (6-Iodo-quinazolin-4-yl)-[3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenyl]-amine hydrochloride (8.2 g, 16.27 mmol), dichlorobis(triphenylphosphine) palladium (II) (570 mg, 0.81 mmol), copper iodide (154 mg, 0.81 mmol), and diisopropylamine (4.78 mL, 34.16 mmol) in anhydrous THF (80 mL) was stirred at room temperature for 5 hours. After concentration, the residue was dissolved in CH 2 Cl 2 (100 mL), washed with aqueous NH 4 Cl and brine, dried over sodium sulfate, and concentrated to give the crude product (7.89 g, 98%) as a light yellow solid which was then used without further purification.
Step E: [6-(3-Amino-prop-1-ynyl)-quinazolin-4-yl]-[3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenyl]-amine
To a suspension of (3-{4-[3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)-carbamic acid tert-butyl ester (1.22 g, 2.46 mmol) in CH 2 Cl 2 (3 mL) was added TFA (3 mL) dropwise. The reaction was stirred at room temperature for 30 minutes. The reaction mixture was then diluted with CH 2 Cl 2 (30 mL) and aqueous saturated sodium bicarbonate. Phases were separated and the aqueous layer was extracted with CH 2 Cl 2 (30 mL). Organic layers were combined, dried over sodium sulfate and concentrated to give the crude product (0.85 g, 88%) as a yellow oil.
Step F: N-cyano-N′-(3-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]-quinazolin-6-yl}-prop-2-ynyl)guanidine
A mixture of 2-phenyl-N-cyano-isourea (50 mg, 0.31 mmol) and [6-(3-amino-prop-1-ynyl)-quinazolin-4-yl]-[3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenyl]-amine (30 mg, 0.076 mmol) in isopropanol (3 mL) was heated at 85° C. in a sealed tube. The reaction was cooled to room temperature after 5 hours. Solvent was removed via rotovap. The residue was then purified by FCC to give the final product (18 mg, 51%) as a light yellow solid. MS ESI (+) m/z 463 (M+1) detected; 1 H NMR (400 MHz, deuterated DMSO) □ 9.9 (s, 1H), 8.7 (s, 1H), 8.6 (s, 1H), 8.2 (s, 1H), 7.8 (m, 2H), 7.75 (m, 2H), 7.2 (m, 3H), 7.0 (m, 3H), 4.22 (m, 2H), 2.42 (s, 3H), 2.2 (s, 3H).
Example 4
N-(5-{4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-furan-2-ylmethyl)-N′-cyano-morpholine-4-carboxamidine
Step A: furan-2-ylmethyl-carbamic acid tert-butyl ester.
Furan-2-ylmethylamine (8.0 ml, 91 mmol) and Boc 2 O (19.8 g, 91 mmol) are dissolved in DCM (40 ml) and stirred at room temperature for 1.5 hours. The reaction mixture is filtered and concentrated under reduced pressure to afford 17.6 g (85 mmol, 93%) of the desired product as an yellowish solid containing CA 4% t-BuOH ( 1 H NMR).
Step B: (5-{4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-furan-2-ylmethyl)-carbamic acid tert-butyl ester
[3-Chloro-4-(3-fluoro-benzyloxy)-phenyl]-(6-iodo-quinazolin-4-yl)-amine hydrochloride (0.913 g, 1.68 mmol) (from Step E, Example 1) is dissolved in DMF (20 ml) and the solution is degassed under nitrogen. The above solution is added over 10 hours to a heated (110° C.) degassed suspension of tricyclohexyl phosphine (0.475 g, 1.7 mmol), palladium dichloride (15.2 mg, 0.086 mmol), potassium acetate (0.35 g, 3.6 mmol), tetra n-butyl ammonium bromide (0.552 g, 2.15 mmol), and Furan-2-ylmethyl-carbamic acid tert-butyl ester (2.9 g, 15 mmol) in DMF (5 ml). Heating is continued for 9 hours after the end of addition. The reaction mixture is cooled, diluted with water and extracted with EtOAc. The combined organic extracts are dried (Na 2 SO 4 ) and concentrated under reduced pressure. Flash chromatography on silica with 10-50% EtOAc:hexanes gradient elution yields 0.450 g (0.78 mmol, 46%) of the clean desired product.
Step C: [6-(5-Aminomethyl-furan-2-yl)-quinazolin-4-yl]-[3-chloro-4-(3-fluoro-benzyloxy)-phenyl]-amine
(5-(4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl)-furan-2-ylmethyl)-carbamic acid tert-butyl ester (0.0218 g, 0.0379 mmol) is dissolved in DCM (2 ml) and TFA (2 ml) is added dropwise. The reaction mixture is stirred at room temperature for 1 hour. The solvent is removed under a nitrogen stream and to the residue are added consecutively saturated aqueous potassium carbonate solution and DCM. The resulting mixture is extracted with DCM containing 5% THF, the combined organic extracts are dried (Na 2 SO 4 ) and concentrated under reduced pressure to yield 17.6 mg (0.037 mmol, 98%) of the clean desired product.
Step D: 1-(5-{4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-furan-2-ylmethyl)-2-phenyl-N-cyano isourea
[6-(5-Aminomethyl-furan-2-yl)-quinazolin-4-yl]-[3-chloro-4-(3-fluoro-benzyloxy)-phenyl]-amine (148 mg, 0.313 mmol) and diphenyl cyanocarbonimidate (83 mg, 0.348 mmol) are suspended in a 1:2 THF:i-PrOH mixture (9 ml), and stirred overnight at room temperature under a nitrogen atmosphere. The resulting suspension is used in the next reaction step without purification.
Step E: N-(5-{4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-quinazolin-6-yl}-furan-2-ylmethyl)-N′-cyano-morpholine-4-carboxamidine
To one third of the crude product suspension from Step H is added morpholine (0.03 ml, 0.34 mmol) and the reaction mixture is heated for 2 hours at 80-90° C. in a sealed reaction vial. The reaction mixture is cooled, morpholine (0.05 ml, 0.57 mmol) is added, and the heating (80-90° C.) is continued for 1 hour. Concentration of the reaction mixture followed by flash column chromatography on silica with a 1:3:96 Et 3 N:MeOH:DCM eluant yields 9.8 mg (0.016 mmol, 15% yield over steps I and J) of clean desired product. MS ESI (+) m/z 612 (M+1) detected; 1H NMR (400 MHz, DMSO-d 6 ) δ 8.88 (s, 1H), 8.76 (s, 1H), 8.56 (s, 1H), 8.18 (d, 1H), 8.03 (s, 1H), 7.90 (s, 1H), 7.82 (d, 1H), 7.75 (d, 1H), 7.47 (m, 1H), 7.29 (m, 3H), 7.18 (m, 1H), 7.07 (d, 1H), 6.55 (d, 1H), 5.27 (s, 2H), 4.62 (d, 2H), 3.63 (m, 2H), 3.51 (m, 2H)
Example 5
N-cyano-N′-(4-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]-quinazolin-6-yl}-thiazol-2-ylmethyl)guanidine
Step A: (4-Bromo-thiazol-2-yl)-methanol (modified procedure from Nicolaou et al., Bioorg. Med. Chem., 7 (1999), 665-697)
2,4-Dibromothiazole (4.31 g, 17.7 mmol) are dissolved in anhydrous diethyl ether (170 ml) and the solution is cooled to −78° C. (dry ice-acetone bath). n-Butyllithium (1.6 M in hexanes, 13 ml, 20.8 mmol) is added dropwise to the reaction mixture and the resulting solution is stirred at the same temperature for 30 minutes. Anhydrous DMF (ml, mmol) is then added at −78° C. and, after being stirred at the −78° C. for 30 minutes, the reaction mixture is warmed to room temperature over a period of 2 hours. Hexanes (300 ml), were added and the resulting mixture is passed through a short silica cake eluting with 30% EtOAc-hexanes. The solvents are evaporated to yield the crude aldehyde which is used directly in the next step.
To a solution of the above aldehyde in MeOH (80 ml) is added sodium borohydride (g, mmol), and the resulting mixture is stirred room temperature for hours. Hexanes (300 ml) are added and the mixture is passed through a short silica cake eluting with EtOAc. The crude alcohol is further purified by flash chromatography on silica with 20-50% EtOAc-hexanes as an eluant to yield g (mmol, %) of the pure desired product.
Step B: 2-Azidomethyl-4-bromo-thiazole
(4-Bromo-thiazol-2-yl)-methanol (1.1 g, 5.7 mmol) in DMF (15 ml) is treated at room temperature under nitrogen atmosphere with trifluoromethanesulfonyl chloride (0.61 ml, 1 equivalent), and Et 3 N (0.8 ml, 1 equivalent). The reaction mixture is stirred for 3 hours at room temperature before the addition of sodium azide (1.11 g, 3 equivalents), followed by overnight stirring at the same temperature. The reaction mixture is diluted with water and extracted with DCM and diethyl ether. The combined organic extracts are dried (MgSO 4 ) and concentrated under reduced pressure to afford the crude product, which is used without purification in the next step.
Step C: (4-Bromo-thiazol-2-yl)-methylamine
Crude 2-Azidomethyl-4-bromo-thiazole from Step E is dissolved in a 1:3:2 THF:EtOH:H 2 O mixture, and treated with PtO 2 (wet, approximately 60 mg). The reaction flask is flushed with hydrogen from a balloon, and stirring under hydrogen atmosphere is continued for 3 hours. The reaction mixture is filtered through a Celite pad, diluted with DCM and diethyl ether, and dried (Na 2 SO 4 ). Chromatography on silica pretreated with 1% Et 3 N in EtOAc with EtOAc-MeOH eluant affords 710 mg (3.68 mmol, 65%) of clean desired product.
Step D: (4-Bromo-thiazol-2-ylmethyl)-carbamic acid tert-butyl ester
(4-Bromo-thiazol-2-yl)-methylamine (705.3 mg, 3.68 mmol) is dissolved in anhydrous DCM (15 ml) and Boc 2 O (898 mg, 4.13 mmol) is added. The reaction mixture is stirred at room temperature for 4 hours. Flash chromatography on silica with 0-20% EtOAc-hexanes affords 770 mg (2.64 mmol, 72%) of pure desired product.
Step E: (4-Trimethylstannyl-thiazol-2-ylmethyl)-carbamic acid tert-butyl ester
(4-Bromo-thiazol-2-ylmethyl)-carbamic acid tert-butyl ester (0.46 g, 1.58 mmol) is added at room temperature to Pd(PPh 3 ) 4 (87 mg, 0.075 mmol) in anhydrous toluene (16 ml) under a nitrogen atmosphere. Hexamethylditin (5.0 g, 15.26 mmol) is added in one portion and the resulting mixture is degassed under nitrogen. The reaction mixture is heated at 100° C. for 3 hours, then cooled to room temperature and loaded directly on a silica column pretreated with 1% Et 3 N in hexanes. Elution with 0-5% EtOAc-hexanes affords the crude product which is further purified by flash chromatography on silica with 0-30% EtOAc-hexanes gradient elution to yield 357.7 mg (0.950 mmol, 60%) of clean desired product.
Step F: (4-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]quinazolin-6-yl}-thiazol-2-ylmethyl)-carbamic acid ter-butyl ester
(4-Trimethylstannyl-thiazol-2-ylmethyl)-carbamic acid tert-butyl ester (191 mg, 0.507 mmol) and [3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenyl]-(6-iodo-quinazolin-4-yl)-amine hydrochloride (0.251 g, 0.478 mmol) (from Step C, Example 3) are dissolved in anhydrous DMF under a nitrogen atmosphere. Hunig's base (0.44 ml, 2.53 mmol), and PdCl 2 (PPh 3 ) 2 are added to the reaction mixture at room temperature. The reaction mixture is degassed and heated at 100° C. overnight. After cooling to room temperature the reaction mixture is diluted with water and thoroughly extracted with EtOAc and DCM. The combined organic extracts are dried (Na 2 SO 4 ) and concentrated under reduced pressure. Flash chromatography on silica with EtOAc-MeOH as an eluant affords 81 mg (0.14 mmol, 28%) of clean desired product.
Step G: [6-(2-Aminomethyl-thiazol-4-yl)-quinazolin-4-yl]-[3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenyl]-amine
(4-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]quinazolin-6-yl}-thiazol-2-ylmethyl)-carbamic acid ter-butyl ester (81 mg, 0.14 mmol) is treated with concentrated aqueous hydrochloric acid (0.5 ml) in EtOAc (6 ml). Reaction progress is followed by LC/MS. Upon reaction completion saturated aqueous potassium carbonate solution is added, the reaction mixture is diluted with water and thoroughly extracted with DCM and EtOAc. The combined organic extracts are dried (Na 2 SO 4 ) and concentrated under reduced pressure to yield 45 mg (0.095 mmol, 68%) of clean desired product.
Step H: 1-(4-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]quinazolin-6-yl}-thiazol-2-ylmethyl)-2-phenyl-N-cyano isourea
[6-(2-Aminomethyl-thiazol-4-yl)-quinazolin-4-yl]-[3-methyl-4-(6-methyl-pyridin-3-yloxy)-phenyl]-amine (45 mg, 0.095 mmol) is dissolved in a 1:2 i-PrOH:THF mixture (6 ml). Diphenyl cyanocarbonimidate (28 mg, 0.12 mmol) is added and the reaction mixture is stirred overnight at room temperature under a nitrogen atmosphere. To drive the reaction to completion diphenyl cyanocarbonimidate (20 mg, 0.09 mmol) is added to reaction mixture, which is stirred at room temperature for another 4 hours. The reaction mixture is then concentrated and purified by flash column chromatography on silica eith MeOH-EtOAc as an eluant. The yield of pure desired product is 42 mg (0.07 mmol, 74%).
Step I: N-cyano-N′-(4-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]-quinazolin-6-yl}-thiazol-2-ylmethyl)guanidine
1-(4-{4-[3-Methyl-4-(6-methyl-pyridin-3-yloxy)-phenylamino]quinazolin-6-yl}-thiazol-2-ylmethyl)-2-phenyl-N-cyano isourea (8.4 mg, 0.014 mmol) is dissolved in a 1:1 mixture of THF:i-PrOH (2 ml), and treated with 2.0 M ammonia solution in MeOH (0.1 ml). The reaction mixture is heated at 80° C. in a sealed reaction vial until the reaction is complete by LC/MS. Flash chromatography on silica with MeOH-EtOAc as an eluant affords 5.7 mg (0.011 mmol, 79%) of pure desired product. MS ESI (+) m/z 522 (M+1) detected; 1 H NMR (400 MHz, DMSO-d 6 ) δ 9.08 (s, 1H), 8.57 (s, 1H), 7.83 (m, 2H), 7.72 (d, 1H), 7.63 (bs, 1H), 7.25 (m, 2H), 7.14 (bs, 2H), 6.98 (d, 2H), 4.70 (m, 2H), 2.45 (s, 3H), 2.23 (s, 3H).
Example 6
N-(3-{4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-yloxy}-propyl)-N′-cyano-N″-(2-dimethylamino-ethyl)-N″-methylguanidine
Step A: 2-(2-Chloro-4-nitro-phenoxymethyl)-pyridine
Sodium hydride (95%, 0.935 g, 37 mmol) is suspended in dry DMF (20 ml) under a nitrogen atmosphere and the resulting mixture is cooled in ice water. To above suspension is added dropwise over 15 minutes pyridin-2-yl-methanol (3.42 g, 31.3 mmol) in dry DMF (20 mL). Next, to the cold reaction mixture is added dropwise over 20 minutes a solution of 2-Chloro-1-fluoro-4-nitro-benzene (5 g, 28.5 mmol) in dry DMF (20 ml). Upon the end of addition the cold bath is removed and the reaction mixture is stirred for another 36 hours. Water (80 mL) was added slowly to the reaction mixture, and a yellow precipitate resulted. The resultant solid is isolated by suction filtration, washed with water (80 ml), and air dried to yield 7.52 g (28.5 mmol, 100%) of the clean desired material as a yellow powder.
Step B: 3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamine
2-(2-Chloro-4-nitro-phenoxymethyl)-pyridine (2.4 g, 9.07 mmol) is suspended in MeOH (30 ml) and treated wet 5% Pt/C (Degussa type, Aldrich, 0.8 g). The flask is flushed with hydrogen gas from a balloon and the reaction mixture is stirred under hydrogen atmosphere until reaction is complete by TLC (ca 2 hours). The reaction mixture is filtered through a Celite plug and the solvent is removed under reduced pressure. The crude product is redissolved in DCM, dried (MgSO 4 ) and concentrated to yield 1.7 g (7.23 mmol, 80%) of the desired product.
Step C: 2-Amino-5-hydroxy-4-methoxy-benzoic acid
5-Hydroxy-4-methoxy-2-nitro-benzoic acid (18 g, 84.51 mmol, J Indian Chem. Soc. 1970, 70, 925) is suspended in MeOH (1 L) and treated PtO 2 (100 mg). The flask is flushed with hydrogen gas and the reaction mixture is stirred under hydrogen atmosphere (45 psi) for 4 hours. The reaction mixture is filtered through a celite plug and the solvent is removed under reduced pressure. The crude product is redissolved in DCM, dried (MgSO 4 ) and concentrated to yield 15.06 g (82.3 mmol, 97%) of the desired product.
Step D: 7-Methoxy-quinazoline-4,6-diol
Piperidine (3 mL, 31 mmol) was added to a mixture of 2-Amino-5-hydroxy-4-methoxy-benzoic acid (8.1 g, 44.26 mmol) and triazine (5.38 g, 66.4 mmol) in MeOH (60 mL). The reaction was then heated to reflux and stir for 6 hours. The reaction was cool to 0° C. The product was isolated by filtration and washed with cold MeOH to give 6.37 g (33.2 mmol, 75%) of desired product.
Step E: Acetic acid 4-hydroxy-7-methoxy-quinazolin-6-yl ester
A mixture of 7-Methoxy-quinazoline-4,6-diol (6.2 g, 32.3 mmol), Ac 2 O (100 mL) and pyridine (10 mL) was heat to 100° C., and stirred for 3 hours. The reaction was then cooled to room temperature and poured to ice water (300 mL). The product was isolated by filtration, washed with water (200 mL) and dried to give 7.61 g (32.4 mmol, 100%) of desired product.
Step F: Acetic acid 4-chloro-7-methoxy-quinazolin-6-yl ester
To a stirred solution of anhydrous DMF (4.5 mL) in DCE (20 mL), cooled in an ice-water bath, is added dropwise under nitrogen a solution of oxalyl chloride (7.9 ml, 90 mmol) in DCE (40 mL). A white precipitate forms during the addition. After the end of addition the cold bath is removed and the reaction mixture is stirred at room temperature for 5 min. Acetic acid 4-hydroxy-7-methoxy-quinazolin-6-yl ester (6.5 g, 27.8 mmol) is added in portions via scoopula under nitrogen flow and the mixture is heated immediately to reflux. Heating is continued for 3 hours, followed by cooling to room temperature. The reaction mixture is poured into excess ice:water mixture (100 mL) and extracted with DCM (500 mL). The aqueous layer is further extracted with DCM (2×50 mL). The combined organic extracts are dried (Na 2 SO 4 ) and concentrated under reduced pressure to yield 5.63 g (22.34 mmol, 80%) of desired product as a tan solid.
Step G: 4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-ol
3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamine (3.9 g, 16.62 mmol) and acetic acid 4-chloro-7-methoxy-quinazolin-6-yl ester (4.62 g, 18.28 mmol) were dissolved in a 1:1 mixture of DCE:t-BuOH (50 mL). The reaction mixture was refluxed for 19 hours and then cooled to room temp. Solvent was removed via rotovap. The crude residue was then suspended in MeOH (80 mL) and NH 4 OH (8 mL, 30% in water) was added to the mixture. Stir for 15 hours at room temp. The reaction was heated to 100° C. and stirred for 1 hour. Cool to 0° C. and product was isolated by filtration and washed with cold MeOH to give 5 g (12.2 mmol, 67% over two steps) of desired product.
Step H: (3-{4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-yloxy}-propyl)-carbamic acid tert-butyl ester
CsOH monohydrate (0.452 g, 2.69 mmol) was added to a mixture of 4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-ol (1 g, 2.45 mmol), (3-bromo-propyl)-carbamic acid tert-butyl ester (0.64 g, 2.69 mmol), tetrabutylammonium iodide (5 mg) and 4 Å molecular sieves (2 g) in DMF (10 mL) at room temp. Stir for 3 hours. The reaction mixture was then filtered through celite and washed with EtOAc (30 mL). The organic solution was washed with water (20 mL) and concentrated. FLC (10:1 EtOAc:Hexanes) provided desired product (1.02 g, 73.7%).
Step I: [6-(3-Amino-propoxy)-7-methoxy-quinazolin-4-yl]-[3-chloro-4-(pyridin-2-ylmethoxy)-phenyl]-amine
TFA (3 mL) was added drop wise to a suspension of (3-{4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-yloxy}-propyl)-carbamic acid tert-butyl ester (0.9 g, 1.59 mmol) in DCM (3 mL). Stir for 1 hour and the reaction mixture was diluted with DCM (20 ml) and sat. NaHCO 3 (20 mL). Phases were separated and organic layer was extracted with DCM (20 mL). Organic layers were combined, dried (Na 2 SO 4 ), and concentrated to give 0.7 g (95%) of desired product.
Step J: N-(3-{4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-yloxy}-propyl)-N′-cyano-N″-(2-dimethylamino-ethyl)-N″-methylguanidine
The primary amine was functionalized to the corresponding N-cyanoguanidine in the similar fashion as described in the previous examples. MS ESI (+) m/z 618 (M+1) detected; 1 H NMR (400 MHz, deuterated DMSO) δ 9.4 (s, 1H), 8.6 (d, J=4 Hz, 1H), 8.4 (s, 1H), 8.0-7.8 (m, 4H), 7.7 (dd, J=8.2 Hz, 1H), 7.6 (d, J=8 Hz, 1H), 7.3 (t, J=7 Hz, 1H), 7.2 (d, J=9 Hz, 1H), 7.17 (s, 1H), 5.2 (s, 2H), 4.18 (t, J=6 Hz, 2H), 3.91 (s, 3H), 3.6-3.4 (m, 4H), 3.39 (t, J=6 Hz, 2H), 3.27 (q, J=6 Hz, 2H), 2.92 (s, 3H), 2.1 (s, 6H), 2.06 (m, 2H).
Example 7
N-(3-{4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-yloxy}-propyl)-N′-cyano-N″,N″-dimethylguanidine
Prepared similarly as N′-(3-{4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-yloxy}-propyl)-N-(2-dimethylamino-ethyl)-N-methyl-N-cyanoguanidine. MS ESI (+) m/z 561 (M+1) detected; 1 H NMR (400 MHz, deuterated DMSO) δ 9.4 (s, 1H), 8.6 (d, J=4 Hz, 1H), 8.4 (s, 1H), 7.95 (d, J=3 Hz, 1H), 7.87 (td, J=8.1 Hz, 1H), 7.81 (s, 1H), 7.67 (dd, J=8.2 Hz, 1H), 7.57 (d, J=8 Hz, 1H), 7.35 (dd, J=7.5 Hz, 1H), 7.25 (d, J=9 Hz, 1H), 7.17 (s, 1H), 7.1 (t, J=6 Hz, 1H), 5.2 (s, 2H), 4.18 (t, J=6 Hz, 2H), 3.91 (s, 3H), 3.5 (q, J=7 Hz, 2H), 2.94 (s, 6H), 2.1 (m, 2H).
Example 8
N-(3-{4-[3-Chloro-4-(3-fluoro-benzyloxy)-phenylamino]-7-methoxy-quinazolin-6-yloxy}-propyl)-N′-cyano-N″-methylguanidine
Prepared similarly as N′-(3-{4-[3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamino]-7-methoxy-quinazolin-6-yloxy}-propyl)-N-(2-dimethylamino-ethyl)-N-methyl-N-cyanoguanidine, except that 3-Chloro-4-(3-fluoro-benzyloxy)-phenylamine in stead of 3-Chloro-4-(pyridin-2-ylmethoxy)-phenylamine was used in Step G in Example 6. MS ESI (+) m/z 539 (M+1) detected; 1 H NMR (400 MHz, deuterated DMSO) δ 9.43 (s, 1H), 8.46 (s, 1H), 7.96 (d, J=3 Hz, 1H), 7.82 (s, 1H), 7.7 (dd, J=9.2 Hz, 1H), 7.5 (q, J=6 Hz, 1H), 7.33 (d, J=8 Hz, 1H), 7.31 (d, J=9 Hz, 1H), 7.27 (d, J=9 Hz, 1H), 7.2-7.1 (m, 2H), 7.03 (m, 1H), 7.69 (m, 1H), 5.2 (s, 2H), 4.18 (t, J=6 Hz, 2H), 3.94 (s, 3H), 2.68 (d, J=6 Hz, 3H), 2.05 (m, 2H).
Example 9
N-cyano-N′-(3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-prop-2-ynyl)-morpholine-4-carboxamidine
Step A: 1-(3-Fluoro-benzyl)-5-nitro-1H-indazole
A modified procedure from WO 99/35146, p. 61 was followed. 5-nitroindazole (3.915 g, 24 mmol) treated with potassium carbonate (3.65 g, 1.1 equiv.), and 3-fluorobenzyl bromide (5 g, 1.1 equiv.) in 41 ml of dry DMF under N 2 . Reaction mixture is stirred at 75° C. for 4 hours. The crude product (yellow solid, 5.536 g) is isolated as in the reference procedure. Acetone (26 ml) is added to the crude product, and the insoluble solids are filtered off. To filtered solution is added water dropwise (12 ml) upon which an oil forms. The mixture is store in freezer at −20° C. for 15 min, upon which the oil solidifies and remains solid after warming to r.t. Chromatography of the solid (silica, 0-10% EtOAc/hexanes) afforded 2.49 g of high Rf material (1-H regioisomer, 9.2 mmol, 38%), 0.7 g of the low Rf material (2-H isomer, 11%) and mixed fractions (0.71 g, 3%).
Step B: 1-(3-Fluoro-benzyl)-1H-indazol-5-ylamine
Follow modified procedure from WO 99/35146. 1-(3-Fluoro-benzyl)-5-nitro-1H-indazole (2.49 g, 9.2 mmol) is suspended in 40 ml absolute EtOH and Pt/C (5%, wet, 150 mg) is added. The reaction mixture is stirred and heated at 60° C. under a hydrogen atmosphere (balloon). Roughly 4 hours into the reaction LC/MS reveals the formation of substantial amounts of product. The mixture is filtered through Celite and concentrated under reduced pressure. Yield: 2.01 g (90.8%) of a white solid.
Step C: [1-(3-Fluoro-benzyl)-1H-indazol-5-yl]-(6-iodo-quinazolin-4-yl)-amine hydrochloride
Follow general procedure from Example 1, step E. 4-chloro-6-iodoquinazoline (1.18 g, 4.06 mmol) is mixed with 1-(3-Fluoro-benzyl)-1H-indazol-5-ylamine (1.09 g, 4.52 mmol), and a mixture of DCE (10 ml) and t-BuOH (10 ml) is added. The mixture is heated at 90° C. (oil bath temperature) for 8 hours. At 5 hours of heating LC/MS reveals substantial amount of product. Yield is 1.35 g (56%).
Step D: (3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-prop-2-ynyl)-carbamic acid tert-butyl ester
[1-(3-Fluoro-benzyl)-1H-indazol-5-yl]-(6-iodo-quinazolin-4-yl)-amine hydrochloride (0.334 g, 0.628 mmol) and Prop-2-ynyl-carbamic acid tert-butyl ester (113 mg, 1.16 equiv.) is treated with i-Pr 2 NH (2 equiv.) in dry THF (4 ml) under N 2 . Pd(PPh 3 ) 4 (25 mg, 0.0356 mmol, 5.7 mol %) and solid CuI (5 mol %) are added next, and the mixture is stirred at r.t. for 3 hours. Workup: THF is removed under reduced pressure and DCM (10 ml) is added. The organic layer is washed with sat. aq. NH 4 Cl solution and brine, dried and concentrated. Chromatography on silica (EtOAc/hexanes) affords the desired pure product (293 mg, 89%).
Step E: [6-(3-Amino-prop-1-ynyl)-quinazolin-4-yl]-[1-(3-fluoro-benzyl)-1H-indazol-5-yl]-amine
(3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-prop-2-ynyl)-carbamic acid tert-butyl ester (285 mg, 0.545 mmol) is suspended in DCM (6 ml) and TFA (6 ml) is added dropwise. The reaction is stirred at r.t. for 2 hours. The solvents are removed in a N 2 stream, DCM (10 ml) is added, and the organic layer is treated with sat. aq. NaHCO 3 and brine, dried, and concentrated to afford the pure product (197.6 mg, 86%).
Step F: 1-(3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-prop-2-ynyl)-2-phenyl-3-cyano-isourea
[6-(3-Amino-prop-1-ynyl)-quinazolin-4-yl]-[1-(3-fluoro-benzyl)-1H-indazol-5-yl]-amine (280 mg, 0.663 mmol) is treated with diphenyl cyanocarbonimidate (163 mg, 1.031 equiv.) in a mixture of i-PrOH (12 ml) and THF (4 ml). Stir mixture overnight, then concentrate to dryness and chromatograph on silica (EtOAc/hexanes) to obtain 186.3 mg (49.6%) of pure desired product.
Step G: N-cyano-N′-(3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-prop-2-ynyl)-morpholine-4-carboxamidine
Material from step F (9 mg, 0.016 mmol) is placed in a reaction vial and dissolved in 2 ml of a 1:1 THF:i-PrOH mixture. Morpholine (0.08 mmol) is added at r.t, and the sealed vial is heated in an oil bath at 80° C. Reaction progress at 80° C. is followed by LC/MS, and the reaction is stopped after reaching 90% conversion (3 hours). Chromatography of the crude on silica (MeOH/EtOAc) affords pure desired product (1.8 mg, 20%). MS ESI (+) m/z 560 (M+1) detected; 1 H NMR (400 MHz, deuterated acetone containing 10% deuterated methanol) δ 8.58 (s, 1H), 8.55 (s, 1H), 8.39 (s, 1H), 8.11 (s, 1H), 7.84-7.76 (m, 4H), 7.65 (d, 1H), 7.37 (q, 1H), 7.12 (d, 1H), 7.04 (m, 2H).
Example 10
N-cyano-N′-(3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-allyl)-N″-(2-methoxy-ethyl)-N″-methylguanidine
Step A: (3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-allyl)-carbamic acid tert-butyl ester
To a cold (ice-water bath) Red-A1 (0.52 ml, 65% wt solution in toluene, 1.74 mmol) solution in THF (3 ml) added a solution of the s.m. alkyne (350 mg, 0.670 mmol) in THF (4 ml). Stir at 0° C. for 2.5 hours. Reaction is quenched with 10% aqueous potassium carbonate solution and diluted with distilled water. The mixture is extensively extracted with EtOAc and DCM, dried, and concentrated. Yield after chromatography (silica, EtOAc/hexanes) is 215.4 mg of pure product (61%).
Step B: [6-(3-Amino-propenyl)-quinazolin-4-yl]-[1-(3-fluoro-benzyl)-1H-indazol-5-yl]-amine
The desired product was obtained through a procedure analogous to the one outlined in Example 9, step E.
Step C: 1-(3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-allyl)-2-phenyl-3-cyano-isourea
The desired material was obtained through a procedure analogous to the one outlined in Example 9, step F.
Step D: N-cyano-N′-(3-{4-[1-(3-Fluoro-benzyl)-1H-indazol-5-ylamino]-quinazolin-6-yl}-allyl)-N″-(2-methoxy-ethyl)-N″-methylguanidine
Material from step C (10 mg, 0.0168 mmol) dissolved in 2 ml of a 1:1 THF:i-PrOH mixture and treated with 10 equivalents of MeHNCH 2 CH 2 OMe and heat to 80° C. The reaction was monitored by LC/MS. Up to five additional equivalents of amine can be added when necessary to drive the reaction forward. The reaction was stopped (by cooling vial to room temperature) when the conversion exceeded 60% (80-90% conversion is usually attained before end of the reaction). Chromatography of the crude on silica (0-10% MeOH-EtOAc) followed by preparative TLC (silica, MeOH/EtOAc) afforded 3.2 mg (34%) of the desired product. MS ESI (+) m/z 564 (M+1) detected; 1 H NMR (400 MHz, deuterated acetone) δ 9.34 (s, 1H), 8.56 (s, 1H), 8.45 (d, 1H), 8.44 (m, 1H), 8.10 (s, 1H), 7.97 (dd, 1H), 7.77 (m, 2H), 7.64 (d, 1H), 7.37 (m, 1H), 7.12 (d, 1H), 7.05 (m, 2H), 6.79 (m, 2H), 6.55 (dt, 1H), 5.73 (s, 2H), 4.31 (m, 2H), 3.36 (s, 3H), 3.12 (s, 3H), 3.63 (m, 4H).
Example 11
The extent to which the compounds of the present invention modulate ErbB kinase activity can be determined using the following enzyme-linked immunosorbent assay (ELISA), which employs a microtiter plate coated with a protein tyrosine kinase specific polymer substrate. The phosphorylation reaction is performed on poly-Glu-Tyr 4:1 (PGT) coated microtiter plates in the presence on Mg ++ , ATP and EGFR. The phosphorylated polymer substrate is detected with a phosphotyrosine specific monoclonal antibody conjugated to horseradish peroxidase (HRP). Chromogenic substrate (TMB) color is quantitated by spectrophotometry.
The assay is performed in a 96-well microtiter plate (Immunlon 4, available from Dynex). To prepare the plate, 100 μL of 0.25 mg/mL Poly(Glu, Tyr) 4:1 Sodium Salt (available from Sigma, Catalog Number P0275) in phosphate buffered saline (PBS) is added to each well and the plates are sealed. Following incubation overnight at ambient temperature, this coating solution is removed and the plates are washed three times with 300 μL of 0.1% Tween 20 (available from Sigma, Catalog Number P2287) in PBS. If not using immediately, the coated microtiter plates may be stored at 2-8° C. with 150 μL of 0.1% Tween 20 in PBS in each well.
The compound to be tested is dissolved in DMSO at an initial concentration of 1.0 mM. This initial concentration is diluted 1:25 in DMSO, and the resulting solution is further serially diluted 1:5 eight times in DMSO. To 10 μL of the initial concentration and each dilution are added 240 μL Reaction Buffer (50 mM HEPES, 125 mM NaCl, 24 mM MgCl 2 , 0.1 mM Na 3 VO 4 (boiled at pH 10 until colorless—approximately 10 minutes—and cooled prior to use), pH 7.3, filtered through a 0.2 micron filter). 25 μL of each compound solution (4% DMSO in Reaction Buffer for control) is placed in a separate microtiter plate well, along with 50 μL Reaction Buffer+ATP (15 μL 10 of mM ATP added to 5 mL Reaction Buffer) and 25 μL Reaction Buffer into which a catalytic amount of baculovirus ErbB2 has been added. The plate is then covered and incubated for 30 minutes at room temperature, after which time all liquid is aspirated from each well. The plate is washed three times with 300 μL of 0.1% Tween in PBS. Residual wash solution is removed by inverting the plate and blotting on a paper towel.
To each well is then added 100 μL of PBS containing 3% bovine serum albumin (protease-free, IgG-free, Jackson Catalog Number 001-000-162), 0.05% Tween 20 and 0.2 μg/mL anti-phosphotyrosine horseradisn peroxidase (available from Zymed, Laboratories, Inc., Catalog Number 03-7720). The plate is covered and incubated for 30 minutes at room temperature, after which time all liquid is aspirated from each well. The plate is washed three times with 300 μL of 0.1% Tween in PBS. Residual wash solution is removed by inverting the plate and blotting on a paper towel. To each well is then added 100 μL of TMB peroxidase substrate system (KPL Catalog Number 50-76-00), and the plate is allowed to incubate for 25 minutes at room temperature, at which time the reaction is stopped by the addition of 100 μL of 1 M phosphoric acid to each well. The plate is tapped gently to ensure mixing.
Within about thirty minutes after the reaction is stopped, the optical density at 450 nm of each well is determined using a microtiter plate reader. A dose response curve is generated by plotting optical density versus compound concentration. IC 50 is calculated from this curve using methods known in the art.
With this assay, the following IC 50 values of selected compounds of the present invention set forth in Table 1 below were determined.
TABLE 1
Example #
IC 50 (nm)
1
85
2
410
3
8
4
13
5
31
6
14
7
33
8
40
9
12
10
17
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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Cyanoguanidine quinazoline and cyanoamidine quinazolamine derivatives that are useful in the treatment of hyperproliferative diseases are disclosed. Methods of treating hyperproliferative diseases in mammals are also disclosed.
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This application claims priority from Provisional application Serial No. 60/107,715 filed Nov. 9, 1998.
This invention relates to low cost, single use, strong and absorbent coverings for health care and commercial bedding.
BACKGROUND OF THE INVENTION
Conventional fabrics for use as bedding in the home and in the health care and commercial fields are generally made of natural fibers, such as cotton or linen, or mixtures thereof with polymeric materials such as polyester, rayon or nylon. These fabrics are comparatively expensive, but in the home they can be laundered for years, reducing the overall cost of the bedding. In the health care and commercial fields however, where numerous individuals use the same conventional linen, intensive laundering protocols are required to remove bodily fluids such as blood, urine and the like, that can cause disease and infections. Thus strong cleaning compounds, such as chlorinated bleach and strong detergents, as well as high temperatures, are required to effectively remove these bodily fluids from the bedding and break down or inactivate the infectious bodies. In turn these harsh laundering protocols begin to deteriorate conventional bedding fabrics, shortening their lifetime to only about 15-17 washing cycles, thus increasing their overall cost. Additionally, the laundering process itself is becoming more expensive. In a health care or commercial facility, the bedding first must be stripped, collected and handled multiple times each day, further adding to the cost of providing bedding for beds, gurneys, cribs, MRI platforms and the like.
Further, health care and commercial providers must maintain a large inventory of sheets, pillow covers, gurney coverings and the like to ensure an adequate supply to meet daily and emergency requirements.
The costs of purchasing and maintaining an adequate supply of clean bedding and coverings has continued to rise. This is due not only to purchase expenses, but also because of the disappearance of a considerable quantity of bedding. For example, patient transport emergency vehicles must also maintain a supply of bedding on hand; when such vehicles are diverted to other health care facilities, such bedding is not returned to its original source. Theft on the part of health care and emergency care providers is not unknown either. Since conventional hospital linens are about the same size as those used in the home, they are equally useful there. Such losses can amount to several millions of dollars per year for a large hospital or commercial establishment.
Thus a search for lower cost alternatives to conventional bedding has been sought. In particular, materials or fabrics that are inexpensive enough to be disposed of after each use, eliminating the need for laundering and handling, would be advantageous.
In order to be cost competitive however, these materials must be inexpensive, but they must also be strong, i.e., they must be able to lift and transfer a patient, wet or dry, from one support surface to another, and they must have an absorbency equal to, and preferably better than, conventional bedding. In addition, the fabric must have a good hand and a texture that is comfortable next to the skin; it must be easy to use, that is, be able to readily cover a surface platform such as a bed or gurney, and it must be readily removable from such surface platform as well.
Disposable materials that have been used to date are made of organic materials, such as organo metallic chelates admixed with floc, or polymeric plastics such as polyethylene or polyester. However, such materials, whether they are extruded or “spun”, tend to stick to the skin, causing discomfort. Further, they have very limited or no absorbency; thus once wetted, the individual must lie on a wet surface until the bedding is changed. Further, currently available disposable bedding tends to stretch under load, unlike conventional bedding. Present day standards for health care bedding require that they be able to lift a 300 pound weight without tearing, so as to be able to transfer a patient from one surface to another, as from a bed to a gurney, without dropping the patient, whether the bedding is wet or dry.
To date, no alternative fabrics have been found that meet all of the present day requirements for disposable bedding for the health care field, or that have potential for commercial fields.
SUMMARY OF THE INVENTION
We have found particular non-woven, strong, lightweight, highly absorbent disposable fabrics that have excellent properties for health care and commercial bed, crib and gurney coverings. This non-woven fabric is comprised of non-woven, randomly entangled natural and synthetic fibers interconnected so that individual fibers are held in place to form a coherent, stable, strong fabric which resembles conventional spun or woven fabrics, particularly in terms of hand. These non-woven fabrics have an unexpectedly high absorbency.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the health care field applies to hospital care, acute care, nursing homes, infant care, as well as humanitarian aid and the like. Commercial fields include hotels, motels, hostels, nautical applications, sleeping bag liners and the like. Other like applications will present themselves to one skilled in the art, and are meant to be included herein.
Fabrics useful in the present invention are described in several patents owned by duPont de Nemours and Company and sold under their trademark “SONTARA”®. These include U.S. Pat. No. 3,485,706 to Evans, U.S. Pat. No. 3,493,462 to Bunting Jr. et al, U.S. Pat. No. 3,508,308 to Bunting Jr. et al and U.S. Pat. No. 3,620,903 to, Bunting, Jr. et al, all of which are incorporated by reference herein. Other manufacturers have similar products on the market and can be substituted for the above-described fabrics. These fabrics have a smooth feel; they are slightly stretchable in one direction; they need only be cut to the desired size and shape of the platform to be covered and finished, or “converted”. The fabric useful herein is principally composed of natural fibers combined with synthetic fibers. These hydroentangled webs display a textile-like hand, they are light in weight, weighing generally between 0.5 to 10 oz per square yard. They are at least as absorbent as, and generally more absorbent, than conventional fabrics made of natural or natural and synthetic blend materials. The addition of cellulosic compositions to the fabrics useful herein increases their absorbency by up to two to three times. They absorb fluids rapidly, and they are strong, whether wet or dry.
These fabrics have been tested and compared both to bed coverings that include natural fibers, such as cotton, and to other bed coverings made of synthetic fibers made in accordance with various well known processes. The synthetic fibers used can be conventional materials such as rayon, nylon, polyester, polypropylene, mixtures thereof or mixtures with other staple fibers. The natural fibers useful herein include wood pulp, paper and the like. The fabrics are made by carding the synthetic fibers to remove clumps, forming fiber strands. These strands are then passed to collectors where they are formed as a single layer or web. Natural materials such as paper or a layer of wood pulp, can be added to the fiber layer. Water jet streams are then used to tangle the fibers so they become interconnected and strong, as explained in U.S. Pat. No. 3,485,706 to Evans, disclosed hereinabove.
The above fabrics thus are light in weight, they are very strong, and, very importantly, we have found they are highly absorbent. In all cases, the above-described non-woven fabric useful in this invention is superior to other non-wovens tested for the present purposes. The non-woven fabrics useful in the invention can be cut into covering sheets and to fitted bottom sheets, for any size bedding platform, particularly including transport and treatment gurneys.
Bottom sheets are fitted by attaching a strip of elastic along at least a portion of the edges of the covering, such as by sewing or gluing the elastic to the fabric.
Treatment gurney mattresses are generally shaped in a six-sided configuration so that the head width is smaller than that of the shoulder or the foot. They have a larger and deeper mattress than transport gurneys. The present materials are particularly cost effective for such platforms. Fitted bottom sheets for these treatment gurneys are made using extra wide fabric, and elastic is used about the majority or all along the outer edge. Nevertheless, because these fitted sheets are of a non-standard size, and are generally narrower than conventional bed bottom sheets, they are not interchangeable. This size difference discourages pilfering. The additional fabric and additional elastic differentiates sheets used on rectangular platforms and those for treatment gurneys; they ensure that the sheet stays affixed to the mattress, particularly when the head or foot thereof is raised or lowered.
Bottom sheets are preferably cut on the bias for added strength. Covering sheets can be cut either on the straight or on the bias. The coverings can be rapidly replaced on the bed, gurney or other platform surface, as required.
The invention will be further described in the following examples, but the invention is not meant to be limited to the details described therein.
EXAMPLE 1
Five fabrics were tested for absorption capacity and speed of absorbency.
Control 1 is a 120 count woven muslim fabric comprising 50% by weight of cotton and 50% by weight of polyester.
Control 2 is a 180 count percale fabric made of 50% cotton and 50% polyester.
Control 3 is a waffle weave polyproylene having a pleasant feel sold as “Protect A Med® by the Protect-A-Med Corporation of Fort Lauderdale, Fla. This product is in commercial use as a disposable covering.
Control 4 is a fabric made from organo metallic chelates and floc sold by Hospital Disposable Linens, Inc of Fort Myers, Fla.: as “Flock-a-lite”. This fabric has a very smooth “plastic film” feel, is not breathable, has no nap and is very elastic. This product is also commercially available as a disposable bed covering.
Control 3 is a waffle weave polypropylene having a pleasant feel sold as “PROTECT A MED®”, a trademarked product of the Protect-A-Med Corporation of Fort Lauderdale, Fla. This product is in commercial use as a disposable covering.
Control 4 is a fabric made from organo metallic chelates and floc sold by Hospital Disposable Linens, Inc. of Fort Myers, Fla. as “FLOCK-A-LITE” fabric. This fabric has a very smooth “plastic film” feel, is not breathable, has no nap and is very elastic. This product is also commercially available as a disposable bed covering.
Example 1 is a sample of the present invention made of a mixture of 45% by weight of polyester and 55% by weight of wood pulp, sold by duPont de Nemours and Company under their trademark SONTARA® for non-woven fabrics.
TABLE I
Weight,
Absorptive
Absorbency Time,
Sample
oz/yd 2
capacity, gm
sec.
Control 1
3.24
13.5
1.6
Control 2
3.40
9.9
1.2
Control 3
1.36
Did not wet after 60 minutes
Control 4
1.40
8.3
18.0
Example 1
2.08
26.1
2.0
Controls 3 and 4 were unsatisfactory because of their long absorbency times or complete lack of absorption. The present fabric has a higher absorptive capacity, almost double, that of the conventional natural fiber-containing mixtures of Controls 1 and 2. The absorption time is substantially the same, particularly as compared to other synthetic fabrics tested.
The Controls and Example were also tested for tear strength, both breaking strength and tear strength. Breaking strength was tested according to ASTM text D5034-95 and tear strength was tested according to ASTM test D2261-96. The results are summarized below in Table II.
TABLE II
Breakinq strength
Tearing Strength, lbs
Fabric
Warp (MD)
Fill (CD)
Warp (MD)
Fill (CD)
Control 1
52
39
3.6
3.7
Control 2
68
46
2.5
2.9
Control 3
27
16
6.1
4.3
Control 4
8
7
1.6
1.1
Example 1
30
23
3.1
1.8
Thus the highest strength fabrics included natural fibers, but the fabric of the present invention was better in break strength than the other synthetic fibers tested that are presently in use as disposable bedding.
EXAMPLE 2
This example simulates the ability of sheets made of the fabric as described above as useful herein to transfer a patient from one surface to another. The tests were done both dry and wet according to tear strength ASTM test D2261-96.
A sheet of the fabric of the invention 39″×85″ in size was conditioned for 48 hours at 70° F. and 50% RH and spread out on a platform. A non-resilient liner was placed on the sheet, and steel weights having a total weight of 300 lbs were uniformly distributed about the center of the fabric. A total of six persons, one positioned at each of the four corners and one each in the middle of the long edges lifted the sheet three feet above the floor and held it there for 30 seconds. Although the sheet cut along the straight of the fabric failed at one of the lift locations at a long edge, the sheet cut along the bias sustained the 300 pound weight without any damage. Thus the present fabric is stronger when cut on the bias.
The above test was repeated except that a quart of water was poured onto the fabric after the conditioning step. No failure of the wet sheet was noted at all.
Although the invention has been described in terms of particular embodiments, one skilled in the art will recognize that various changes can be made by substituting like synthetic fabrics. The invention is only meant to be limited by the scope of the appended claims.
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Specific nonwoven fabrics having a good hand, high strength both wet and dry, and very high absorbency are useful for disposable health care and commercial bedding material. These fabrics are composed of randomly entangled natural and synthetic fibers interconnected so that the individual fibers are held in place to form a coherent, stable, strong fabric having a high absorption capacity. The fabrics are cut and converted to the desired dimensions. Bottom coverings can include elastic strips that can be fastened for a close fit to beds, cribs, gurneys and the like, regardless of shape.
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This application is a continuation of application Ser. No. 433,357 filed Dec. 22, 1982, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to plant food solutions, and more particularly, to storage stable liquid compositions comprising urea, uncondensed methylolurea, and water, combined as plant food solutions containing high nitrogen concentrations which exhibit properties of low saltout temperatures and low phytotoxicity.
2. Description of the Prior Art
Urea is one of the most economical and widely used plant food nitrogen sources. It is mainly used as a granular solid or as a mixed aqueous solution with an ammonium salt such as nitrate. The mixed solutions are necessary to achieve the commercially necessary high nitrogen concentrations and low saltout temperatures. Saltout temperature (hereinafter called SOT) is that temperature at, and below, which a plant food solution is no longer clear because one, or more, of the solution constituents has precipitated. Unfortunately, aqueous urea solutions containing substantial nitrogen concentrations have SOT's which are too high for general commercial use. For example, the maximum nitrogen concentration which may be achieved in an aqueous urea solution having a SOT of 0° C. is 16 weight percent.
Urea in aqueous solution frequently causes plasmolysis, or burn, in plants treated with the required amounts of nitrogen, particularly where the solution is allowed to contact the foliage of the plants. Mixed aqueous solutions containing urea with an ammonium salt, such as nitrate or sulfate, have even higher burn potential than does aqueous urea.
The burn tendency of urea has been reduced by many workers in the field by condensing it with formaldehyde to produce slow releasing urea polymers as indicated by Tisdale and Nelson on pages 174-176 in the Second Edition of Soil Fertility and Fertilizers.
Kealy in U.S. Pat. No. 3,235,370 provided a non-condensed urea-formaldehyde liquid suspension which was storable for 30 days. He did not provide an economical urea, urea-formaldehyde, water solution; a clear solution storable for about one year or more; nor an eutectic urea, methylolurea, water solution having a low SOT. U.S. Pat. No. 3,462,256, to Justice, et al, discloses a concentrated urea-formaldehyde solution containing 20 percent water or less in which between 50 and 80 percent of the formaldehyde is present as methylene ureas.
U.S. Pat. No. 4,304,588 to Moore discloses a clear storage stable, concentrated urea-formaldehyde-based solution containing 50 percent or more of the urea in the form of methylolurea with an overall molar ratio of urea to formaldehyde between 1.4 and 1.9, and a process for the preparation of this solution. Although the solution disclosed was low in the potential for burning plant foliage, no teaching was provided regarding economical eutectic solutions containing urea, methylolurea, and water, having high total nitrogen concentrations and low SOT's. The addition of urea to the product of U.S. Pat. No. 4,304,588, or to other urea-formaldehyde products of the prior art, to improve economics caused a significant increase in the SOT of the mixture, to a point where it is not useful as a plant food solution under normal circumstances.
Thus, no teaching was available from the prior art which would allow the blending of low-burn liquid urea-formaldehyde products with low cost nitrogen plant food chemicals to produce economical plant food solutions which were useful under a wide range of storage times and temperatures, while still retaining a lower tendency to cause burn to treated plants than urea or inorganic nitrogen fertilizers. Such a liquid plant food composition has been especially needed for fertilization of turf and other grasses, and for foliar feeding of many crop and ornamental plants and could be used as a row crop fertilizer or as a manufacturing solution for other liquid or solid fertilizers.
SUMMARY OF THE INVENTION
The present invention provides a novel urea-methylolurea-water concentrate of high agronomic value which is storage stable, and economical, and exhibits desirably low SOT's. The compositions of the present invention are plant food solutions which will remain substantially clear for about one year of more and will not precipitate solid materials at temperature of about 14° C. or higher and preferably not at 0° C. The composition of this invention comprises: between 19 and 31 weight percent total nitrogen, of which total nitrogen between 50 and 75 percent is derived from urea; uncondensed methylolurea, amounting to 1 part by weight per 0.5 to 2.1 parts of urea; and water, amounting to between 30 and 45 weight percent of the total composition. The preferred composition of the present invention contains between 23 and 28 weight percent total nitrogen and is more specifically defined as comprising between 21 and 43 weight percent urea, between 14 and 33 percent uncondensed monomethylolurea, and between 32 and 43 percent water. The compositions of the present invention are further characterized by a pH between 7 and 11 and preferably between 8.5 and 9.5.
Undesirably, SOT is increased when urea is added to methylolurea and other urea-formaldehyde solutions of the prior art, which usually contain about 15 percent water. The addition of water to these solutions, in the absence of added urea, also increases SOT. I have now found that urea and water can be combined with methylolurea in a previously unknown composition to achieve a storage stable solution, containing high nitrogen concentrations, which will not precipitate at normal winter fertilizer storage temperatures.
Methylolureas are formed by the reaction of aqueous urea and formaldehyde. The most common of these compounds are monomethylol- and dimethylolurea. Dimethylolurea tends to breakdown to produce free formaldehyde, so that it is not a satisfactory material for use as a plant food without further reaction. Methylolureas, and particularly monomthylolurea, upon heating at acid, neutral or basic conditions condenses to form methylolurea ethers which are not effective for use in the composition of the instant invention, when two or more monomethylolurea moeities are combined as an ether, because SOT is increased significantly. When aqueous monomethylolurea is acidified, particularly at elevated temperatures, or heated at certain neutral or basic conditions, methylene urea compounds and polymers form. These compounds and polymers have reduced solubilities and are frequently almost totally insoluble. Condensation of methylolurea to either ethers are methylene urea compounds and polymers is undesirable because of increased SOT's, and it has been found that the methylolurea used in the composition of the present invention must be substantially uncondensed with monomethylolurea amounting to 90 percent, or more, of the total urea-formaldehyde portion of the composition.
The composition of the present invention provides a plant food solution which is storage stable for about one year or more, to achieve the storage stability, it is necessary that the methylolurea be substantially uncondensed, and that the pH of the composition be between 7 and 11, and preferably between 8.5 and 9.5. When methylolurea is produced as a commercial aqueous solution, it sometimes contains enough base-buffering material to hold the pH of the composition of this invention in the desired range. Base-buffering solutions found to be effective in maintaining pH in the required range for extended periods of storage were: ammonium hydroxide, sodium carbonate, potassium carbonate, potassium formate, and sodium formate. Although condensation of monomethylolurea is slow enough at pH's between 7 and 11 to allow storage for many practical uses of the composition of this invention, maximum storage times of about one year, or more, were obtained where pH was maintained in the preferred area between 8.5 and 9.5.
The compositions of this invention may be achieved by simply blending the required ingredients in their pure or aqueous forms, or by blending commercial solutions or solids to produce the required composition. The composition may also be prepared by the in-situ reaction of urea and formaldehyde in the presence of sufficient excess urea and water to produce the desired ingredient content.
It is possible to optimize the solubility of a urea-methylolurea-water solution by use of eutectic mixtures at temperatures even higher than 14° C. However, at the eutectic point nitrogen contents are not significantly improved over those of straight urea-water solutions, and also solutions having SOT's higher than 14° C. cause frequent practical problems, such as plugged lines in mildly cool weather, and are of little practical value.
BRIEF DESCRIPTION OF THE DRAWINGS
The composition of this invention may be illustrated by reference to the FIGURES representing plant food solutions of this invention:
FIG. 1 is a diagram plotting total nitrogen content in solution at saltout vs. percent of the nitrogen in the composition as urea with parameters of SOT's .
FIG. 2 is a diagram plotting water content in solution at saltout vs. the ratio of urea to methylolurea in the composition with parameters of SOT's .
FIG. 3 is a diagram plotting water content in solution at saltout vs. the urea content of the solution, with parameters of SOT's .
FIG. 4 contains phase diagrams showing urea, water, and methylolurea contents at the compositions where precipitation of solids occurs at temperatures of -12°, 0°, and 14° C. The areas of the diagram titled "Liquid At -12° C." define all urea, water, and methylolurea compositions which are clear liquids. All other areas define compositions which contain at least some salted out solids at -12° C. The areas titled "Liquid At 0° C." define compositions which are clear liquids at 0° C. Compositions liquid at -12° C. are also liquid at 0° C. The areas titled "Liquid At 14° C." define compositions which are clear liquids at 14° C. Compositions which are clear liquid at -12°, and 0° C. are also liquid at 14° C. The phase diagrams were derived by determining saltout temperatures of various mixtures of water, crystal urea, and commercial methylolurea, and then plotting the compositions of the three components at constant saltout temperatures of -12°, 0°, and 14° C.
Referring to FIG. 1, it can be seen that urea, methylolurea, and water compositions in accordance with the proportions of the present invention form eutectic compositions having greatly enhanced solubilities for urea when total nitrogen content is between 19 and 31 percent. It also may be seen that a plant food solution containing a urea-methylolurea-water composition may be prepared which has a SOT of 0° C. with 54 percent of the nitrogen derived from urea at total nitrogen concentrations of either about 16 or 30 percent by weight in the solutions at saltout, the nitrogen variations being caused by use of different amounts of water. If the eutectic and optimum composition is used, about a 26 percent total nitrogen solution may be prepared much more economically, deriving 69 percent of the total nitrogen from urea. Similar eutectics may be seen on FIG. 1 for SOT's of -12° and 14° C.
Referring to FIG. 2, the criticality of the water content in the urea-methylolurea-water composition may be seen. Surprisingly, the ratio of urea to methylolurea possible for a given SOT does not continuously increase as water content of the composition increases, but peaks between 30 and 40 percent water concentration, depending to a small degree upon the SOT. It may be seen that a 0° C. SOT is obtained using a 1 to 1 weight ratio of urea to methylolurea with about 29 and 51 percent water contents. With the eutectic composition of the present invention a 0° C. SOT was achieved using a 1.5 to 1 weight ratio of urea to methylolurea when the water content is about 38 percent by weight. Similar eutectics were obtained at SOT's of -12°, 0°, and 14° C. at water contents of 37 to 40 percent. A urea to methylolurea ratio of 2.1 was obtained at a SOT of 14° C.
Referring to FIG. 3, it may be seen that in addition to increasing the ratio of urea to methylolurea which may be used for a given SOT, the actual amount of urea contained in the solution may be increased by using the composition of the present invention. It may be noted that a solution having a 0° C. SOT and containing 50 percent water may only contain about 23 percent urea, whereas it may contain about 38 percent urea at the optimum composition containing about 36 percent water.
It may be seen that greatly enhanced amounts of urea may be utilized in the area of the urea-methylolurea-water eutectics, so that compositions having SOT's lower than 14° C. may be obtained with compositions containing between 19 and 31 weight percent nitrogen of which between about 50 and 75 percent is derived from urea.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Plant food compositions, falling within the scope of this invention, are those plant food compositions having SOT's no greater than 14° C., which comprise aqueous solutions of urea and methylolurea having urea/methylolurea weight ratios between 0.9 and 2.1, total nitrogen contents amounting to between 19 and 31 weight percent, of which total nitrogen between 50 and 75 percent is derived from urea, and water contents amounting to between 30 and 45 weight percent of the total composition. The compositions of this invention are characterized by pH's between 7 and 11. Any departure from these ratios, concentrations, and pH's result in plant food compositions having unsatisfactory SOT's and storage lives.
The preferred embodiments of the present invention are more specifically defined as those plant food compositions having SOT's no greater than 0° C. comprising between 23 and 28 weight percent total nitrogen, between 21 and 43 percent urea, between 14 and 33 percent substantially uncondensed methylolurea of which 90 percent or more is monomethylolurea, and between 32 and 43 percent water, at a pH between 8.5 and 9.5.
The compositions of the present invention may be obtained in a conventional manner by simple admixture of urea, methylolurea and water. A simple preparation may be made by admixing water and urea crystals or prills into an aqueous solution of monomethylolurea and adjusting pH to the desired range by adding small amounts of aqueous potassium carbonate or bicarbonate.
Additionally, these compositions may be obtained by reacting aqueous formaldehyde with excess urea, and water with sufficient buffering agent to produce the required composition directly in-situ without further blending.
The compositions of the present invention are produced as concentrates and are readily adapted for transport and storage. These concentrates are employable directly as fertilizers for the soil and foliage and for manufacturing solid fertilizers. They may be blended with other plant food materials and water to produce plant food solutions for application to the foliage of ornamental and agricultural plants. The compositions of the present invention are further characterized as being substantially free of nitrogen containing precipitates, and hence are storage stable over extended periods of ambient or low temperatures.
The compositions of this invention may be employed in foliar applications, may be applied in irrigation water, may be incorporated in the soil, and applied directly to fertilize the soil. Minor amounts of other ingredients, such as 0.1 to 1 percent surfactant, may be encorporated in the composition to achieve an even coverage of foliage. In addition, small amounts of pesticides, fungicides, and herbicides may be included in small amounts of about 1 percent where desirable.
In order to demonstrate the invention, the following examples are given with all parts and percentages by weight unless otherwise specified:
EXAMPLE 1
A concentrated nitrogen was prepared by blending at ambient temperature in a one-liter beaker equipped with a magnetic bar stirrer, ingredients in the order listed as follows: aqueous monomethylolurea containing 40.7 percent monomethylolurea, 670 grams; and urea crystals, 330 grams; and 2.7 grams of sodium carbonate. A completely clear solution having a pH of 8.1 and a total N content of 23.6 percent was obtained which had a SOT of -12° C. The percent of the total nitrogen derived from free urea was 64.1
EXAMPLE 2
A concentrated nitrogen plant food solution was prepared for shipment, storage, and use in the custom lawn fertilizer industry, starting with 52.7 parts of a commercial methylolurea solution containing 30.7 percent total nitrogen having the following composition:
______________________________________Component Wt %______________________________________Monomethylolurea 48.0Urea 29.5Methylenediurea 3.0Ammonia 1.0Potassium Bicarbonate 4.3Water 14.2______________________________________
To the above methylolurea solution, containing 94 percent of its urea-formaldehyde compounds as monomethylolurea, was added 28.1 parts of water and 19.2 parts of hot aqueous urea liquor containing 90 percent urea, and the solution was mixed at ambient temperature until homogeneous in a large steel batch tank to produce a total of 50 tons of solution. The SOT of the final clear mixture which contained 24.0 percent total nitrogen of which 62.7 percent derived from free urea, was -12° C., and pH was 9.1.
EXAMPLE 3
Another concentrated nitrogen plant food solution was prepared using the same commercial methylolurea solution, containing 30.7 percent total nitrogen, as used in Example 2. To 50 parts of that solution were added 22 parts water and 28 parts of hot aqueous urea, containing 90 percent urea. The SOT of the final composition, containing 27.0 percent total nitrogen of which 68.0 percent derived from urea, was 10° C. The K 2 O content of the plant food concentrate was found to be 1.0 percent. The ratio of urea to methylolurea was 1.56 and total water content in the composition was 31.9 percent.
EXAMPLE 4
The produce from Example 2 was shipped by tank truck, and stored in a large steel tank prior to blending with additional water and potassium chloride to produce a solution for direct application to residential lawns. The analysis of the formulated solution applied to Kentucky Bluegrass Turf was 4-0-1. The solution was applied at a rate of 1.3 pounds of nitrogen per 1000 square feet of turf area in Southern Ohio in August. The turf showed good response within a 7-day period with the green color of the grass deepening significantly. There was no leaf burn or yellowing of the blade tips.
A similar treatment in adjacent turf plots using a 4-0-1 solution formulated with urea as the only nitrogen source clearly showed tip burn and yellowing on the Bluegrass.
The concentrated composition of Example 2 was stored in a steel drum for one year and remained clear with no precipitated solids evident.
EXAMPLE 5
A concentrated nitrogen plant food solution suitable for shipment, storage, and use in the foliar feeding of crops and ornamental plants is prepared in four stirred stainless steel reactors operating in a continuous manner in series, with each reactor jacketed for heating and cooling. Ingredients, having an overall urea to formaldehyde mol ratio of 2.79, are charged continuously to the first reactor and overflowing from the first through the fourth reactor in order in amounts listed as follows:
______________________________________Ingredients Feed Rate, lbs/hr______________________________________Ammonia 167.7Urea Liquor (90% Urea) 5627.7NaOH Solution (50% Na0H) 384.9CO.sub.2 Gas 158.9HCHO Solution (50% HCHO) 2407.5Water 3817.9Total 12564.6______________________________________
The reactors are operated to allow a total reaction time of 60 minutes at temperatures between 90° and 93° C. and pH's between 11.0 initially and 9.1 in the product discharged from the final reactor. The liquid product is cooled to ambient temperature as it leaves the fourth reactor, and is stored in steel storage tanks at ambient temperatures. The composition of the stored product is as follows:
______________________________________Components Wt %______________________________________Monomethylolurea 28.3Urea 27.0Methylenediurea 1.8Ammonia 0.6Potassium Bicarbonate 2.5Water 39.8______________________________________
The final composition contains 22.6 percent total nitrogen of which 55.0 percent derives from free urea and has a SOT of -14° C. The pH of the final product is 9.5.
Water soluble base buffering materials can be added to the compositons of this invention before production, or during storage to maintain the pH required for stability. Buffering materials used successfully include: ammonium hydroxide, sodium carbonate, potassium carbonate, potassium formate, and sodium formate. Ammonium hydroxide is the normal aqueous form of ammonia which may be added either as ammonium hydroxide, ammonium salts, or anhydrous ammonia. In the buffering reaction, the base buffering materials may be converted completely, or partially, to other compounds, usually salts. For example, alkali carbonates are usually converted to the bicarbonates and/or the formates in the desired pH ranges of the present invention. Mixtures of the base buffering materials are normally employed, usually including ammonium hydroxide and an alkali metal salt.
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Storage stable liquid plant food compositions are provided exhibiting low saltout temperatures, high nitrogen concentrations, and reduced nitrogen release rates, comprising urea, uncondensed methylolurea, and water, present in particular proportions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a line pressure control arrangement for an automatic transmission which includes an adaptive self-adjusting feature which compensates for wear and/or temperature changes, and more specifically to such a system which modifies the updating process in accordance with the use of auxiliary devices which consume engine power output and which reduce the amount of torque which is actually supplied to the transmission to drive the vehicle.
2. Description of the Prior Art
JP-A-63-92863 discloses a transmission arrangement of the nature wherein, in order to obviate the deterioration of shift characteristics due to friction element wear and/or changes in hydraulic fluid temperature and the like, the level, to which the line pressure should be controlled, is frequently updated by determining the actual time period defined between the point in time at which a given shift initiates and the point in time at which the shift is completed, with a predetermined optimal time. In the event that the actual period required for the shift to take place is found to be longer than the predetermined one, the level of the line pressure is incremented and vice versa.
However, with this type of arrangement in the event that auxiliary devices such as air conditioners and the like are provided, the amount of engine torque, which is required to drive the compression during use of the same, is substantial and reduces the actual amount of torque which is being supplied to the input shaft of the transmission. This creates a problem in that, during the use of such power consuming devices, the line pressure tends to be adjusted to a level lower than normal in order to compensate for the reduced amount of torque being supplied to the transmission. Accordingly, if the use of the power consuming device is terminated, the amount of engine torque which was used to drive the same is then added to the torque being supplied to the transmission. This brings about the situation wherein the level of line pressure is temporarily set at a level which is inadequate for the increased amount of torque being currently supplied and tends to result in friction element slippage and the like. Conversely, if the power consuming device is switched on after a period of non-use, the reverse situation, wherein the line pressure is set at level which is higher than that required for the amount of torque being supplied to the transmission input shaft, tends to come about. Under these conditions the excessively high line pressure level tends to engage the friction elements more abruptly than desired and leads to the generation of shift and/or select shock.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a control which obviates the above mentioned type of drawback wherein the line pressure level is adjusted to abnormally low levels during the operation of high load devices such as air conditioner compressors, power steering oil pumps and the like, which consume energy output from the engine and reduce the amount of torque which is supplied to the input shaft of the transmission.
In brief, the above object is achieved by an arrangement wherein the adaptive correction of the line pressure level is inhibited while the high load device or devices are sensed as being in use.
More specifically, a first aspect of the present invention is provided in an automatic transmission which is operatively coupled to an engine and which features: a source of line pressure via which friction elements of the transmission are engaged; means for sensing a plurality of operational parameters which are related to transmission shifting and for using the sensed operational parameters to determine a line pressure correction value via which the level of line pressure which is output from the source is corrected; and means for sensing the operation of a device which consumes engine rotational energy and reduces the amount of engine torque which is supplied to the transmission, and for inhibiting the determination of the line pressure correction value during the operation of the device.
A second aspect of the invention is provided in a vehicle which features: an engine for producing rotational energy; a transmission operatively connected to the engine for receiving rotational energy therefrom, the transmission including a source of line pressure via which friction elements of the transmission are operated; a device which consumes rotational energy produced by the engine and reduces the amount of rotational energy supplied from the engine to the transmission, when in use; sensor means for sensing transmission operational parameters; line pressure control means responsive to the sensor means for determining the difference between an actual shift time and a target shift time and for producing a correction value via which the level of line pressure which is produced by the source is corrected; and means responsive to the operation of the device for inhibiting the production of the correction value via which the line pressure level is corrected, during the operation of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the gear train of a transmission of the nature to which the present invention is applied;
FIG. 2 is a table showing the friction engagement patterns which are used to produce the various forward and reverse speeds of the gear train shown in FIG. 1;
FIG. 3 shows the hydraulic control circuit used to control the engagement of the friction elements of the FIG. 1 gear train;
FIG. 4 is a schematic diagram showing the electronic control arrangement which is used in connection with the hydraulic control circuit shown in FIG. 3; and
FIG. 5 is a flow chart which depicts the steps of a control routine which implements the control according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a gear train of an example of the type of transmission to which the present invention can be applied. In this arrangement, a torque converter 10 operatively interconnects an engine output shaft 12 and a transmission input shaft 13 in a manner to establish a drive connection therebetween. Although not illustrated, it will be understood that the engine has a throttle valve via which the amount of air which is supplied to the combustion chambers thereof is controlled.
In this embodiment the transmission is of the type which produces four forward speeds with an overdrive and a single reverse. The transmission input shaft 13 is connected to a turbine runner of the torque converter 10, while an output shaft 14 is connected to a final drive gear assembly (not shown). The transmission also includes a first planetary gear set 15, a second planetary gear set 16, a reverse clutch 18, a high clutch 20, a forward clutch 22, an overrunning clutch 24, a low & reverse brake 26, a band brake 28, a low one-way clutch 29, and a forward one-way clutch 30. The torque converter 10 is provided with a lock-up clutch 11.
The first planetary gear set 15 comprises a sun gear S1, a ring gear R1, and a pinion carrier PC1 rotatably supporting pinion gears P1, which mesh with the sun and ring gears S1 and R1. The planetary gear set 16 comprises a sun gear S2, a ring gear R2, and a pinion carrier PC2 rotatably supporting pinion gears P2 which mesh with the sun and ring gears S2 and R2.
The carrier PC1 is connectable to the input shaft 13 via the high clutch 20, while the sun gear S1 is connectable to the input shaft 13 via the reverse clutch 18. The carrier PC1 is connectable to the ring gear R2 via the forward clutch 22 and the forward one-way clutch 30 which are arranged in series with the forward clutch 22, or via the overrunning clutch 24 which is arranged in parallel to both the forward clutch 22 and forward one-way clutch 30.
The sun gear S2 is directly connected to the input shaft 13, while the ring gear R1 and the carrier PC2 are constantly connected to the output shaft 14. The low & reverse brake 26 is arranged to hold the carrier PC1 stationary, while the band brake 28 is arranged to hold the sun gear S1 stationary. The low one-way clutch 29 is arranged to allow rotation of the pinion carrier PC1 in a "forward" direction (the same direction as the engine shaft 12), and prevent the rotation in the opposite or "reverse" direction.
In this transmission, the rotation of the various elements (S1, S2, R1, R2, PC1, and PC2) of planetary gear sets 15 and 16 is determined by the selective engagement of the hydraulically operated friction elements, namely, the clutches 18, 20, 22, 24, and brakes 26, 28, in a manner which varies the gear ratio of the transmission i.e., the ratio of the revolution speed of the input shaft 13 to the revolution speed of the output shaft 14.
Four forward speeds and a single reverse speed are provided by actuating the clutches 18, 20, 22, and 24, and the brakes 26 and 28 in the manner illustrated in FIG. 2. It will be noted that in this figure the circles denote engagement of a friction element while oe1 and oe2 denote the ratio of number of teeth of the ring gear R1 to that of the sun gear S1 and a ratio of number of teeth of the ring gear R2 to that of the sun gear S2.
FIG. 3 shows a hydraulic control system used to control the above described gear train arrangement. This hydraulic control system comprises a line pressure regulator valve 40, a pressure modifier valve 42, a line pressure control solenoid 44, a modifier pressure accumulator 46, a pilot valve 48, a torque converter relief valve 50, a lock-up control valve 52, a first shuttle valve 54, a lock-up solenoid 56, a manual valve 58, a first shift valve 60, a second shift valve 62, a first shift solenoid 64, a second shift solenoid 66, a servo charger valve 68, a 3-2 timing valve 70, a 4-2 relay valve 72, a 4-2 sequence valve 74, a first reducing valve 76, a second shuttle valve 78, an overrunning clutch control valve 80, an overrunning clutch solenoid 82, an overrunning clutch reducing valve 84, a 1-2 accumulator 86, a 2-3 accumulator 88, a 3-4 accumulator 90, a N-D accumulator 92, an accumulator control valve 94, and a filter 96 which are interconnected as illustrated.
It will be noted that the above mentioned elements are also circuited with the torque converter 10 (which includes an apply chamber 11a and a release chamber 11b for the lock-up clutch 11), the forward clutch 22, the high clutch 20, the band brake 28 (the band brake 28 including a second speed apply chamber 28a, a third speed release chamber 28b, and a fourth speed apply chamber 28c), the reverse clutch 18, the low & reverse brake 26, and the overrunning clutch 24. In addition the circuit also includes a variable capacity vane type oil pump 34, an oil cooler 36, a forward lubrication circuit 37, and a rear lubrication circuit 38 in the illustrated manner.
A detailed description of the operation of these valves is omitted for brevity. However, for further disclosure relating to the same, reference may be had to "NISSAN FULL RANGE ELECTRONICALLY CONTROLLED AUTOMATIC TRANSMISSION RE4R01A TYPE" published by Nissan Motor Company Limited in March, 1987 (publication No. A261C07) and U.S. Pat. No. 4,730,521 issued to Hayasaki et al on Mar. 15, 1989. In this automatic transmission, the magnitude of the line pressure is controlled by a line pressure control solenoid 44. The manner in which the control is carried out is described on pages 1-22 to 1-24 of the above-mentioned service manual. Reference is also made to U.S. Pat. No. 4,807,496 issued to Hayasaki et al on Feb. 28, 1989 for features relating to line pressure control.
FIG. 4 shows a transmission control unit 300 which controls the solenoids 44, 56, 64, 66 and 82. The control unit 300 comprises an input interface 311, a reference pulse generator 312, a CPU (a central processor unit) 313, a ROM (a read only memory) 314, a RAM (a random access memory) 315, and an output interface 316 which are operatively connected to an address bus 319, and a data bus 320.
The control unit 300 receives signals from an engine revolution speed sensor 301, an output shaft revolution speed sensor (a vehicle speed sensor) 302, a throttle opening degree or position sensor 303, a select position switch 304, a kickdown switch 305, an idle switch 306, a full throttle switch 307, an oil temperature sensor 308, an input shaft revolution speed sensor (turbine revolution speed sensor) 309, an overdrive switch 310 and an air conditioner switch 600.
The outputs of the control unit 300 are supplied to the shift solenoids 64 and 66, overrunning clutch solenoid 82, lock-up solenoid 56, and line pressure control solenoid 44. It will be noted that the shift valves valves 60 and 62 which are responsive to the shift solenoids 64 and 66 while the pressure modifier valve 42 is responsive to the line pressure control solenoid 44.
For further reference to the control of the solenoids 44, 64 and 66, and valves 42, 60 and 62, reference can be had to pages 1-22 to 1-27 of the service manual (publication No. A261C07) and to U.S. Pat. No. 4,730,521.
In order to control the level of line pressure in accordance with the present invention, the control unit implements a control routine of the nature shown in FIG. 5. As shown, the first two steps 502, 504 of this routine are such as to read in the throttle opening and vehicle speed (viz., parameters indicative of engine load and vehicle speed). In step 506, this data is used in combination with a pre-recorded shift schedule data to determine which gear ratio the transmission should be conditioned to produce. At step 508, the gear ratio nominated in step 506 is compared with the gear ratio currently being produced. In the event that the two gear ratios are the same, the routine returns. However, on the other hand, if there is a difference and a shift is indicated as being necessary, the routine goes onto to step 510 wherein the instant status of the air conditioner switch is determined. In the event that the air conditioner is not in use the routine goes to step 512 wherein the actual shift time is determined by monitoring the rotational speeds of the input and output shafts (viz., the outputs of the output shaft rotational speed sensor 302 and input shaft rotational speed sensor 309). Merely by way of example, the shift time can be taken from the point in time the shift command is issued to the point in time the ratio of the input and output shaft rotational speed assume a value indicative of the gear ratio to which the instant shift is being made.
In step 514 the derived shift time is compared with the value indicative of an optimal shift. The difference, if any, is used to derive a correction value which is recorded in step 516 and subsequently applied to line pressure level control. That is to say, the correction value is used to modify the duty cycle which is being applied to the line pressure control solenoid 44, and thus, in turn, modify the modulation operation of the line pressure regulator valve 40.
However, in the event that the air conditioner is found to be in use, then the routine returns directly from step 510 by-passing the adaptive line pressure correction steps. In this manner the effect of the changes of torque at the input shaft of the transmission due to the use or non-use of high load devices such as air conditioners and the like can be obviated.
It will be noted that the instant invention is not limited to monitoring the operation of air conditioners and may be extended to any other type of load which can be selectively put into use. By way of example, it is within the purview of the instant invention to monitor the condition of the vehicle headlights, interior lights, high drain electrical devices, windshield wipers and servo devices such as oil pumps associated with power steering mechanisms.
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In order to prevent the line pressure level from being adjusted to abnormally low levels during the operation of a high load device such as an air conditioner compressor, oil pump and the like, which device consumes energy output from the engine and reduces the amount of torque which is supplied to the input shaft of the transmission, the adaptive correction of the line pressure level is inhibited while the high load device or devices are sensed as being in use.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vehicle with an anti-lock mechanism.
2. Related art
A cylinder lock is attached to the front part of a lock device. In the cylinder lock, as known, a key rotor is rotatably disposed within a rotor case. A plural number of tumblers are radially movably mounted on the key rotor, while being urged by spring members in the protruding direction. To lock, the ends of the tumblers are brought into engagement with tumbler engaging grooves formed in the inner peripheral surface of the rotor case, whereby the key rotor is locked in its rotation. When a correct key is inserted into a key hole of the key rotor in this locking state of the device, the key moves the tumblers to disengage from the tumbler engaging grooves. In this state, the key is turned and then the key rotor is turned.
A lock member to be rotated together with the key rotor is provided on the cylinder lock. The lock member controls to lock and unlock a locking mechanism.
There is a case where someone forcibly unlocks the lock device for crime purposes, for example, by inserting a key altered for crime purposes (referred to as a wrong key) or a screwdriver into a key hole of the key rotor. A possible measure taken for this type of unlocking is as follows:
A mechanically weak part is formed at a mid part of the key rotor when longitudinally viewed. When the key rotor is turned by a rotational force in excess of a predetermined value of force, the weak part is broken. When the weak part is broken, the key rotor is turned, but the lock member is not turned. Therefore, there is no chance of unlocking the locking mechanism.
For this reason, the above measure is cable of preventing the theft of the vehicle, but needs replacement of broken parts with correct ones since the key rotor is broken.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a lock device which rejects its unlocking without any damage of related parts when the key rotor is forcibly by a wrong key.
To achieve above object, there is provided a lock device comprising:
a rotor case fixedly mounted onto a body;
a sleeve, rotatably disposed within said rotor case, having axially extending guide grooves formed in the outer peripheral surface thereof and tumbler engaging grooves formed in the inner eripheral surface thereof;
a key rotor, rotatably disposed within said sleeve, having a plural number of radially extending tumbler locating grooves, and an engaging portion formed at the rear part of said key rotor, said key rotor being rotatable by a key;
tumblers, movably located in said tumbler locating grooves, respectively in a state that spring members, respectively, urge said tumblers in the direction in which said tumblers are protruded out of said tumbler locating grooves, said tumbler operating such that before said key is inserted into said key rotor, one end of each said tumbler is protruded from said tumbler locating grooves and brought into engagement with said tumbler engaging grooves, and when a correct key is inserted into said key rotor, said tumblers are moved into said tumbler locating grooves;
a lock member to be rotated together with the key rotor, said lock member being provided on said cylinder lock, a rotation of said lock member controlling to lock and unlock a locking mechanism;
a rotation transmitting member having a reception engaging portion at the front part thereof, which will receive and be engaged with said engaging portion of said key rotor in a disengaging manner, said rotation transmitting member being axially movably disposed between said lock member and said key rotor;
prepressed means urging said rotation transmitting member in the direction in which said reception engaging portion is brought into engagement with said engaging portion, and when said reception engaging portion is engaged with said engaging portion, said rotation transmitting member transmitting a rotation force of said key rotor to said lock member;
slide members being axially movably located in said guide grooves of said sleeve while being in contact with said rotation transmitting member, and being rotated together with said sleeve; and
cam means located between the fore ends of said slide members and said rotor case, when said sleeve is turned together with said key rotor by a force in excess of a predetermined value of force in a state that said tumblers are engage with said tumbler engaging grooves, said slide members are moved backward through a cam action, to thereby disengage said engaging portion from said reception engaging portion.
In the thus constructed steering lock device, when the key rotor is turned by use of a wrong key, at least some of the tumblers are engaged with the tumbler engaging grooves. Therefore, the sleeve is turned together with the key rotor.
When the sleeve is turned by a rotation force below a predetermined force of rotation, an engaging force of the cam means located between the fore ends of the slide members and the rotor case locks the sleeve and the key rotor in their rotation.
When the sleeve is turned together with the key rotor by a force in excess of a predetermined value of force, the slide members are moved backward through a cam action by the cam means, With the backward movement of the slide members, the rotation transmitting member while resisting the urging force of the spring members. As a result, the reception engaging portion of the rotation transmitting member is disengaged from the engaging portion of the key rotor. In this state, the rotation force of the key rotor is not transmitted to the cam shaft, and the key rotor is in an idling state.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view showing a two-wheeled motorized vehicle steering lock device which is an embodiment of the present invention, the steering lock device being in a state that a key rotor is set at an "off" position;
FIG. 2 is a front view showing the steering lock device of FIG. 1;
FIG. 3 is a cross sectional view taken on line A--A in FIG. 1;
FIG. 4 is a cross sectional view taken on line B--B in FIG. 1;
FIG. 5 is a cross sectional view taken on line C--C in FIG. 1;
FIG. 6 is a cross sectional view taken on line S--S in FIG. 1;
FIG. 7 is a cross sectional view taken on line E--E in FIG. 1;
FIG. 8 is a development showing checking raised parts of a rotor case and raised guides of a body;
FIG. 9 is a longitudinal sectional view showing a part of the steering lock device in which a key rotor is inserted into the device;
FIG. 10 is a longitudinal sectional view showing a part of the steering lock device in which the key rotor is disengaged from a rotation transmitting member; and
FIG. 11 is a longitudinal sectional view showing a part of the steering lock device in which the key rotor is disengaged from the rotation transmitting member when the device is in a "LOCK" state.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A two-wheeled motorized vehicle steering lock device which is the preferred embodiment of the present invention will be described with reference to the accompanying drawings.
In FIGS. 1 and 2, a body 1 of the steering lock device is fixedly mounted at a position near a steering shaft (not shown) of a two-wheeled motorized vehicle. A cylinder lock 3 is disposed in a front tubular portion 2 of the body 1. A cam shaft 4 with a protruded cam portion 4a and a steering locking mechanism 5 are disposed at the substantially central portion of the body 1. An ignition switch 6 coupled with the rear part of the cam shaft 4 is disposed in the rear portion of the body 1. A cap 7 is applied to the outside of the front tubular portion 2.
A rotor case 10 of the cylinder lock 3, cylindrical in shape, is fixedly attached to the front tubular portion 2. A sleeve 11, cylindrical in shape, is rotatably disposed within the rotor case 10. A couple of guide grooves 12, axially extended, are formed in the outer peripheral surface of the sleeve 11 while being oppositely disposed to each other when seen in cross section (also illustrated in FIG. 4). A quaternary or two couples of tumbler engaging grooves 13 are formed in the inner periphery surface of the sleeve 11 while each couple of tumbler engaging grooves 13 are oppositely disposed and a straight line connecting one couple of the tumbler engaging grooves 13 is perpendicular to a straight line connecting another couple of tumbler engaging grooves 13.
A key rotor 14 is rotatably inserted into the sleeve 11 in a state that the front part of the key rotor:r 14 is protruded forward beyond the rotor case 10. A case 15 is applied to the front part of the cylinder lock 3, thereby covering the front part of the rotor case 10 and that of the key rotor 14. A circular opening 16 is formed in the front end (the right side in FIG. 1) of the case 15. "LOCK", "OFF", "ON", "P" and others are marked on the front end surface of the case 15 while being arranged around the circular opening 16.
A key insertion hole 17, while axially extending, is formed in the key rotor 14. A plural number of tumbler locating grooves 18, which radially extend, are formed in the key rotor 14. An engaging protruding portion 19 as an engaging portion is integral with the rear part of the key rotor 14. Tumblers 20 are movably located in the tumbler locating grooves 18, respectively. In this case, prepressed means, e.g., spring members 21 urge respectively the tumblers 20 in the direction in which the tumblers 20 are protruded out of the tumbler locating grooves 18.
In this case, the cylinder lock 3 allows a key 22 to be inserted into and pulled out of the key rotor 14 when the key rotor is located at any of the positions "LOCK", "OFF" and "P".
A rotation transmitting member 27, which is formed with a slider 25 and a plate 26 applied to the slider 25 from the rear side of the slider, is disposed between the cylinder lock 3 and the cam shaft 4 in a state that it is movable in the axial direction. The front side of the slider 25 has an engaging recess portion 28 as a reception engaging portion which will receive and be engaged with the engaging protruding portion 19 of the key rotor 14 in a disengaging manner. A fitting cylindrical portion 30 which is fit into a fitting recess portion 29 of the cam shaft 4, is provided on the rear side of the slider 25. A spring member 31 is located between the fitting cylindrical portion 30 and the fitting recess portion 29, and a spring member 32 is located between the plate 26 and the cam shaft 4. The urging forces of the spring members 31 and 32 urge the rotation transmitting member 27 in the direction in which the engaging recess portion 28 is brought into engagement with the engaging protruding portion 19.
In this case, the fitting cylindrical portion 30 of the slider 25 is left being fit to the fitting recess portion 29 of the cam shaft 4. When the key rotor 14 is turned in a state that the engaging recess portion 28 of the slider 25 is in engagement with the engaging protruding portion 19 of the key rotor 14, a rotation of the key rotor 14 is transmitted to the cam shaft 4, through the rotation transmitting member 27.
A couple of protrusions 33, while oppositely disposed, are protruded from the outer periphery face of the plate 26 (FIG. 5). To check the movement of the protrusions 33, a couple of raised parts 34 and 35 are provided on the rear end of 1he rotor case 10, while protruding to the rear side (FIG. 8). The body 1 includes couples of raised guides 36 and 37, which are protruded forward, at locations where those guides are confronted with the plate 26.
The checking raised parts 34 for checking the movement of the protrusions 33 of the plate 26 are formed at the rear end of the rotor case 10. Therefore, when the key rotor 14 is turned from "OFF" to "LOCK" and from "ON" to "P", it is necessary to push the key rotor 14 rearward (downward in FIG. 8) while resisting the urging forces of the spring members 31 and 32, to thereby retract rearward the protrusions 33 from the positions of the checking raised parts 34 and 35.
Slide members 38 like bars are being axial lovably located in the guide grooves 12 of the sleeve 11. The fore and rear ends of the slide members 38 are protruded outward from the guide grooves 12 when viewed in the axial direction, and the rear ends thereof are in contact with the outer periphery of the front end face of the slider 25 of the rotation transmitting member 27. Recess portions 39, each opened to the rear side, are formed in the rear side of the front portion 10a of the rotor case 10 at locations corresponding to the slide members 38. The front ends of the slide members 38 are inserted into those recess portions 39, respectively. As shown in FIG. 7, the right and left sides of the fore end of each slide member 38 are slanted to form cam faces 40, and the corresponding locations of the inner surface of each recess portion 39 are also slanted to form cam, faces 41. Those cam faces 40 and 41 form cam means.
The steering locking mechanism 5 includes a movable cam frame 45, a lock bar 46 and a spring member 47. The movable cam frame 45 is located within a housing 44 of the body 1 in a state that the movable cam frame 45 is movable in the direction which obliquely intersects the axis of the cam shaft. The lock bar 46 is coupled with one end of the movable cam frame 45. The spring member 47 urges the movable cam frame 45 and the lock bar 46 in the direction of an arrow A. With rotation of the cam shaft 4, the movable cam frame 45 and the lock bar 46 are movable in the direction of the arrow A and in the direction opposite to the former by the protruded cam portion 4a.
In a state that the cam shaft 4 or the key rotor 14 is turned to the position "LOCK" or "P", the steering locking mechanism 5 operates in the following manner. The fore end of the lock bar 46 is protruded from the housing 44 and engaged with an engaging groove of the steering shaft (not shown), whereby the steering shaft is locked in its rotation.
The operation of the steering lock device thus constructed will be described.
A structural state of the steering lock device in which the key rotor 14 is turned to the position "OFF" is illustrated in FIGS. 1 and 2. In this state, the ignition :switch 6 is in an off state; the lock bar 46 of the steering locking mechanism 5 is at a disengaging position; and the steering .Locking mechanism 5 is in an unlocking state. In a state that nothing is inserted into the key insertion hole 17, the tumblers 20 are respectively protruded from the tumbler locating grooves 18 into the tumbler engaging grooves 13 of the sleeve 11.
When the key 22, which is correct, or not altered, is inserted into the key insertion hole 17, the tumblers 20 are moved, by the key 22, so as to be put into the tumbler locating grooves 18 while resisting the urging forces of the spring members 21. To turn the key rotor 14 to the position "LOCK" from this state, the key rotor 14 is first pushed. Then, the protrusions 33 of the plate 26 retract from the checking raised parts 34 and 35. Thus, the key rotor 14 is turned in the direction of an arrow B (FIG. 2) while pushing the key rotor 14. When the key rotor L4 is turned to the position "LOCK", the steering locking mechanism 5 operates such that the movable cam frame 45 and the lock bar 46 move in the direction of the arrow A, and the lock bar 46 comes in engagement with the steering shaft to be in a locked state (FIG. 11).
When the key rotor 14 is turned in the direction of an arrow C, opposite to the direction of the arrow B (FIG. 2), to the position "ON" in a state that the key rotor 14 is in th(e position "OFF", the ignition switch 6 is turned on through the cam shaft 4. In this state, a start switch (not shown) is operated or a kick lever (not shown) is kicked to start up the vehicle engine. Incidentally, if the key rotor 14 is turned up to the position "ON", the steering locking mechanism 5 is left unlocked.
To turn the key rotor 14 from the position "ON" to the position "P", the key rotor 14 is turned in the direction of the arrow C while pushing the key rotor 14. When the key rotor 14 is turned to the position "P", the ignition switch 6 is a parking mode; a light (not shown) is lit up; and the steering locking mechanism 5 is in a locked mode as at the position "LOCK".
Let us consider a case where a wrong key is inserted into the key insertion hole 17 in a state that the key rotor 14 is at the position "OFF". In this case, the key rotor 14 is forcibly turned in the direction of the arrow B or C in a state that the key rotor 14 is pushed. At this time, the tumblers 20 are engaged with the tumbler engaging grooves 13 of the sleeve 11. Therefore, the sleeve 11 is also turned together with the key rotor 14.
When the sleeve 11 is turned together with the key rotor 14 by a force in excess of a predetermined value of force, the cam faces 40 of the fore ends of the slide members 38 are brought into engagement with the cam faces 41 of the recess portions 39. As a result, the sleeve 11 and the key rotor 14 are checked in their rotation, and the cam shaft 4 is also checked in its rotation.
When the sleeve 11 is turned together with the key rotor 14 by a force in excess of a predetermined value of force, the slide members 38 are moved backward (in the direction of the arrow D in FIGS. 1 and 7) through a cooperative cam action of the cam faces 40 and the cam faces 41. With the backward movement of the slide members 38, the rotation transmitting member 27 is moved backward while resisting the urging force of the spring members 31 and 32. As a result, the engaging recess portion 28 of the slider 25 is disengaged from the engaging protruding portion 19 of the key rotor 14 (FIG. 10). When this state is set up, a rotation force of the key rotor 14 is not transmitted to the cam shaft 4, and the key rotor 14 is put in an idling state and fails to unlock.
At this time, the fore end of the slide members 38 is in contact with the rear side of the front portion 10a of the rotor case 10, and when reaching a position corresponding to the recess portions 39, it is inserted into the recess portions 39 again.
Also in a case where the key rotor 14 is forcibly turned by means of the wrong key in a state that the key rotor 14 is at the position "LOCK" or "P", the sleeve 11 and the key rotor 14 are check in their rotation and the cam shaft 4 is also checked in its rotation when the sleeve 11 and the key rotor 14 are turned by a rotating force below a predetermined value of force. When the sleeve 11 and the key rotor 14 are turned by a rotating force above a predetermined value of force, the rotation transmitting member 27 is moved backward through the cam action of the cam faces 40 and the cam faces 41, so that the engaging protruding portion 19 of the key rotor 14 is disengaged from the engaging recess portion 28 of the slider 25 (FIG. 11). In the illustration of FIG. 11, the key rotor 14 is not pushed backward. In this state, the rotation force of the key rotor 14 is not transmitted to the cam shaft 4, and the key rotor 14 is put in an idling state. In this case, the steering locking mechanism 5 is kept locked.
When the key rotor 14, which is at any of the positions "LOCK", "OFF" and "P", is forcibly turned by means of the wrong key, the steering lock device of the embodiment operates such that the rotation transmitting member 27 is moved backward through the cam action of the cam faces 40 and 41, with the aid of the slide members 38; the engaging protruding portion 19 of the key rotor 14 is disengaged from the engaging recess portion 28 of the rotation transmitting member 27; and the key rotor 14 is idling. The result is to prevent the unlocking of the steering lock device and to prevent the related parts thereof from being broken. And thereafter, the user can use the steering lock device as usual or without any exchanging of parts.
It will be understood that the invention may be modified, altered and changed without departing from the true spirits and scope of the invention. For example, three slide members 38 may be provided.
As seen from the foregoing description, when a key rotor of a vehicle lock device of the invention is forcibly turned by means of, for example, a wrong key, a rotation transmitting member is moved backward through a cam action of cam means with the aid of slide members. With this motion, the key rotor is disengaged from the rotation transmitting member, and the key rotor is in an idling state. Therefore, there is no chance of unlocking of the device and breaking the related parts of the device.
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A vehicle lock device is disclosed to impede a person from using a wrong key. When a key rotor is forcibly turned by a wrong key, the key rotor with the aid of tumblers turns a sleeve. The sleeve then moves slide members backward through a cooperative cam action. The front ends of the slide members have cam faces that are designed to correspond to guide grooves of the sleeve and recess portions of a rotor case. The backward movement of the slide members disengages a rotation transmitting member from the key rotor so that the key rotor is in an idle state.
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TECHNICAL FIELD
[0001] This invention relates to a hybrid dump bailer for use in a wellbore, and a method of using a hybrid dump.
BACKGROUND OF THE INVENTION
[0002] In subterranean wells, such as oil and gas wells, there are occasions when material, such as cement slurry or other chemicals, need to be introduced into the well bore. One common example is the introduction of cement slurry into a well bore to seal the well bore or the introduction of cement slurry above a bridge plug to seal off a section of the well bore. This is typically accomplished by what is commonly known in the industry as a dump bailer. Dump bailers are introduced or carried into a subterranean well on a conduit, such as wire line, electric line, continuous coiled tubing, threaded work string, or the like, and discharge or “dump” the cement slurry into the well bore.
[0003] There are two general types of dump bailers: (1) gravity feed bailers and (2) positive displacement bailers. Gravity feed dump bailers are some of the most commonly used dump bailers in the industry. One reason for this is its simplicity. However, gravity dump bailers present many drawbacks. Chief among them is the possibility of “stringing,” which occurs when the cement slurry does not completely discharge at the desired depth and the cement slurry is strung out through the well. Additionally, most gravity dump bailers include a seal, such as a ceramic disk, that is broken to allow the cement slurry to flow. The seal can be broken by a pin or, more frequently, shattered by an explosive charge. Positive displacement dump bailers address many of the deficiencies of the gravity dump bailers by elimination of the explosive charge and by providing force to expel the cement slurry out of the bailer.
[0004] There are several types of positive displacement dump bailers. Most positive displacement dump bailers rely on a sweep piston use to force the cement slurry or material out of the bailer. These systems may use a weight, either alone or with some actuating system, to force the piston down the bailer or the systems may use the pressure differential between atmospheric (well bore) pressure and the internal tool pressure to push the piston down the length of the bailer. While the positive displacement bailers overcome many of the deficiencies of the gravity dump bailers, they have several drawbacks. One of the main drawbacks is the use of bailer tubes, which hold the cement slurry. Because the sweep piston is forced through the bailer tubes, the bailer tubes must have a consistent inner diameter with a smooth wall bore to prevent the sweep piston from becoming lodged in the bailer tube and to reduce the friction between the pipe wall and the cement slurry. Additionally, because multiple bailer tubes are typically used, care must be taken not to damage the threaded connections. If the threaded connections are over tightened, the inner diameter of the bailer tube could neck down, causing the sweep piston to hang up.
[0005] Therefore there exists to address the shortcomings of the current art exists.
BRIEF SUMMARY OF THE INVENTION
[0006] In one aspect, the present invention utilizes a hybrid dump bailer for use in introducing material, such as cement slurry, into a well bore. The hybrid dump bailer includes a tool body having a longitudinal tool bore; at least one bailer tube; the bore including a piston with a seal rod and a pressure pulse piston with a connector rod and collet, wherein the collet has been configured to receive the seal rod; and a lower connection mechanism for connecting the tool body to bailer tubes. The dump bailer also includes a piston spring and a pressure pulse piston spring used to move the piston and pressure pulse piston.
[0007] Preferably, the hybrid dump bailer includes a head space above the piston and also includes a passageway, wherein the passageway is configured to allow fluid communication between the head space and tool body.
[0008] It is preferred that the hybrid dump bailer include a fluted connector, wherein the fluted connector and the lower tandem sub limits the travel of the pressure pulse piston.
[0009] It is also preferred that the hybrid dump bailer also includes a solenoid valve, wherein the solenoid valve can be remotely opened to allow fluid communication between the headspace and the upper solenoid housing.
[0010] In this aspect of the invention, the hybrid dump bailer also includes a plug, wherein the plug is secured in the bailer cage by a shear pin.
[0011] In another aspect, the present invention hybrid dump bailer includes a tool body having a longitudinal tool bore. The tool body also includes a top contact sub, a solenoid valve housing, a solenoid valve base, an inflow housing, a metering collet sub, a pressure chamber, a lower tandem sub, and a lower piston housing at least one bailer tube. The bore includes a piston with a seal rod and a pressure pulse piston with a connector rod and collet, wherein the collet has been configured to receive the seal rod; and an lower connection means for connecting the tool body to bailer tubes.
[0012] Preferably, the hybrid dump bailer also includes a piston spring and a pressure pulse piston spring.
[0013] It is also preferred that the hybrid dump bailer also includes a head space above the piston and a passageway through the solenoid valve base, wherein the passageway is configured to allow fluid communication between the head space and solenoid valve housing.
[0014] This aspect of the invention also includes a fluted connector, wherein the fluted connector and the lower tandem sub limit the travel of the pressure pulse piston.
[0015] It is also preferred that the hybrid dump bailer also includes a solenoid valve, wherein the solenoid valve can be remotely opened to allow fluid communication between the headspace and the upper solenoid housing.
[0016] The hybrid dump bailer also includes a plug, wherein the plug is secured in the bailer cage by a shear pin.
[0017] It is also preferred that the hybrid dump bailer where in the top contact sub, solenoid valve housing, solenoid valve base, inflow housing, metering collet sub, pressure chamber, lower tandem sub, and lower piston housing are connected by a threaded connection; however other connections such as welded connections are contemplated.
[0018] In another aspect, the invention provides a resetting tool for a hybrid dump bailer, which includes an inlet valve; a relief valve; a compression piston; and a compression rod.
[0019] Further aspects of the invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 schematically depicts one embodiment of the hybrid bailer of this invention in the ready to run position;
[0021] FIG. 1A schematically depicts a close up view of the contact sub and solenoid housing of the hybrid dump bailer of this invention;
[0022] FIG. 1B schematically depicts a close up view of the solenoid valve base and the inflow housing of the hybrid dump bailer of this invention;
[0023] FIG. 1C schematically depicts a close up view of the metering sub and pressure pulse chamber of the hybrid dump bailer of this invention;
[0024] FIG. 1D schematically depicts a close up view of the tandem sub and lower pressure pulse chamber of the hybrid dump bailer of this invention;
[0025] FIG. 1E schematically depicts a close up view of the lower sub and the bailer cage of the hybrid dump bail of this invention;
[0026] FIG. 2 schematically depicts one embodiment of the hybrid dump bailer of this invention after the tool has been run;
[0027] FIG. 3 shows a typical gel strength v. time curve for a cement slurry;
[0028] FIG. 4 schematically depicts the hybrid dump bailer and resetting tool of this invention; and
[0029] FIG. 5 schematically depicts the hybrid dump bailer and resetting tool of this invention once the tool case has been reset with the resetting tool.
DETAILED DESCRIPTION OF THE INVENTION
[0030] As used herein, “a” or “an” means one or more than one. Additional, distal refers to the end of the element closest to the setting mandrel of the setting tool and proximal end refers to the end of the element closest to the firing head of the setting tool.
[0031] The methods and apparatus of the present invention will now be illustrated with reference to FIGS. 1 through 5 . It should be understood that these are merely illustrative and not exhaustive examples of the scope of the present invention and that variations which are understood by those having ordinary skill in the art are within the scope of the present invention.
[0032] Turning now to FIG. 1 , which shows hybrid bailer 100 loaded and energized to discharge cement slurry into a well bore. While this example will discuss the discharge of cement slurry into the well bore, it is also contemplated that the hybrid dump bailer 100 could be used to deposit other material such as sand and chemicals. The hybrid dump bailer 100 includes a tool body made up of top contact sub 10 , solenoid valve housing 20 , solenoid valve base 30 , inflow housing 40 , metering collet sub 51 , pressure pulse chamber 50 , lower tandem sub 60 , and lower piston housing 70 . Bailer tubes 81 , bottom sub 80 , and bailer cage 90 are also connected to the tool body to complete to hybrid dump bailer. Each section will be discussed in further detail below.
[0033] The top contact sub 10 , which is shown in close-up in FIG. 1A , is connected to solenoid valve housing 20 by a threaded connection. While other connections, such as welded connections, are contemplated, the threaded connection is preferred because it allows the top contact sub to easily be removed for service or replacement. To further seal the connection, o-rings 18 are used. Polymer and copolymer o-rings such as Buna-N or nitrile rubber are preferred; however, other materials are contemplated and the selection will depend on the service conditions the hybrid dump bailers are exposed to. The top contact sub 10 includes a central bore 12 , which houses a spring 14 and a contact pin 16 . The central bore 12 is lined with an insulating material 13 , such as polyether ether ketone (“PEEK”), to prevent top contact sub 10 from becoming energized. Other electrical insulators, such as ceramics, carbon, rubbers, and plastics, can also be used. When the top contact sub 10 is fully mated with solenoid valve housing 20 , spring 14 is compressed as contact pin 16 is connected to electrical contact receptacle 21 . The force exerted by compression of the spring 14 , forces the contact pin 16 to seat within the receptacle of contact receptacle 21 thereby passing electrical current from contact pin 16 to receptacle 21 .
[0034] Electrical contact receptacle 21 is located within solenoid valve housing 20 and is surrounded by PEEK insulator 23 . As discussed above, other insulating material may be used. The receptacle is connected to brass contact 22 . A ceramic electrical feed-thru 24 is connected to brass contact 22 . Feed-thru 24 passes electrical current from brass contact 22 to flex spring contact 25 and flex spring 26 , which is in contact with solenoid valve contact 27 . Solenoid valve housing 20 also includes an opening, which is plugged by plug 29 .
[0035] Solenoid valve base 30 and inflow housing 40 are shown in close-up in FIG. 1B . Solenoid valve base 30 is connected on top side to solenoid valve housing 20 and on the bottom side to inflow housing 40 by a threaded connection. As previously discussed other connection mechanisms, such as welded connections and the like, are contemplated; however, the threaded connection is preferred. Additionally, o-rings 38 are incorporated to seal the device. Solenoid valve base 30 has recess designed to receive solenoid valve 32 , a side opening, which is plugged by plug 33 , check valve 35 , and a passageway 36 . Check valve 36 is located in a passageway that provides fluid communication between the side opening and the bottom of solenoid valve base 30 . When plug 33 is removed, fluid is allowed to pass through check valve 35 and into head space 41 , which is created by the bottom of solenoid valve base 30 , inflow hosing 40 , and piston 42 . Check valve 35 prevents flow of fluid from head space 41 through the check valve to the side opening.
[0036] Passageway 36 connects head space 41 with solenoid valve 32 . When solenoid valve actuator 31 (see FIG. 1A ) is energized, the solenoid valve 32 opens, allowing fluid to flow from head space 41 through passage way 36 and into head space 29 of solenoid valve housing 20 (see FIG. 1A ). Passageway 36 also includes a side opening 37 . When solenoid valve base 30 is completely connected to solenoid valve housing 20 , side opening 37 is sealed. Solenoid valve housing 20 can be backed off from solenoid valve base 30 , thus exposing side opening 37 to allow any pressure in head space 41 to be bled off, should, for example, solenoid valve 32 not function properly.
[0037] As shown in FIG. 1C , inflow housing 40 is connected on its other end to metering collet sub 51 via a threaded connection. As previously discussed, this is the preferred connection; however, other connections are contemplated. Inflow housing 40 also includes inflow passageway 49 . This allows this section of bailer 100 to operate at atmospheric pressure. Piston 42 , which is located within the centre bore of inflow hosing 40 , is connected to seal rod 43 . A piston spring 44 is positioned between piston 42 and metering collet sub 51 .
[0038] Metering collet sub 51 has a central bore through which seal rod 43 passes. Seal rod 43 is designed to be received and held by collet 52 . Plug 33 is removed and a fluid is pumped through check valve 35 into head space 41 . Although hydraulic fluid is preferred, other fluids such as compressed air or other gases can be used. In normal operation, the pressure in head space 41 is increased to approximately 400 psig above ambient. This pressure provides the force necessary to push piston 42 down and compress piston spring 44 , thus forcing sealing rod 43 into collet 52 .
[0039] The other end of metering collet sub 51 is connected by threaded connection to pressure pulse chamber 50 . In addition to collet 52 , pressure pulse chamber 50 includes upper connector rod 53 , pressure pulse piston spring 54 , collet base 55 , fluted connector 56 (see, e.g. FIG. 1 ), inflow passageways 57 (see FIG. 1D ), and lower connector rod 58 . Collet 52 is connected to upper connector rod 53 via a threaded connection. The other end of upper connector rod 53 is connected to fluted connector 56 via a threaded connection. Again, other connection means, such as a welded connection, are contemplated; however a threaded connection is preferred to allow for ease of replacement of parts and assembly of the hybrid dump bailer. Pressure pulse piston spring 54 is located between collet base 55 and fluted connector 56 . Pressure chamber inflow passageways 57 , like inflow passageways 49 , allow well bore fluid to enter bailer 100 , thus equalizing the pressure difference between the well bore and the bailer. Because the pressure chamber is open to the atmosphere and well bore fluid is in the interior, connector 56 is fluted to allow fluid to flow past the connector.
[0040] Referring to FIG. 1D , lower connector rod 58 is connected to fluted connector 56 via a threaded connection. Lower connector rod 58 passes through tandem sub 60 , which is connected on its upper end to pressure chamber 50 and on its lower end to lower piston housing 70 via a threaded connection. Again, other connections are contemplated, but a threaded connection is preferred. The bottom end of lower connector rod 58 is connected to lower pressure pulse piston 71 . Lower piston housing 70 is connected at its lower end via threaded connection to bailer tube 81 . Depending on the amount of material to be introduced into the well bore, one or more bailer tubes may be connected.
[0041] One advantage of the invention is that the bailer tubes do not have to meet the exacting standards, nor do they need to be treated with as much care, as the prior art bailer tubes. The prior art bailer tubes had to be manufactured with exacting internal diameter tolerances because small restrictions in the inner diameter could cause mis-runs in gravity bailers. Moreover, in prior art positive displacement bailers, which force a piston through the bailer tubes to dump the cement, variances in the inner diameter, can cause the piston to hang up, also causing mis-runs. Further, extra care must be taken when making up a section of bailer tubes because over torqueing the connection can cause the inner diameter to narrow at the connection. The new design of this invention is not dependent on the consistency of the inner diameter. This allows the bailer tubes to be manufactured from less expensive material and methods.
[0042] Referring to FIG. 1E , the last bailer tube 81 is connected to bottom sub 80 . Bottom sub 80 has a plug 82 . Plug 82 is attached to bottom sub 80 by shear pin 83 . Shear pin 83 can be a screw or other pin which holds the plug in pace. In the preferred embodiment, shear pin 83 is a brass screw that has a hole drilled in the center of the screw to reduce the amount of shear force necessary to shear the screw to approximately 200-250 lb F . Alternative materials, such as metal alloys and plastics can also be used as long as the shear force can be controlled. Bottom sub 80 is then connected to bailer cage 90 . Bailer cage 90 includes many openings used to direct the dump material in the well. As shown in FIG. 2 , bailer cage 90 also serves to capture plug 82 so it can be reused.
[0043] Referring back to FIG. 1 , hybrid bailer 100 is shown in the ready-to-run position. In this position, hydraulic fluid, which has been pumped into head space 41 , forces piston 42 down, compressing piston spring 44 between piston 42 and collet base 51 . Collet 52 , which receives the distal end of seal rod 43 , is a spring finger collet that grips the distal end of seal rod 43 when pressure pulse piston spring 54 is compressed between fluted connector 56 and collet base 51 . Depending on the amount of cement slurry to be dumped, a number of bailer tubes 81 containing cement slurry are attached to the lower piston housing 70 . In the preferred embodiment, a water pad of the type know in the art is placed on top of the cement slurry.
[0044] Referring to FIG. 2 , once hybrid bailer 100 is lowered into the well bore to the location were the cement slurry is to be dumped, solenoid valve 32 is opened, allowing the hydraulic fluid to flow from head chamber 41 through passageway 36 and into void space 28 of solenoid valve housing 20 , thereby relieving the pressure in head chamber 41 . This allows spring 43 to push piston 42 up, thereby disconnecting rod 43 from collet 52 . Once rod 43 is disconnected from collet 52 , spring 53 then forces fluted connector 56 down, thereby accelerating pressure pulse piston 71 . As pressure pulse piston 71 accelerates it strikes the water pad creating a pressure pulse, or shock wave, that is transmitted to the cement slurry. The pressure pulse creates a force that shears shear pin 83 , there by freeing plug 82 , which travels to and is contained by the bottom of bailer cage 90 .
[0045] Once the cement slurry is mixed and added to the bailer tubes, the cement slurry begins to gel. This is due to a number of factors including: (1) the ionic charges from the various slurry components; (2) the density of the slurry; (3) the slurry remaining static in the bailer tubes; (4) the elevated temperatures and pressures the slurry is subject to prior to dumping; and (5) the long time delay between the time the slurry is mixed and the time it is dumped. Once the cement slurry begins to gel, it becomes static has a tendency to remain static. Thus, once the cement slurry gels, it resists flow. In gravity and positive displacement bailers, this is one of the most common causes of mis-runs and stringing of cement in the well bore. FIG. 3 shows a predicted cement slurry gel strength time curve. As shown in the time curve, once the cement slurry is mixed and poured into the bailer tube, it begins to quickly gain gel strength while the bailer is run in the well bore. It may take upwards of two hours from the time the cement is mixed before it is dumped into the well bore. Thus, to guarantee that the cement slurry will flow out of the dump bailer, pressure pulse piston 71 must create sufficient force to break the cement slurry gel. Once the gel is broken, the cement slurry has favorable rheological properties, allowing the cement slurry to flow out of bailer cage 90 . FIG. 3 shows that once hybrid bailer 100 is dumped, the shock wave breaks the gel causing the gel strength to quickly drop. Once the cement slurry is in the well casing, it once again becomes static and the gel strength rapidly increases until the cement is set.
[0046] Once hybrid bailer 100 has dumped the cement slurry into the well bore, it is raised to the surface and bailer tubes 81 are removed. Bailer cage 90 is also removed, cleaned, and plug 82 is recovered and shear pin 83 is removed. Plug 82 is then inspected and, if there is no damage, it is reinstalled in bailer cage 90 using a new shear pin 83 . Bailer tubes 81 are cleaned and inspected. Depending on the amount of cement slurry to be dumped, additional bailer tubes may be added or removed and the bailer tubes can then be refilled with cement slurry and a water pad.
[0047] Referring to FIG. 4 , hybrid bailer 100 is now reset by attaching lower piston housing 80 to resetting tool 200 . Resetting tool 200 includes inlet valve 205 , relief valve 210 , compression rod 220 , and compression piston 225 . Compression rod 220 is connected to compression piston 225 on one end and has a notch that mates with the bottom of pressure pulse piston 71 . Referring to FIG. 5 , after resetting tool 200 is attached to the bailer, relief valve 210 is closed and inlet valve 205 is opened, allowing a high pressure fluid to be introduced into resetting tool 200 . This fluid can be high pressure water, air, or any other fluid with sufficient pressure to force lower piston 71 up, thereby compressing pressure pulse piston spring 54 between connector 56 and collet base 55 . Once pressure pulse piston spring 54 has been compressed, plug 33 is removed. A solenoid valve 32 , which is normally closed, is energized to open so the hydraulic fluid can be pumped into head chamber 41 forcing piston 42 down, thereby compressing piston spring 44 and forcing rod 43 into collet 52 . Once head chamber 41 is charged, plug 33 is replaced, inlet valve 205 is closed, and resetting tool 200 is removed. Once removed, relief valve 210 is opened to relieve the pressure in resetting tool 200 . Finally, the bailer tubes can then be reattached and hybrid bailer 100 is ready to run again.
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A hybrid dump bailer is disclosed herein comprising a bailer tubes for containing a material, such as cement slurry, to be dumped. The hybrid dump bailer comprises a pressure pulse piston that is accelerated by a spring causing a pressure pulse to expel the material to be dumped. The hybrid dump bailer further comprises a collet, a retaining rod, a piston, valve, and a supply of pressurized fluid which is holds the pressure pulse piston in place while the spring is compressed. Once the valve is opened, releasing the pressurized fluid, the retaining rod separates from the collet allowing the pressure pulse piston to accelerate can produce the pressure pulse to dump the material.
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BACKGROUND OF THE INVENTION
When a gaseous fluid (gas) is provided for mixing with another gas such as air, and then the mixture is to be used in a process of some kind, it is necessary to be able to control flow of the gas, and for this purpose valves are provided in the pipe or duct in which the gas flows. In these cases, it is usually necessary that the valve be capable of positively and reliably shutting off when gas flow is to end. These valves are mechanical devices and as such can malfunction for a number of reasons such as excess stress, vibration, particles in the gas stream, wear, or defects in manufacturing, any of which can result in leakage when the valve purportedly is shut. This is always undesirable, and may be a hazard if the gas involved has potential for doing harm if leakage occurs. Therefore it is important that leakage be reduced to an absolute minimum. However, it is not possible totally to prevent gas leakage in every valve of a large installed base because of the certainty of eventual deterioration and defects for a small fraction of valves, as well as the certain knowledge that the humans who have responsibility for proper operation of the gas control valves will not always perform their duties of inspection, use, and maintenance without error. For all these reasons, it is evident that means for sensing gas leakage in a valve provide an extra measure of safety and economy in the operation of such valves.
Perhaps the most common instance of gas flow control arises in the use and control of gaseous fuels (of which natural gas and propane are examples) used for heating and for industrial purposes. A very common situation is in gas fired burner systems where the burner is run for a period of time and then shut off when sufficient heat has bee provided. The gaseous fuel is mixed with air in a proportion and manner allowing for efficient combustion and heat generation. Such systems have frequent valve operation, and accordingly there is over a long period of operation, a non-zero probability of valve malfunction. While the remainder of this patent description will deal with sensing leakage of such gaseous fuels, the reader should understand that the description can apply to any situation where gas flow must be shut off on occasion and where the leakage of gas through the valve when shut is undesirable.
It is necessary for such systems using gaseous fuels regardless of their size to have their sequence of operation controlled, with each individual step necessary for safe and efficient operation of the heating unit occurring at the proper time. At the same time, there are a number of tests of operation and function which must be performed at preset times in the sequence to assure that previous steps have been performed properly. The newest versions of these systems use a microprocessor connected to control the elements of the heating unit. The microprocessor is programmed to command the sequence of the various functions which must be performed prior to, during and following an actual combustion operation.
These combustion systems typically include a combustion chamber, a source of the pressurized gaseous fuel, an air duct for carrying a flow of combustion air to the combustion chamber, a fuel injection nozzle within the air flow for supplying the gas to the combustion air so as to permit mixing of the fuel and air prior to entering the combustion chamber, and a valve for regulating flow of the fuel. Larger types of these systems have combustion air induced into the combustion chamber by use of a blower. There is a pipe which conducts the fuel from its source to the inlet port of the valve and another pipe which conducts the fuel from the outlet port of the valve to the nozzle.
It is customary in large systems to use a modulating fuel valve which can be opened to a number of different positions. In a system where there is a microprocessor which controls combustion system activity, such valves typically are electrically controlled by a solenoid receiving a valve control signal from the microprocessor. Modulating the valve between its closed and full open position controls the amount of fuel provided to the combustion chamber, and hence the rate of heat output. By adjusting speed of the blower or the position of dampers within the air duct the amount of air and fuel can be controlled so as to maintain almost precisely the stoichiometric fuel-air ratio. When there is no longer a demand for heat, the microprocessor sets the valve control signal to a closure value or signal which commands the valve to close completely, and the closure signal is maintained until another demand for heat occurs. For safety's sake, the valve is typically held closed by a spring against which the solenoid acts when opening the valve. Thus the closure signal state of the valve control signal may well be nothing more than the absence of electrical power to the solenoid.
As mentioned above, it is important that a valve responds to the closure signal by reliably, promptly and completely shutting so that unsafe amounts of gas cannot pass to the nozzle after the closure signal has been applied to the valve. In the past, there have been various design approaches to assure that such gas valves close reliably. For example, frequently two valves are used serially so that malfunction of both valves is necessary before fuel leakage occurs. It is common to specific periodic intervals for checking valve performance or to specify a service life after which the valve must be replaced. However, these approaches are relatively expensive and simply reduce the likelihood of valve leakage rather than allowing immediate correction of the leakage whenever it happens.
Another approach is to use devices which sense the presence of leaks and signal an operator when leakage is detected. There ar basically three different approaches which these type of devices use. A first senses flow within the fuel supply pipe when the valve is supposed to be closed, allowing the inference of a fuel leak. A second senses fuel pressure, inferring leaks from a change in pressure somewhere within the fuel delivery system. Neither of these techniques have the ability to sense potentially dangerous leaks in large systems where large amounts of fuel flow while the valve is open, because even a small amount of fuel flow on a percentage of maximum basis can be a relatively large amount of fuel in absolute terms.
A third type of leak detector relies on sensing presence of fuel within the system downstream of the fuel valve when the valve is receiving its closure signal. U.S. Pat. No. 3,999,932 describes a system using pressure buildup resulting from a gas leak in the control valve to close an auxiliary valve and shut down gas flow to the system. Of course, malfunction of the auxiliary valve or a failure of pressure buildup may allow leaks to occur. U.S. Pat. No. 4,375,353 discloses the use of a catalytic ga detector to detect presence of gas leaking into the combustion chamber of a furnace. The known characteristic of catalytic detectors to change their output with age or exposure to certain compounds may affect the reliability of their leak detection function.
Recently developed semiconductor devices called "microbridges" can accurately measure both the thermal conductivity and specific heat of gases, from which can be inferred the concentration of fuel in a fuel-air mixture. These sensors use highly stable noble metals and refractory materials as the elements in direct contact with the gas on which the measurements are performed. Such sensors typically include for example a pair of thin film temperature transducers adjacent a thin film heater, with the gas to be measured occupying a space between them. Semiconductor sensors of this type are discussed in more detail in one or more of U.S. Pat. Nos. 4,478,076; 4,478,077; 4,504,144; 4,651,564; and 4,683,159, all having an assignee common with the present application.
It known that the specific heat and thermal conductivity of gaseous fuels commonly used in burners today are substantially different from these properties for air. When the fuel is mixed with air, these properties of the resulting mixture differ from those of either pure fuel or pure air and are a function of the concentration of fuel in the air. Accordingly, it is known that by measuring either or both of these aforementioned properties one can determine the concentration of the gaseous fuel in air if the type of gaseous fuel involved is known.
BRIEF DESCRIPTION OF THE INVENTION
We have found that leaks in a fuel control valve can be detected in certain circumstances by sensing the concentration of fuel downstream from the valve. Such a valve is typically used in a combustion system of the type having a combustion chamber, a source of pressurized gaseous fuel, an air duct for carrying combustion air to the combustion chamber, a blower or other means for inducing airflow in the air duct to the combustion chamber, and a fuel injection nozzle within the air flow. The valve is used for stopping and for regulating the flow of the fuel, closing responsive to a closure signal supplied by a control unit. A first pipe conducts the fuel from its source to the valve and a second pipe conducts the fuel from the valve to the nozzle.
In this invention, the valve further has an outlet chamber. There are means provided for injecting air at a preselected flow rate into the valve's outlet chamber. In such a system fuel leaked by the valve can be sensed by apparatus which includes a sensing chamber in indirect flow communication with at least one of the second pipe in the downstream chamber of the valve. Within the sensing chamber there is a sensor of the type described above for detecting presence of the fuel. The sensor provides the sensor signal whose value is representative of the fuel concentration within the air within the sensing chamber. The sensor's signal is supplied to a comparison unit which in turn provides a leakage signal responsive to the closure signal and a predetermined deviation in the value of the sensor signal from a predetermined standard.
The term "indirect flow communication" used extensively above means that the concentration of fuel in the gas within the sensing chamber is representative of the concentration of gaseous fuel in the air in the space with which the sensing chamber communicates. The mixture within the sensing chamber may have been established because of molecular level mechanisms such as Brownian movement causing individual molecules of fuel to enter the sensing chamber until the concentration is representative of the space communicating with the sensing chamber. It is also possible that the mixture of gases within the sensing chamber is a sample directly taken from the space with which the sensing chamber communicates. It is important for accurate sensing of the fuel concentration within the sensing chamber that the gases within the sensing chamber are not convecting, i.e., being kept in motion by a pressure or temperature differential or by mechanical stirring, while measurements are made. The measurements made by the microbridge sensor relies on the heat convection characteristics of the gas surrounding it, and any kind of forced motion of this gas alters its heat convection characteristics, and hence the measurements as well.
"Diffusing communication" is a related term meaning that mixing of the gases within the sensing chamber with gases outside the sensing chamber occurs almost totally because of differences in concentration of fuel in the two spaces, typically involving the aforementioned Brownian movement mechanism. "Diffusing communication" does not refer to mixing driven by temperature or pressure differentials.
The predetermined standard against which the sensor signal is measured depends on the sensor value for the maximum allowable concentration of fuel downstream from the valve after the valve is shut. This value in turn depends on the sensor values for pure air and for pure gaseous fuel.
A method for use with such a combustion system for sensing fuel leakage in the valve includes the steps of providing a chamber in diffusing communication with at least one other second pipe in a downstream chamber of the valve and then sensing the concentration of the fuel in the chamber. A fuel concentration signal whose value is representative of the fuel concentration in the air within the sensing chamber is compared with a preselected standard while the control unit is providing the closure to the valve. If there is a predetermined deviation in the value of the fuel concentration signal from the preselected standard then a leakage signal is provided which indicates unacceptable leakage of fuel by the valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a structural diagram of a combustion system employing the invention for electronic leak detection.
FIG. 2 shows an alternative location for the sensing chamber.
FIG. 3 shows an alternative arrangement for injecting air into the valve's downstream chamber.
FIG. 4 shows an embodiment combining within the downstream fuel duct, flow sensing with fuel concentration sensing.
FIG. 5 is a program flow chart specifying the operations performed by a microprocessor implementing the method of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a combustion system 10 in which the invention is implemented. Among the conventional elements in it are the fuel source 11 shown diagrammatically as a pipe into the end of which is introduced gaseous fuel. There is downstream from this source a fuel flow sensor 12 whose purpose is to measure the flow rate of fuel in pipe 22. Pipe 22 is connected to an inlet chamber 39 of a valve assembly 16 which includes a valve seat 20 and a movable valve element 27. Valve element 27 is shifted between open and closed positions by a solenoid comprising winding 18 and armature 19 and which opens valve 16 by pulling valve element 27 away from seat 20. When electrical current does not flow in winding 18, spring 23 presses against the end of armature 19 to press element 27 against seat 20 and hold valve 16 closed. There is an outlet pipe 21 attached to the output port of valve 16. Pipe 21 conducts gaseous fuel flowing through valve 16 to a nozzle 24.
Combustion air is provided by a fan 38 which induces flow of air in air duct 37 as indicated by the arrows. Nozzle 24 is placed in duct 37 in a position which allows sufficient mixing of the fuel and air to permit efficient combustion. Combustion takes place in a chamber 36 as symbolized by the flame outline shown emanating from nozzle 24.
There is in the body of valve 16 an outlet chamber 35 having an orifice 17 through which bleeds a preselected flow rate of air into outlet chamber 35. This air mixes with fuel flowing through the valve from the inlet chamber 34 to the outlet chamber 35. When valve 16 is open the amount of air bleeding through orifice 17 into the fuel stream is an insignificant percentage of the total fuel stream. When valve 16 is closed ideally no gas passes through valve 16 between flange element 27 and seat 20. In the ideal case, and because of this flow of air through orifice 17, after a period of time after valve 16 has shut, flow through pipe 21 is of air only with no fuel component. While there are a number of ways to bleed air into orifice 17, the means which we prefer and which is shown in FIG. 1 is to place the body of valve 16 within air duct 37 with orifice 17 in an upstream (with respect to a surface of the valve housing surrounding the outlet chamber 35. It is also possible to have a separate hose or pipe connecting orifice 17 with the flow of air in duct 37. It is also possible to have a separate source of bleed air for introducing air into output chamber 35 through orifice 17.
As a practical matter, it is difficult to prevent a small amount of gas from leaking through valve 16 when it is closed. The size of orifice 17 and the pressure differential across it should be chosen to achieve a fuel concentration in pipe 2 arising from such leads when valve 16 is closed and the outlet chamber has been purged, of below one-tenth, or better, of below one-twentieth, of the lowest explosive limit of the gaseous fuel concentration in air. Combustions, Flames, and Explosions of Gases, 3d ed., 1987, by B. Lewis and G. Von Elbe, pub. Academic Press, reports that the lowest explosive limit fuel concentration for natural gas is 5.3% and for propane is 2.2%, both by volume.
For sensing the fuel concentration within outlet chamber 35, there is provided a sensing chamber 13 in communication with the downstream side of valve seat 20 through an orifice 15 to thereby allow gaseous molecules to pass between the two chambers. Chamber 14 may be located opposite the outlet port 40 of outlet chamber 35. We prefer that sensing chamber 13 is in what we call diffusing communication with the path of the fuel downstream from valve seat 20. At the very least chamber 13 should be in indirect flow communication with outlet chamber 35. (See the definitions of "diffusing communication" and "indirect flow communication" in the Brief Description of the Invention above.) In this embodiment the fuel concentration within chamber 14 will accurately track the fuel concentration in outlet chamber 35, although perhaps lagging it by a number of seconds. The important consideration is that the gas in chamber 13 is stagnating and has little macroscopic movement so that the thermal conductivity or heat capacity measurement of the gas on which sensor 14 bases its fuel concentration determination is not affected by convention of the gas within chamber 13.
It is also possible to place the sensing chamber in diffusing communication with outlet pipe 21, as shown in FIG. 2. There is shown therein a pipe 44 connecting pipe 21 to a sensing chamber 43. Screens 42 are placed in pipe 44 to prevent any forced convection of the gaseous fuel mixture (or pure air) flowing through outlet pipe 21. A sensor 14 is placed within chamber 43 to determine the fuel concentration of the gas therein.
Referring again to FIG. 1, the control apparatus for implementing this leak sensing procedure is shown as comprising a comparison unit 30 which functions in connection with the sequencing of the various burner functions which are initiated and timed by a control unit 31. There are two distinct phases of operation of burner system 10 during which leak detection occurs. The first phase (first because it immediately precedes the second in time) is the so-called post purge cycle, "post purge" referring to the fact that the purging occurs after the combustion interval. When demand is satisfied in a burner system of the type in which this invention is intended for use, valve 16 is shut by placing a valve closure signal on valve control signal path 26. After the valve 16 is shut by the valve closure signal issued by control unit 31, combustion ceases for lack of fuel within chamber 36. However, there may still be a substantial amount of combustible fuel within and downstream from the valve 16 which may accumulate in chamber 36 and mix with air to create a potential hazard. To deal with this situation, the practice is to run the blower 38 during a postpurge interval, typically for from 30 and 60 seconds, to exhaust these combustible gases. Blower 38 is under the control of control unit 31 which provides a run signal on a signal path 33 from control unit 31 to blower 38 during which blower 38 operates. The blower control signal is provided via path 33 to comparison unit 30. The valve closure signal on path 26 which causes valve 16 to close is provided to comparison unit 30 also.
It is most convenient to describe the operation of FIG. 1 in terms of the kind and sequence of the functions of control unit 31 and comparison unit 30. In a typical installation, comparison unit 30 and control unit 31 will be combined in a single microprocessor. This microprocessor is programmed to perform the functions of comparison unit 3 to implement this invention and also all of the other functions as well which are necessary for operation of the burner system. FIG. 5 is a flowchart of software which may be placed in such a microprocessor to cause it to function as comparison unit 30 in implementing this invention. Functions which will typically be performed by control unit 31 have been omitted from FIG. 5 except where necessary in explaining the invention.
There are various signals which are provided to control unit 31 and comparison unit 30 by the sensors. If quantitative, they will be processed internally in digital format by the microprocessor, and thus, must be presented as digital signals to the microprocessor. Since such sensors typically provide an analog output, the signal is provided to an analog to digital converter before being applied to the microprocessor and its control unit 31 and comparison unit 30 functions. Some microprocessors have an analog to digital circuit integral with the microprocessor which can be used to perform these conversions. Thus, the fuel concentration signal from sensor 14 and the fuel flow rate signal from sensor 12 are both typically processed as digital values.
Such microprocessors usually have an internal real time clock whose value can be accessed by the software by reading or writing into a clock register. A separate clock circuit independently updates the contents of the clock register at regular intervals, typically adding one to the clock register contents every millisecond.
The various control signals issued by comparison unit 30 and control unit 31 may be Boolean to indicate one of two states for the element involved, or may be either digital or analog if the particular element to which the signal is directed has the capability of modulating the level of its operation. For example, it may be possible to set valve 16 in a variety of open positions depending on the particular demand requirements and time in the operating sequence. Similarly, the speed of fan 38 may be selectable by control unit 31. In either of these cases, it is necessary to specify the operating level for the element involved, and this forms a part of the burner control algorithm which the control unit 31 function of the microprocessor implements. The leakage signal from comparison unit 3 which indicates whether the valve 16 is leaking an unacceptable amount is a Boolean value having a "0" value for example to indicate proper operation and a "1" value to indicate excess leakage.
One should understand that the function and sequence of the various operations performed by comparison unit 30 and described by the flowchart of FIG. 5 will typically be run at times which may be scheduled with reference to the real time clock. It should also be understood that the order in which the sequence of these functions or operations is performed may vary substantially as long as the overall function of this system is unaffected. In FIG. 5 there are 3 different types of functional elements. Those in rectangles are operation functions which specify some data manipulation activity such as setting the contents of one register to a different value or providing some external signal such as a leakage signal in activity element 81. There are also connector elements such as element 70 which specifies a jump or branch destination in the software implementing the functions of this flowchart. There are also decision elements which involve testing for a particular condition and selecting the instructions to be executed following this test on the basis of the results of that test. For example, in decision element 72, the value of the control unit's internal clock is greater than or equal to a particular time stored within the microprocessor comprising comparison unit 30 and control unit 31. Lastly, within the various elements of FIG. 5, parentheses should be interpreted to mean "the contents of" whatever register or data cell is contained within the parentheses.
The software instructions represented by the flowchart of FIG. 5 are intended to be executed at periodic intervals. Accordingly, activity element 71 provides for setting the next fuel concentration value sample time in a convenient data register. This value may be extracted from a table or be generated by simply adding a fixed time quantity to the current value of the next fuel concentration value sample time. The time between successive fuel concentration value samples will be typically a parameter established in the software at the factory. Decision element 72 represents the testing of the contents of the clock register to be greater than or equal to the next fuel concentration value sample time. If the clock register is smaller than this value then the time for reading the next fuel concentration value has not yet been reached. Accordingly, the "no" decision branch shows a return to the start of element 72. In a typical system, the microprocessor will execute other instructions before again making this test.
When the time to next test the fuel concentration value signal has elapsed then activity element 73 specifies that the contents of a new fuel concentration (f/c) value sample register is stored in an old f/c value sample register. Both of these registers may be individual random access memory locations within the microprocessor comprising comparison unit 30. The activity symbolized by element 74 occurs immediately thereafter and specifies that the signal on path 25 representing the fuel concentration value sensed by sensor 14 is sampled, converted to digital format, and stored in the new f/c value sample register.
As can be seen in FIG. 1, the fan operation signal on path 33 and the valve closure signal on path 26, both of which are provided by control unit 31, are supplied to comparison unit 30 as well as to the respective fan 38 and valve 16 which they control. In a typical embodiment, where comparison unit 30 and control unit 31 comprise the same microprocessor, there may be simply a control bit corresponding to each of these functions which specifies that the blower 38 is operating or the valve 16 is closed. In decision element 76, the internal value specifying valve closure signal status is tested and if the valve closure signal is not present o path 26 (meaning that valve 26 is or should be open), then the proper point in the operating sequence of system 10 for employing the elements of this invention has not yet been reached. Of course, the sensor 14 can detect the condition of the valve being open by the fact that the gas properties sensed are those of pure gaseous fuel, and it may well be that an operating system will perform such a test. This loop is executed a regular intervals while valve 16 is being held open by the absence of the closure signal. The old f/c value sample register and the new f/c value sample register will both contain the value indicating 100% fuel concentration while the valve is being held open.
If the valve closure signal is present then the software tests whether the blower operating signal is present a indicated by decision element 77. This is necessary because different tests are performed depending on whether the operating sequence is in the post purge mode, or if the post purge interval has elapsed and the burner system 10 is in its ready mode waiting for the next demand signal to start the operating sequence once again. If the blower operating signal is present then the fuel concentration value within outlet chamber 35 should continually decrease during the post purge interval. The software instructions symbolized by decision element 78 tests the contents of the new f/c value sample register to be less than the contents of the old f/c value sample register less some constant k. This constant k will be provided to comparison unit 30 as part of the data transferred o data path 40. The value k will be selected to reflect the minimum decrease in the fuel concentration value over the sample time interval tolerable in a properly operating system. Since the change in fuel concentration value will decrease towards the end of the purge interval, it is possible that k should be made a function from the time of the start of the post purge operation, and conceivably may even become zero at the end of a long purge. If this test is passed satisfactorily, then control is transferred back to the A connector element 70 preparatory to again executing the instructions symbolized by activity element 71. Should the test of decision element 78 be failed, then activity is transferred to connector element 80 and to the activity element 81 providing for issuing a leakage signal. Activity then proceeds further to activity element 82 where instructions are executed which removes and reissues the valve closure signal so as to attempt again to close the valve 16. It is entirely possible that upon another attempt, the valve 16 will close properly. However, any malfunction in a fuel valve 16 is a potentially serious condition which should be investigated by the operator as quickly as possible. Hence, it is important that the leakage signal be issued in any event. Processing path 83 then indicates that other processing occurs
If the post purge interval has been completed then decision element 77 transfers instruction execution to the instructions symbolized by decision element 84. These instructions test the contents of the new f/c value sample register to be less than a threshold f/c value. This threshold value too may be provided with the installation of the software in the microprocessor comprising comparison unit 30 and control unit 31. Typically the threshold f/c value should be some fraction, perhaps 50 percent, of the f/c value which constitutes a hazard. If this test is failed then control is transferred to connector element 80 and the instructions specified by activity elements 81 and 82 are executed. This function of this part of the software assures that a warning is instantly provided if valve 16 starts to leak during the standby interval between successive operating sequences.
There are a number of variations on the system as shown in FIG. 1 which may be employed in implementing the invention. In FIG. 3 instead of relying on blower 38 for bleed air to purge gas from chamber 35, there is a small purge blower 45 connected by duct 47 to chamber 35. We contemplate that blower 45 will run continuously, so that there will be a slow but steady movement of air through pipe 21. There is an enclosure 46 which is within pipe 21 and in indirect flow communication with the gases within pipe 21 through an orifice not shown in FIG. 3. A sensor 51 similar to sensor 13 of FIG. 1 measures a parameter of the gas within enclosure 46 from which can be deduced the fuel concentration of this gas. Should valve 16 leak then an increase in fuel concentration in pipe 21 will be sensed by sensor 51. The signal from sensor 51 is processed in a fashion very similar to the processing for the signal of sensor 13, although perhaps the various parameters may be somewhat different because of the different locations of the sensing chambers and because of the presence of air injected at all times directly into chamber 35 by blower 45.
In FIG. 4 an embodiment for the sensing device 46 in FIG. 3 is disclosed as comprising a small enclosure 50 mounted on an interior wall of pipe 21. Enclosure 50 has a funnel-shaped inlet orifice 59 facing upstream within pipe 21. There is a valve 52 within enclosure 50 which is urged toward orifice 53 by spring 54 and which when blocking orifice 53 prevents flow of gas within pipe 21 through the interior of housing 50. At selected times an activation signal is applied on path 57 to solenoid 56. The activation signal causes the valve 52 to withdraw from the orifice 53 against the force of spring 54 and allows the gas stream within pipe 21 to enter housing 50. The gas stream can flow through enclosure 50 and out orifice 55 to thereby assure that the entire interior of enclosure 50 is suffused with gas having a composition identical to that of the gas stream in pipe 21. After a period of time, the activation signal on path 57 is removed and spring 54 again presses valve 52 into orifice 53 to prevent flow of gas through the interior of enclosure 50. With orifice 53 thus plugged, there is no forced convection of ga within enclosure 50 and sensor 51 will not have the accuracy of the fuel concentration value read by it affected by such forced convection. It is necessary to wait for a short period of time after closing orifice 53 before sampling the value provided by sensor 51 to allow the turbulent motion of the gas within enclosure 50 to abate.
Control unit 61, which can be considered to be similar to control unit 31, provides an activation signal on path 57 at scheduled times. Comparison unit 60 also receives the activation signal and is conditioned thereby to perform tests similar to those described in connection with FIG. 5 on the f/c value signal provided on path 58. A similar leakage signal is provided on path 62 should the f/c value encoded in the signal on path 58 fall outside of the parameter values established. This alternative embodiment enjoys the advantages of forced convection in receiving prompt exposure to changes in fuel concentration within outlet chamber 35 of valve 16 and within pipe 21, and at the sam time provides for accurate sensing of fuel concentration. Such a sensing device may also be used during actual combustion to sense the velocity of the fuel stream within pipe 21 to thereby determine the rate of fuel delivery.
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A leak detector for a valve controlling flow of fuel to a combustion chamber employs a fuel concentration sensor in a sensing chamber placed downstream from the valve seat. The valve has a downstream chamber which is in communication by diffusion through an orifice, with a source of pressurized air. By injecting air into the downstream chamber through this orifice after the valve has closed and then measuring with the sensor the fuel concentration within the sensing chamber, excessive fuel leakage by the valve can be detected.
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FIELD OF THE INVENTION
[0001] The present invention relates to fabrication of fiber optic devices, and more particularly to a fabrication method that produces fiber optic devices having improved intrinsic resistance to external environmental conditions.
BACKGROUND OF THE INVENTION
[0002] The widespread and global deployment of fiber optic networks and systems mandates that fiber optic devices and components operate reliably over long periods of time. This mandate imposes stringent performance requirements on various fiber optic devices and components that are used in such networks and systems. In this respect, since fiber optic devices and components are expected to operate reliably for decades or more, prior to qualification for use, such components are typically subjected to an array of mechanical and environmental tests that are designed to measure their long term reliability.
[0003] Guarantees of long term performance become especially crucial in application where the cost of failure is very high (e.g., submarine applications.) One of these tests is a damp/heat soak test, where a fiber optic device or component is exposed to elevated temperature and humidity conditions (typically 85° C. and 85% relative humidity) for an extended period of time. Fiber optic couplers exposed to such conditions may exhibit a gradual drift in insertion loss. Eventually, this drift will cause a coupler to fail to meet its assigned performance specifications.
[0004] It is believed that the primary cause for the above-identified drift is water vapor or some component, constituent or by-product of water vapor diffusing into the exposed core glass of the coupler and changing the coupler's index of refraction.
[0005] In an attempt to prevent migration of moisture into the coupling region, it has been known to provide improved packaging for optic couplers, with the goal of eliminating exposure to external environment. For example, prior art approaches have included packaging fiber optic couplers and other fiber optic components inside a metal tubing and sealing the ends of the tubing with a polymeric material, such as a silicon-based material or epoxy. These types of packaging have not proved successful in preventing the aforementioned problem.
[0006] Other prior art approaches have focused on reducing the introduction of water vapor during the manufacturing process. These attempts include the use of heat sources, such as a solid state heaters alone, that introduce less hydrogen/water during fabrication of a coupler, than is introduced using an “open flame” heat source. However, these attempts have also failed. Such approaches are deficient because it has been discovered that the introduction of water and water related species during fabrication is not a major cause of long-term drift of optical properties under damp heat accelerated aging conditions. See Maack et. al, Confirmation of a Water Diffusion Model for Splitter Coupling Ration Drift Using Long Term Reliability Data. See also, Cryan et al., Long Term Splitting Ration Drifts in Singlemode Fused Fiber Optic Splitters, Proc. Nat. Fiber Opt. Eng. Conf. Jun. 18-22, 1995.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, there is provided a method of forming an optical device having a region treated by deuterium, comprising the steps of maintaining first and second optic fibers proximate to one another along a segment, and fusing together the segment to form a coupling region in the presence of a flame produced by combustion of deuterium gas.
[0008] In another aspect, the invention provides a method where the first and second optical fibers have different propagation constants.
[0009] In another aspect, the invention provides a method where a diameter of said first optic fiber is modified to change the propagation constant.
[0010] In another aspect, the invention provides a method where the diameter of one of the optic fibers is modified by heating the optic fiber while stretching the first optical fiber to reduce its diameter in a portion of the optic fiber.
[0011] In another aspect, the invention provides a coupler comprising at least two optic fibers having respective longitudinal segments, where the longitudinal segments are fused together in the presence of a flame produced by combustion of deuterium gas.
[0012] In another aspect, the invention provides a method where another chemical or compound is added to the deuterium fuel.
[0013] In another aspect, the invention provides a method where oxygen is added to the deuterium fuel.
[0014] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and advantages of the invention will be realized and attained by the structure and steps particularly pointed out in the written description, the claims and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
[0016] [0016]FIG. 1 is a schematic diagram of a preferred embodiment of an optical fiber before stretching.
[0017] [0017]FIG. 2 is a schematic diagram of a preferred embodiment of an apparatus used to stretch an optical fiber.
[0018] [0018]FIG. 3 is an enlarged schematic diagram of a preferred embodiment of an optical fiber after a pre-taper operation has been performed.
[0019] [0019]FIG. 4 is an enlarged isometric view of a preferred embodiment of an apparatus and a coupler.
[0020] [0020]FIG. 5 is a graph showing change is splitting loss over time.
[0021] [0021]FIG. 6 is a graph showing median time to failure for various optical devices.
[0022] [0022]FIG. 7 is a chart showing probability distributions of rates of change of splitting loss at 85° C./85%RH.
[0023] [0023]FIG. 8 is a table including data from TTF experiments.
DETAILED DESCRIPTION OF THE INVENTION
[0024] In the art, the term “optic device” generally refers to active elements or apparatus, whereas the term “optic component” generally refers to passive elements or apparatus. The present invention is applicable to both fiber optic devices and fiber optic components. Accordingly, as used herein, the term “optic device(s)” shall refer both to optic ices and optic components.
[0025] Furthermore, it should be appreciated that while the present invention is described herein with particular reference to fiber optic couplers, it is contemplated that the present invention is applicable to other optic devices.
[0026] As is well known to those skilled in the art, a fiber optic coupler is a device that passively splits or combines light between two or more optical fibers. An evanescent-wave couple is one in which optical energy is transferred from one optical fiber to another by virtue of the electromagnetic field overlap between the two cores of the fibers. Since the evanescent field of an optical fiber is an exponentially decaying field, the cores of the two fibers must be brought into close proximity.
[0027] One common method for constructing evanescent-wave couplers is with a technique known as fused biconical taper (FBT). In fused biconical taper, couplers are fabricated by heating two optical fibers until they coalesce into a composite waveguiding structure. While the fibers are being heated, they are slowly stretched and tapered. This causes the light in the fiber to spread out far enough into the composite structure where it can be coupled to the other fiber.
[0028] Any number of optical fibers can be coupled together using the FBT technique. In addition, the various optical fibers that are coupled can be similar or dissimilar to one another. For example, one or more of the fibers can have different intrinsic propagation constants. In other cases, one or more of the fibers can also be pre-tapered or not pre-tapered. In other cases, the various fibers include a mix of different propagation constants and pre-tapering. Generally, the disclosed method of fabricating an optical device can be used regardless of the number and/or characteristics of any of the fibers involved.
[0029] It has long been known that the wavelength dependence of a single-mode coupler could be modified by fabricating the coupler with fibers having different propagation constants. A mismatch in the propagation constants of the two fibers that comprise the coupler can be simply introduced by preselecting two fibers having different propagation constants. However, since all fibers differ to some extent, successful results with one particular pair of fibers will not ensure similar results with another pair.
[0030] Because of the limitations associated with pre-selecting two fibers having different propagation constants, pre-tapering one or more of the optical fibers can be used to change the propagation constant of one or more of the fibers. In this way, wavelength flattened couplers and wavelength independent couplers can be made. Also, pre-tapering can also be used when manufacturing devices with intentionally high wavelength dependence, such as WDMs.
[0031] In one example, a method of making a single-mode evanescent-wave coupler having reduced wavelength dependence may be summarized by the following steps:
[0032] (a) providing first and second single-mode optical fibers having substantially identical propagation constants;
[0033] (b) modifying the diameter of the first optical fiber, e.g., by heating the first optical fiber along a first longitudinal segment thereof while stretching the first optical fiber to reduce the diameter of the first longitudinal segment, the reduced diameter being substantially uniform along the first longitudinal segment (referred to as “pre-tapering”);
[0034] (c) maintaining the first and second optical fibers in parallel juxtaposition with one another along a portion of the first longitudinal segment; and
[0035] (d) fusing together the portions of the first and second optical fibers maintained in parallel juxtaposition to form a coupling region.
[0036] A detailed description of the foregoing method is found in U.S. Pat. Nos. 4,798,438 and 4,632,513. These patents are incorporated herein by reference in their entirety.
[0037] A single-mode, evanescent-wave coupler is fabricated using two single-mode fibers. Each fiber has a core and cladding region. In many instances, the cladding region comprises two concentric cladding layers having different indices of refraction. The inner cladding layer has an index of refraction lower than that of the core of the fiber. The outer cladding layer, sometimes called the substrate, has an index of refraction greater than the inner cladding layer but not necessarily equal to the index of refraction of the core. This type of fiber is commonly called “depressed cladding” fiber by those skilled in the art. It should be noted that other types of fibers do not have an outer cladding layer or substrate having a relatively high index of refraction. These fibers are referred to as “matched cladding” fibers. Again, this is just one example of a coupler than can be made.
[0038] Referring now to the drawings where the illustrations are for the purpose of disclosing the preferred embodiment of the invention only, and not for the purpose of limiting same, an exemplary method for fabricating an optical device in accordance with the present invention will now be described.
[0039] [0039]FIG. 1 is a schematic diagram of a side view of an optical fiber. Optical fiber 100 includes a section 102 . In some cases, this section is about three to four centimeters, but section 102 can be longer or shorter. Optical fiber 100 preferably includes a protective buffer layer 108 and in section 102 , this protective layer 108 is preferably removed. Many different well known methods can be used to remove protective layer 108 , including mechanical or chemical techniques. The exposed section 102 of fiber 100 is then preferably chemically cleaned and rinsed. A resultant fiber 100 is shown in FIG. 1 having a buffered region 104 and exposed region 106 . Notice that buffered region 104 includes protective layer 108 .
[0040] Generally, more than one fiber can be used to construct a fiber optic device, so the procedure for removing the protective layer of a fiber can be used on the appropriate fibers.
[0041] [0041]FIG. 2 is a schematic diagram of an apparatus 200 for pre-tapering and stretching optical fiber. Apparatus 200 includes a base 202 and a first moving stage 204 and a second moving stage 206 . Preferably, disposed between first and second stages 204 and 206 , respectively, is a heating element 208 . For purposes of description, first and second stages 204 and 206 are disposed along a longitudinal axis of base 202 . Heating element 208 is preferably capable of motion in many different directions. For example, heating element 208 can move both longitudinally, that is, towards either the first 204 or second stage 206 , and heating element 208 can also move laterally, that is, perpendicular to the longitudinal direction.
[0042] First and second stages 204 and 206 are capable of moving. In the embodiment shown in FIG. 2, first stage 204 can move towards and away from heating element 208 and also towards and away from second stage 206 . Likewise, second stage 206 can move towards and away from heating element 208 and first stage 204 . First stage includes a first grasping portion 210 and second stage 206 includes a second grasping portion 212 . First and second grasping portions are designed to hold and retain an optical fiber 214 .
[0043] Because of this arrangement, first stage 204 and second stage 206 are able to retain one or more fibers between them and their motion can be used to affect the retained fibers. In one example, where pre-tapering of one or more of the fibers is desired, the diameter of fiber 214 may be modified by mounting fiber 214 onto moveable stages 204 and 206 and heating a portion of fiber 214 with heating element 208 . A movable gas torch 208 that provides a flame is preferably used as heating element 208 .
[0044] While gas torch 208 moves with respect o fiber 214 , first stage 204 and second stag 206 are slowly moved in opposite directions, in this case, away from each other, in order to stretch fiber 214 and reduce its diameter. This heating process is also referred to as a “flame brush process.” Any time a torch flame is applied to fiber, deuterium can be used as the fuel for the flame. This includes the pre-taper process discussed above. It is possible to use regular hydrogen for the fuel in the pre-taper operation and then use deuterium for other stages of the manufacturing process. However, it is preferred that deuterium is used as the torch fuel for all of the manufacturing process steps.
[0045] A typical profile of fiber 214 after being stretched and heated in this manner is shown in FIG. 3. Fiber 214 includes a heated section 302 that has a substantially constant yet reduced diameter 304 over a substantial length. Fiber 214 also includes a first un-stretched portion 308 and a second un-stretched portion 310 . Heated section 302 gradually tapers up to the original fiber diameter 306 of un-stretched portions 308 and 310 . The final diameter of fiber 214 in the heated region 302 is controlled by the amount fiber 214 is stretched. In some cases, a uniform relative motion between fiber 214 and the flame 208 (see FIG. 2) is used to obtain a constant fiber diameter along the heated section 302 of fiber 214 . In this way, a pre-tapered fiber 214 that has been treated with deuterium is made.
[0046] In an alternative method to the stretching process described above, the diameter of a fiber cladding and core may be modified in accordance with an etching process. Although a variety of known etching techniques may be used, one suitable etching technique is a heated etching technique. In this technique, a fiber is placed in close proximity to an etching station which is heated by a thermoelectric module. An amount of etchant, usually a drop or so, is placed on top of the etching station to etch a longitudinal portion of the fiber. After the fiber has been etched to the desired diameter, the fiber is rinsed with water to prevent further etching.
[0047] [0047]FIG. 4 shows another embodiment of the present invention where multiple fibers are coupled. Although, for clarity, only two fibers are shown in the example shown in FIG. 4, any number of fibers can be coupled using this process. Embodiments with more than 2 fibers are certainly envisioned. The principles of the invention can be applied to situations where any time N number of fibers are drawn while a torch flame is applied. For example, U.S. Pat. No. 5,355,426, assigned to the same assignee as the present invention and which is herein incorporated by reference in its entirety, teaches an MxN coupler. The present invention can be used to make those MxN couplers disclosed in U.S. Pat. No. 5,355,426, as well as any other coupler having any number of coupled fibers.
[0048] Returning to FIG. 4, a first fiber 402 and a second fiber 404 are positioned proximate one another and retained by grasping members 410 and 412 . Grasping members 410 and 412 can be any device that is capable of securely retaining and holding optical devices. Preferably, grasping members 410 and 412 are mounted to movable stages as shown in FIG. 2. In the embodiment shown in FIG. 4, first and second fibers 402 and 404 are initially wound together to form a coupling region 406 .
[0049] With reference to FIG. 4, fibers 402 and 404 are preferably maintained proximate to one another as coupling region 406 is heated and formed. In an exemplary embodiment, fibers 402 and 404 are maintained in parallel juxtaposition. Coupling region is fused in order to form a coupler. In this regard, fusion occurs by heating coupling region 406 while grasping members 410 and 412 stretch fibers 402 and 404 . It should be appreciated that fibers 402 and 402 may be twisted together along portions of their length prior to heating and stretching.
[0050] In accordance with an embodiment of the present invention, the heating source is preferably a gas torch heat source 414 , as described above. However, in accordance with the present invention, heat source 414 uses deuterium (D 2 ) gas as a fuel supply 416 to produce a flame 418 , as will be explained further below. Heat source 416 can be moved about coupling region 406 while fibers 402 and 404 are in axial tension. Heat source 416 can be applied until fibers 402 and 404 are fused together throughout the desired length of coupling region 406 . Accordingly, a deuterium treated optic coupler is produced.
[0051] It should be understood that the coupler fabrication method described above is exemplary, and that alternative methods of fabricating couplers using a heat source are well known to those skilled in the art. The present invention is suitable for use in connection with these alternative fabrication methods, wherein the heat source is suitably modified to provide a flame produced by the combustion of deuterium gas.
[0052] Furthermore, it should be understood that the fibers being heated and fused to form a coupler may include identical fibers, for example, having the same propagation constants, or the fibers can be mismatched fibers, for example, having different propagation constants. Again, this heating method, that uses deuterium as its fuel supply, can be used regardless of the number, characteristics, and/or the similarities or differences among the various fibers that are coupled.
[0053] In accordance with the present invention, the conventional gas, usually hydrogen gas (H 2 ), that is used as a fuel supply in gas torch heat source to generate a flame, is replaced with deuterium (D 2 ) gas. A flame is produced by the combustion of deuterium gas, rather than the conventional gas, usually hydrogen gas. Deuterium, being a nuclear isotope of hydrogen, is for all practical purposes chemically similar to hydrogen. However, deuterium is heavier than hydrogen, and various modifications can be made to the manufacturing process to accommodate the slight weight difference between hydrogen and deuterium. For example, the gas flow rate for the deuterium gas can be modified from the gas flow rate used for hydrogen gas to optimize combustion, and achieve a suitable pull signature. In some embodiments, a mixture of deuterium and another gas is used.
[0054] In one embodiment, a deuterium flame is applied at room pressure (˜1 atm) and room temp. (˜20 C). Flow rate of deuterium gas is around 215 sccm for a standard wavelength flattened 50% coupler, but will vary from device to device. Oxygen, as well as other elements, may also be added as a torch fuel as the recipe requires.
[0055] Generally, most typical devices are made by supplying hydrogen only to the torch. As indicated in other portions of this disclosure, a typical flow rate would be 215 sccm deuterium. Since no oxygen is supplied to the torch as a fuel, this can be referred to as a 100% deuterium mixture, but of course ambient oxygen is consumed in the combustion and ambient oxygen participates in the combustion process.
[0056] In other embodiments, oxygen is supplied to the torch. This can be a way of controlling flame temperature and size. Oxygen can also be supplied to control the completeness of the combustion. And, oxygen can be supplied to control the rate of combustion as well.
[0057] The following is one embodiment where oxygen is added to the deuterium fuel. A certain kind of microcoupler is typically pulled with 85 sccm hydrogen and 30 sccm oxygen.
[0058] Another embodiment where oxygen is added to the deuterium is a kind of coupler that employs an 80 micron payout fiber. (A reduced cladding fiber, RC 1300). The recipe for this involves an elaborated series of steps in which the hydrogen/oxygen mixture is varied greatly.
[0059] In an initial “prefuse” step, the D 2 /O 2 mixture is set to 70 sccm/250 sccm (22% D 2 by volume). After the torch has been placed under the fibers, the flow are settings are changed to 124 sccm D 2 /250 sccm O 2 (33% D 2 by volume, with higher total flow rate).
[0060] After this initial “prefuse”, the coupler is pulled with 90 sccm deuterium, with no oxygen.
[0061] These examples illustrate the wide range of possible D 2 /O 2 mixtures. Not only do the percentages vary widely, but also the total flow rates. Also, oxygen can be added to only certain steps in the manufacturing process and omitted in other steps.
[0062] Furthermore, in any process where hydrogen is conventionally used, deuterium can be substituted to make a passivated version of the device. And, in addition, other elements or compounds can also be added if desired. Also, oxygen can be replaced with other chemicals if desired.
[0063] In accordance with the present invention, control parameters for stretching a fiber during coupler fabrication may be modified from standard settings wherein a hydrogen gas fuel supply is used. For instance, in the case of fabrication of 50% wavelength-flattened optic couplers, the primary modification of the control parameters is the pre-taper settings.
[0064] In this regard, optic couplers produced using a deuterium gas fueled heat source (referred to herein as “deuterium couplers”) require that the pre-tapered fiber have a significantly greater degree of pre-taper than couplers fabricated using a hydrogen gas fueled heat source. It is believed that the “deuterium heating” method may effect the refractive index of the fibers differently than the standard “hydrogen heating” method.
[0065] As shown below, preliminary observations indicate that using deuterium (D 2 ) gas as a fuel supply for the heat source effectively doubles the median “time to failure” (TTF) of devices in 85° C./85% relative humidity (RH) environmental testing.
[0066] The present invention will now be further described by way of the following examples:
EXAMPLE 1
DEUTERIUM PASSIVATION DAMP HEAT AGING EXPERIMENT
[0067] Twenty-five (25) 50% wavelength flattened optic couplers (WFC) were manufactured using a deuterium gas fueled heating source, with the goal of attaining passivation (i.e., to treat in order to reduce the chemical reactivity of its surface) of the couplers to damp heat aging. These deuterium couplers, along with eleven (11) 50% WFCs produced using the standard “hydrogen heating” method, were aged at 85° C. and 85% relative humidity (RH) for approximately 2000 hours and 1265 hours, respectively. The eleven standard couplers act as a control group.
Optic Fiber Parameters for 50 % WFC Deuterium Coupler:
[0068] D 2 flow rate: 215 sccm
[0069] O 2 flow rate: 0 sccm
[0070] Stage separation: 40 mm
[0071] Pre-taper torch velocity: 22 mm/min
[0072] Pre-taper flame brush width: 11 mm
[0073] Pre-taper right stage velocity: 2.75
[0074] Pull torch velocity: 36 mm/min
[0075] Pull flame brush width: 6.5 mm
[0076] Pull left stage velocity: 2.5 mm/min
[0077] Pull right stage velocity: 2.5 mm/min
[0078] Pull after stop jump:3.5%
[0079] Torch height: 10.5 mm
[0080] Pull distance: 7.16 mm (average)
[0081] Pretaper fiber diameter: 117.85 microns
Optic Fiber Parameters for 50% WFC Standard Coupler:
[0082] D 2 flow rate: 215 sccm
[0083] O 2 flow rate: 0 sccm
[0084] Stage separation: 40 mm
[0085] Pre-taper torch velocity: 22 mm/min
[0086] Pre-taper flame brush width: 11 mm
[0087] Pre-taper right stage velocity: 1.65 mm/min
[0088] Pull torch velocity: 36 mm/min
[0089] Pull flame brush width: 6.5 mm
[0090] Pull left stage velocity: 2.5 mm/min
[0091] Pull right stage velocity: 2.5 mm/min
[0092] Pull after stop jump:3.5%
[0093] Torch height: 10 mm
[0094] Pull distance: 7.75 mm (average)
[0095] Pretaper fiber diameter: 120.56 microns
[0096] Procedure: Coupling ratio (CR) data were processed to correct for artifacts of the measurement system, specifically the appearance of piecewise discontinuities. Times to failure (TTF) were extrapolated from a linear least squares fit to data in cases where the device did not exhibit failure within the duration of the test. Failure criterion is a change in CR of 0.2 dB.
[0097] Results: FIG. 8, includes a table that includes a ranking of TTF (median time to failure) for optic couplers fabricated using deuterium (D 2 ) gas as a heat source fuel supply (“deuterium couplers”), and for optic couplers fabricated using conventional hydrogen gas as a heat source fuel supply (“standard couplers”)
[0098] It is observed that the median time to failure (TTF) for the deuterium couplers is approximately 3,300 hours. In contrast, the median time to failure for the standard couplers is approximately 1000 hours. The fraction of deuterium couplers with TTF>2000 hrs is 18/25, while the fraction of standard couplers with TTF>2000 hrs is 2/11. Failure criterion is a change in splitting loss of 0.2 dB or greater.
[0099] [0099]FIG. 5 is a graph showing the average splitting loss change in decibels (dB) versus time, in hours, in a high temperature, high humidity environment, for a number of control couplers 502 and a number of couplers treated with deuterium in accordance with the present invention. The deuterium treated couplers are significantly more tolerant of adverse environmental conditions. The deuterium treated devices were able perform with a splitting loss change of less than 0.20 dB for more than three times the duration of a conventional optical device. This is also shown in FIG. 6, which shows a bar graph comparing the mean time to failure for a control group 602 and a deuterium treated group 604 .
[0100] [0100]FIG. 7 is a chart showing probability distributions of rates of change of splitting loss at 85C/85%RH for both control 702 and deuterium 704 passivated couplers. These distributions illustrate the advantage of the deuterium passivated couplers over the control devices. As clearly demonstrated in FIG. 7, the rates of splitting loss change for the former is reduced by a factor of approximately 3.3 with respect to the latter. This both increases the median time to failure (MTF) by a factor of approximately 3.3 and also results in a narrower distribution in aging rates.
[0101] It should be understood that the present invention can be used regardless of the other particular details for manufacturing optic devices (e.g., pulling methods, clamping methods, fiber arrangement, etc.) In this regard, the present invention is suitably used in connection with a wide variety of coupler manufacturing methods and packaging strategies. Moreover, the present invention may be applied in combination with other techniques for improving reliability and performance of optic devices.
[0102] Other modifications and alterations will occur to others upon their reading and understanding of the specification. In this regard, it should be appreciated that the fabrication method of the present invention may be suitably used with any heating technique that applies a flame to an optic device during fabrication thereof. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.
[0103] The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
[0104] Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.
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A method for producing fiber optic devices having improved intrinsic resistance to external environmental conditions and a fiber optic device made my the method are disclosed. The fabrication method produces an optic device that is treated with deuterium. The method includes a step for treating and/or making optical devices in the presence of a flame produced by the combustion of deuterium gas or a mixture including deuterium.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a functional polyurethane prepolymer, a method of preparing polyurethane by using the functional polyurethane prepolymer, and an application method thereof, in particular to a functional polyurethane prepolymer prepared by a non-isocyanate route, a method of preparing polyurethane by a using the functional polyurethane prepolymer, and an application method thereof.
2. Description of Related Art
Polyurethane (PU) is a common polymer material widely used as a sports cushion material, an elastomer material, an adhesive material, a waterproof material or a coating material.
In a conventional PU preparation process, the PU is synthesized by using isocyanates (such as diisocyanates and polyisocyanates) and polyols (such as diols or polydhydroxy polyols with high functionality) as major raw materials, but the manufacturing process of this sort usually requires phosgene which is a severely toxic pollutant. If the phosgene is leaked accidentally during the manufacturing process, the phosgene will pose an immediate threat to our environment and jeopardize our health such as causing pulmonary edema, and the manufacturing process itself will lead to a certain degree of risk. Therefore, scientists attempt to use non-isocyanates routes (which use absolutely no isocyanates at all) to manufacture polyurethane (PU).
In 1993, Takeshi Endo proposed a PU manufacturing method without using any diisocyanates, wherein five-membered cyclic carbonates (Bis(cyclic carbonate)s) and primary amines are reacted at room temperature to produce a high yield of β-position hydroxyl PU (2-Hydroxyethylurethane), and the reaction is represented by the following chemical equation:
Typically, the starting material (cyclic carbonate) of hydroxyl PU is prepared by a nucleophilic ring opening reaction of oxirane and carbon dioxide. As indicated in past literatures, cyclic carbonate is mainly prepared by a reaction of oxirane, carbon dioxide, and a catalyst at high pressure, and the common catalysts include amine, phosphine, quaternary ammonium salt, antimony compound, porpyrin and transition metal complex, and the manufacturing conditions and process involve a high level of difficulty. Until recent years, the ring opening reaction of oxirane and carbon dioxide taken place at normal pressure (1 atmosphere) was developed.
Professor Takeshi Endo, et al. further published a preparation of hydroxyl PU by using di-functional amines and di-functional cyclic carbonates, and subsequent research reports related to the ring opening reaction of cyclic carbonates provided the related reaction conditions, and specifically pointed out that the ring opening reaction has a high chemoselectivity, and will not be affected by existing water, alcohols, or esters, so that the cyclic carbonate can be reacted with a compound containing a primary amine under appropriate reaction conditions for a ring-opening polymerization, and the reaction is represented by the following chemical equations:
However, the aforementioned method is developed for the PU prepolymer with an amino functional group at an end and having a maximum average molecular weight falling within the range from 5000 g/mole to 8000 g/mole. The ring opening reaction process of the aforementioned method requires a time (20 hours or more), and this product cannot be applied for a coating application directly and effectively.
SUMMARY OF THE INVENTION
The present invention provides a method of preparing a polyurethane (PU) prepolymer, and the method does not use any conventional isocyanate as a raw material, and the manufacturing process does not require the use of phosgene. Epoxy resin and carbon dioxide are used as major raw materials for the preparation of the macromolecular polyurethane prepolymer.
The preparation method of the present invention comprises the following steps:
(1) Material mixing: An epoxy resin and a catalyst are mixed uniformly until the epoxy resin is dissolved completely to form a mixed raw material; and
(2) Thermal reflux: Carbon dioxide gas is introduced into the mixed raw material, and a thermal reflux is performed at a high temperature for a predetermined time to form a bis-(cyclic carbonate) containing compound (BCC).
The aforementioned reaction is represented by the following chemical equations:
(3) Ring-opening polymerization: After a bis-(cyclic carbonate) containing compound (BCC) and a di-amine, compound are mixed uniformly, and the ring-opening polymerization is represented by the following chemical equations:
(4) The amino-terminated PU prepolymer (obtained from the above reaction) is mixed and reacted with a di-acrylate compound (AHM) via a Michael to obtain an UV curable polyurethane, and the Michael addition is represented by the following chemical equations:
The present invention further provides a method of preparing polyurethane comprising the following steps:
(1) Material mixing: An epoxy resin and a first catalyst are mixed uniformly until the epoxy resin is dissolved completely to form a mixed raw material; (2) Thermal reflux: Carbon dioxide gas is introduced into the mixed raw material, and a thermal reflux is performed at a high temperature for a predetermined time to form a bis-cyclic carbonate-containing oligomer; (3) Microwave reaction: The bis-cyclic carbonate-containing oligomer is mixed with a second catalyst uniformly, and then a ring-opening polymerization with one or more di-amine compound is performed to form a PU prepolymer containing an amino group at an end; and (4) Michael reaction: The aforementioned PU prepolymer with mixed with a third catalyst uniformly, and then a compound with an acrylic functional group is added to perform a Michael reaction at a low temperature to form an UV curable polyurethane.
The present invention further provides an application method of polyurethane, wherein the polyurethane is produced by using an epoxy resin, carbon dioxide and a polyamine compound as major raw materials, and the application method comprises the following steps:
(1) Dipping: An UV curable PU (UV-PU) material and a photoinitiator are mixed uniformly to form a PU raw material solution, and a fabric is placed into the PU raw material solution for pressure suction. Make sure the fabric absorbs a sufficient amount of the PU raw material. (2) Photoreaction: The treated fabric is placed into a medium pressure mercury lamp UV irradiation is provided for fixing the PU raw material solution onto a surface of the fabric.
The method of the present invention does not require the conventional use of isocyanates and polyols as raw materials for preparing PU, and epoxy resin and carbon dioxide, and then di-amine oligomer are used as starting raw materials and polyamines are added to prepare the PU prepolymer, and the PU prepolymer produced by this method can be further used for synthesizing an UV curable PU (UV-PU) in a simple and convenient manner, and the UV-PU can be further coated onto a fabric surface, and the fabrics with UV-cured PU surface treatment is adopted to form a washing resisting and long-lasting hydrophilic or hydrophobic PU treated fabrics.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, as well as its many advantages, may be further understood by the following detailed description and drawings in which:
FIG. 1A shows a Fourier infrared spectrum of polypropylene glycol diglycidyl ether (PPG-DGE) used in a first preferred embodiment of the present invention;
FIG. 1B shows a Fourier infrared spectrum of PPG-type cyclic carbonates formed in the first preferred embodiment of the present invention;
FIG. 2 shows a Fourier infrared spectrum of polyurethane (PU) formed in the first preferred embodiment of the present invention;
FIG. 3 is a SEM photo of the produced UV curable polyurethane coated onto surfaces of fabric fibers and washed by water for 30 times in accordance with the first preferred embodiment of the present invention;
FIG. 4A shows a Fourier infrared spectrum of bisphenol A epoxy resin used in a second preferred embodiment of the present invention;
FIG. 4B shows a Fourier infrared spectrum of bis(cyclic carbonates) (BCC) formed in the second preferred embodiment of the present invention;
FIG. 5 shows a 1 H NMR spectrum of bisphenol A epoxy resin used in the second preferred embodiment of the present invention;
FIG. 6A shows a 1 H NMR spectrum of bis(cyclic carbonates) (BCC) formed in the second preferred embodiment of the present invention;
FIG. 6B shows a 13 C NMR spectrum of bis(cyclic carbonates) (BCC) formed in the second preferred embodiment of the present invention; spectrum;
FIG. 7 is a Fourier infrared spectrum of polyurethane (PU) formed in the second preferred embodiment of the present invention; and
FIG. 8 shows a SEM photo of the produced UV cross-linking polyurethane coated onto surfaces of fabric fibers, processed by a UV light bridge, and washed by water for 30 times in accordance with the second preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the first preferred embodiment, the polyurethane (PU) prepolymer is prepared by an epoxy resin which is polypropylene glycol diglycidyl ether (PPG-DGE), and the aforementioned polyurethane prepolymer is used for manufacturing polyurethane (PU) and UV curable polyurethane (UV-PU), and the UV curable polyurethane (UV-PU) is further applied as a water-resisting material.
(1) Method of Preparing Polyurethane Prepolymer:
In this preferred embodiment, the polyurethane prepolymer is bis(cyclic carbonate) which is a PPG-type cyclic carbonate, the epoxy resin is polypropylene glycol diglycidyl ether (PPG-DGE), and the catalyst is lithium bromide (LiBr), and the method of preparing a PU prepolymer comprises the following steps:
(S 11 ) Material mixing: PPG-DGE (5 moles) and lithium bromide (5 mole percents) are mixed uniformly until the PPG-DGE is dissolved completely to form a mixed raw material; and
(S 12 ) Thermal reflux: Carbon dioxide gas is introduced into the mixed raw material, and a thermal reflux is performed at the pressure of one atmosphere and a temperature of 100° C. for 24 hours to form a bis(cyclic carbonate) product.
In this preferred embodiment, a large quantity of deionized water and ethyl acetate are used for rinsing the bis(cyclic carbonates) product to remove remained catalysts and achieve the purification effect, so as to obtain a highly pure transparent colorless bis(cyclic carbonate) liquid.
With reference to FIGS. 1A and 1B , a Fourier-transformed infrared spectroscopy is used for detecting and tracing the elimination state of the epoxy functional group (910 cm −1 ) and the formation state of the cyclic carbonate functional group (1800 cm −1 ). The Fourier infrared spectra show that the epoxy functional group is fully converted into the cyclic carbonate functional group.
(2) Method of Preparing PU Prepolymer Containing an Amino Group at an End:
The bis(cyclic carbonates) product produced by the aforementioned method can be used for manufacturing a PU prepolymer containing an amino group at an end, and the method comprises the following steps:
(S 21 ) Microwave treatment: The aforementioned bis(cyclic carbonate) product (0.1 mole), lithium bromide (5 mole percents) and Jeffamine compound (a di-amine D-2000, 0.15 mole) are mixed uniformly, and then a microwave reactor with the power of 100 W is provided for performing a ring-opening polymerization for half an hour to form a PU prepolymer containing an amino group at an end.
With reference to FIG. 2 for a Fourier-transformed infrared spectrum of PU obtained in accordance with the preparation method of the present invention, a formation of an amino ester functional group is observed at the wavelength of 1720 cm −1 , indicating that the cyclic carbonate functional group (1800 cm −1 ) of the cyclic carbonate functional group in this step will disappear with the reaction time, and will be converted into an amino ester functional group (1720 cm −1 ).
In the microwave treatment step (S 21 ), the Jeffamine compound is a polyamine compound well known to those ordinarily skilled in the art, and the compound used in this preferred embodiment is one selected from the group of hydrophilic aliphatic diamines (such as 1,4-butanediol bis-3-aminopropyl ether), ethylene diamines, aliphatic diamines (such as 1,12-diaminododecane), aromatic diamines (such as m-xylyene diamine) or a hydrophobic diamine compounds, such as polydimethylsiloxane (PDMS) diamine.
In addition, the microwave treatment step (S 21 ) further selectively adds a solvent for a dilution to reduce the viscosity of the reactants, wherein the solvent can be ethyl lactate (EL), and the quantity of EL in this preferred embodiment is equal to 10 mL, and the Fourier infrared spectrum of the PU containing an amino group at an end after the reaction takes place is the same as that of the one added with a catalyst.
Further, microwave intensity used in the microwave treatment step (S 21 ) can be adjusted to a range from 15 W to 150 W, and the microwave treatment time can be adjusted to a range from 0.5 hour to 2 hours.
(3) UV Curable Polyurethane (UV-PU):
The PU prepolymer formed in accordance with the aforementioned method can be further used for manufacturing an UV-PU, and the method comprises the following steps:
(S 31 ) Michael reaction: The aforementioned PU prepolymer and a catalyst (triethyl amine, TEA) (5 mole percents) are mixed uniformly, and then 20 mL of ethyl acetate is added, and the mixed materials are dropped slowly into 0.2 mole of a compound containing diacrylate at 0° C. (or in an ice bath), and the Michael reaction is performed in the ice both for 24 hours to remove the catalyst TEA and ethyl acetate to produce an UV-PU material.
In the Michael reaction step (S 31 ), the ethyl acetate solvent may not be added for the reaction.
(4) Application of UV-PU:
The UV-PU material obtained in accordance with the method of the present invention can be used for forming a mesh bonding on a fabric surface and can be embedded into the surface of fiber bundles easily, so that the hydrophilic polymer in the fabric will not be changed or lost easily by rinsing, and the original hydrophilic property of the hydrophilic resin can be maintained, so as to obtain the long-lasting rinsing-resisting super-absorbent fabric, and the application method comprises the following steps:
Dipping: The aforementioned UV-PU material is diluted by ethyl acetate (EA) to the concentration of 1˜10 wt %, and 5 phr of photoinitiator benzoin alkyl ether (1173) is added to form a UV-PU solution, and different fabrics (PET) are placed into the aforementioned UV-PU solution for pressure suction. After the fabric sufficiently absorbs the solution, and a fabric is placed into the PU raw material solution for pressure suction and make sure the fabric absorbs a sufficient amount of PU raw material.
Photoreaction: The aforementioned fabric is placed into a medium pressure mercury lamp UV irradiation for fixing the PU raw material solution onto the treated fabric to form a double-bond methyl acrylic functional group in of the UV-PU material, and a radical cross-linking reaction is performed to produce a mesh bonding, and the UV-PU material can be embedded into a surface of the fiber bundles easily, so that the hydrophilic polymer in the fabric will not be damaged or lost easily by rinsing, and the original hydrophilic property of the hydrophilic resin can be maintained, so as to obtain the long-lasting washing-resisting super-absorbent fabric.
With reference to FIG. 3 for a SEM photo of the produced UV-PU solution coated onto surfaces of fabric fibers and washed by water for 30 times in accordance with the first preferred embodiment of the present invention, the photo shows that the high-density mesh bonding formed by the UV-PU material on the fabric surface is not damaged or lost by rinsing, and the original hydrophilic property of the hydrophilic resin is maintained.
In this preferred embodiment, the photoinitiator is a photosensitizing agent such as benzophenone (BP) or a reactive diluent with acrylic double bonds is added into the UV-PU solution to increase the concentration of the acrylic double bonds, so as to enhance the crosslink density of the UV-PU material.
In the second preferred embodiment, bisphenol A epoxy resin such as diglycidyl ether bisphenol A (DGEBA) is used as the epoxy resin for preparing the polyurethane prepolymer, and the aforementioned polyurethane prepolymer is used for manufacturing polyurethane (PU) and UV cross-linking polyurethane (UV-PU), and the UV cross-linking polyurethane (UV-PU) is further applied as a water-resisting coating material.
(1) Method of Preparing Polyurethane Prepolymer:
In this preferred embodiment, the bis(cyclic carbonates) (BCC) so formed is a polyurethane prepolymer, the epoxy resin is di-glycidyl ether of bisphenol A (DGEBA), and the catalyst is lithium bromide (LiBr). The method of preparing a polyurethane prepolymer comprises the following steps:
(S 11 ) Material mixing: DGEBA (5 moles) and lithium bromide (5 mole percents) are mixed uniformly until the DGEBA is dissolved completely to form a mixed raw material; and
(S 12 ) Thermal reflux: Carbon dioxide gas is introduced into the mixed raw material, and a thermal reflux is performed at a pressure of one atmosphere and a temperature of 100° C. for 24 hours to form a BCC product (or oligomer).
The BCC product obtained in accordance with this preferred embodiment can be rinsed by a large quantity of deionized water to remove remained catalyst and solvent to achieve the purification effect, and then baked and dried to a fine pure white BCC powder.
With reference to FIGS. 4A , 4 B, 5 , 6 A and 6 B for Fourier infrared spectra that detect the elimination state of the epoxy functional group (910 cm −1 ) and the formation state of the cyclic carbonate functional group (1800 cm −1 ), the Fourier infrared spectra show that the epoxy functional group is sufficiently converted into the cyclic carbonate functional group. In addition, a nuclear magnetic resonance (NMR) is used for performing a structure analysis to confirm the molecular structure of the BCC product produced in according to the procedure of this preferred embodiment.
(2) Method of Preparing a PU Prepolymer Containing an Amino Group at an End:
The BBC product produced in accordance with the aforementioned method can be used for preparing a PU prepolymer, and the preparation method comprises the following steps:
(S 21 ) Microwave treatment: The aforementioned BBC product (0.1 mole), lithium bromide (5 mole percents) and aliphatic amine which is Jeffamine D-2000 (0.15 mole) are mixed uniformly, and a microwave reactor with the power of 100 W is provided for performing a ring-opening polymerization for half an hour to form a PU prepolymer containing an amino group at an end.
With reference to FIG. 7 for a Fourier-transformed infrared spectrum of PU obtained by this method, a formation of an amino ester functional group is observed at the wavelength of 1720 cm −1 . In this step, the cyclic carbonate functional group (1800 cm −1 ) in the cyclic carbonate functional group disappears with the reaction time and is converted into an amino ester functional group (1720 cm −1 ). The PU prepolymer formed by this method has a molecular weight of 20000 g/mole or above, which can be used more easily in the following applications.
In the microwave treatment step (S 21 ), a solvent can be added to dilute the solution and reduce the viscosity of the reactants, wherein the solvent is ethyl lactate (EL) or ethyl acetate (EA), and the quantity of the solvent used in this preferred embodiment is equal to 10 mL, and the Fourier infrared spectrum of the produced PU prepolymer containing an amino group at an end shows the same result with the one added with a catalyst.
(3) Method of Preparing UV Curable Polyurethane (UV-PU):
The PU prepolymer produced according to the aforementioned method can be used for preparing the UV-PU, and the preparation method comprises the following steps:
(S 31 ) Michael reaction: The aforementioned PU prepolymer and a catalyst (triethyl amine, TEA) (5 mole percents) are mixed uniformly, and then 20 mL of ethyl acetate is added, and 0.2 mole of a compound containing diacrylate is dropped into the solution slowly at 0° C. (or in an ice bath), and then the Michael reaction is performed in the ice bath for 24 hours to remove the catalyst TEA and ethyl acetate to produce an UV-PU material.
In the Michael reaction step (S 31 ), the solvent ethyl acetate solvent may not be used in the reaction.
In this preferred embodiment, the compound containing diacrylate is 3-Acryloyloxy-2-hydroxypropyl methacrylate.
(4) Application of UV-PU:
The UV-PU material obtained according to the method of the present invention method can be used to form a mesh bonding on a fabric surface and can be embedded into a surface of fiber bundles successfully, so that the hydrophilic polymer in the fabric will not be changed or lost easily by rinsing, and the original hydrophilic property of the hydrophilic resin can be maintained, the long-lasting washing-resisting super-absorbent fabric. The application method comprises the following steps:
Dipping: The aforementioned UV-PU material is diluted by ethyl acetate (EA) to a concentration of 1˜10 wt %, and then 5 phr of photoinitiator such as benzoin alkyl ether, (1173) is assed to form a UV-PU solution, and various different fabrics (PET, cotton) are placed into the UV-PU solution for pressure suction and make sure that the fabric absorbs a sufficient amount of PU raw material.
Photoreaction: The aforementioned fabric is placed into a medium pressure mercury lamp UV irradiation for fixing the PU raw material solution onto the treated fabric to form a double-bond methyl acrylic functional group in of the UV-PU material, is used for performing a radical cross-linking reaction of the double-bond methyl acrylic functional group in the UV-PU material to produce a mesh bonding, and the UV-PU material can be embedded into the surface of fiber bundles successfully, so that the hydrophilic polymer in the fabric will not be damaged or lost easily by rinsing, and the original hydrophilic property of the hydrophilic resin can be maintained, so as to obtain the long-acting washing-resisting super-absorbent fabric.
With reference to FIG. 8 for a SEM photo of the produced UV cross-linking polyurethane coated onto surfaces of fabric fibers and washed by water for 30 times in accordance with the second preferred embodiment of the present invention, the SEM photo shows that the high-density mesh bonding of the UV-PU material formed on the fabric surface is not damaged or lost by rinsing, and the original hydrophilic property of the hydrophilic resin is maintained.
In this preferred embodiment, the photoinitiator is a photosensitizing agent such as benzophenone (BP) or a reactive diluent with acrylic double bonds is added into the UV-PU solution to improve the crosslink density of the UV-PU material.
In this preferred embodiment, the epoxy resin is bisphenol A epoxy resin or di-glycidyl ether of bisphenol A (DGEBA). However, the invention is not limited to these substances only, but any equivalent epoxy resin such as Epoxy-128, Epoxy-506, Epoxy-904, aliphatic epoxy resin, PPG-DGE, PEG-DGE and any combination of the above can be used in the present invention as well.
In summation of the description above, the present invention provides a novel process for manufacturing the polyurethane prepolymer and the UV curable polyurethane without using isocyanates and polyols as raw materials, so as to avoid the use of harmful substance such as phosgene and reduce the risk of harming our environment. In addition, the method of the present invention is simple and convenient and requires no specific ambient conditions. Compared with the conventional preparation methods, the present invention has the advantages of protecting the environmental and achieving the energy-saving and carbon reduction effects.
Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, to promote the progress in science and the useful arts, the invention is disclosed and is intended to be limited only by the scope of the appended claims.
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A method of preparing polyurethane prepolymer does not require using a toxic isocyanate monomer (manufactured by harmful phosgene) as a raw material. Epoxy resin and carbon dioxide are used as major raw materials to form cyclic carbonates to be reacted with a functional group oligomer, and then amino groups in a hydrophilic (ether group) or hydrophobic (siloxane group) diamine polymer are used for performing a ring-opening polymerization, and the microwave irradiation is used in the ring-opening polymerization to efficiently synthesize the amino-terminated PU prepolymer, and then an acrylic group at an end is added to manufacture an UV cross-linking PU (UV-PU) oligomer which can be coated onto a fabric surface, and the fabric is dried by UV radiation for a surface treatment to form a washing-resisted long lasting hydrophilic or hydrophobic PU fabric.
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TECHNICAL FIELD
The present invention relates to a bulb-type lighting source that uses a light-emitting element such as an LED, and in particular to a technology for more effective heat dispersal from the light-emitting element.
Background Art
In recent years, research and development of technologies that employ light-emitting elements such as LEDs in lamps has progressed in the lighting field (see Patent Literature 1), and so bulb-type lighting sources that are alternatives to incandescent light bulbs have come under consideration (see Patent Literature 2 and 3). A bulb-type lighting source is sought that is restricted to external dimensions matching those of incandescent light bulbs for considerations of compatibility with lighting equipment, and also that can produce a total luminous flux suitable for use in lighting applications.
To produce a total luminous flux suitable for use in lighting applications, a rather high electrical power input must be applied to LEDs. As it happens, as electrical power input to an LED increases, so too does heat generated by the LED, thus leading to a rise in temperature. In an LED, high temperatures are accompanied by a drop in luminous efficacy. Therefore, the expected total luminous flux cannot be obtained through a simple increase in electrical power input. For this reason, standard practice is to place a large-volume heat sink member at the surface opposite the LED mounting surface of the LED mounting substrate (i.e. the bottom surface) in order to enhance the heat dispersal characteristics of the LED.
Citation List
Patent Literature
[Patent Literature 1]
Japanese Patent Application Publication No. 2005-038798
[Patent Literature 2]
Japanese Patent Application Publication No. 2003-124528
[Patent Literature 3]
Japanese Patent Application Publication No. 2004-265619
[Patent Literature 4]
Japanese Patent Application Publication No. 2005-294292
SUMMARY OF INVENTION
Technical Problem
Thus far, lamps that employ light-emitting elements such as LEDs have rarely assumed a structure with a sealed mounting substrate, and have obtained a heat dispersal effect by relying on natural cooling of the mounting substrate and of the heat sink member at the bottom surface of the mounting substrate.
However, in a bulb-shaped lighting source, a protective cover (globe) is required to cover the mounting substrate in order to allow use in ordinary domestic light fixtures. Thus, a heat dispersal effect through natural cooling cannot very well be expected. Also, as mentioned above, there is a limit on the volume of the heat sink member at the bottom surface of the mounting substrate because the external dimensions of bulb-shaped lighting sources are restricted. If a bulb-shaped lighting source is to use light-emitting elements such as LEDs in this way, the heat dispersal structure must be taken into consideration due to such various limitations.
The present invention has been achieved in view of the above problems, and an aim thereof is to provide a bulb-type lighting source that employs a light-emitting element and that has better heat dispersal characteristics than the conventional technology.
Solution to Problem
In order to solve the above problems, the present invention provides a bulb-type lighting source that receives electric power supplied via a base, comprising: a bowl-shaped case which accommodates a power supply circuit in an inner space thereof and to which the base is attached, a first heat sink member that closes a mouth of the bowl-shaped case, a mounting substrate that is in surface contact with a front surface of the first heat sink member opposite a rear surface of the first heat sink member that faces the inner space of the bowl-shaped case, a light-emitting unit that is mounted on a front surface of the mounting substrate opposite a rear surface of the mounting substrate which is in surface contact with the first heat sink member and that includes (i) a light-emitting element that emits light upon receiving electric power supplied by the power supply circuit and (ii) a wavelength conversion element that converts wavelengths of the light emitted by the light-emitting element, a globe that at least covers the light-emitting unit in light emission directions thereof, a second heat sink member that has a first part in surface contact with a region of the front surface of the mounting substrate where the light-emitting unit is not mounted and that has a second part in surface contact with the first heat sink member.
Advantageous Effects of Invention
According to research concerning heat sink structure, the inventors discovered that when a heat dispersal pathway originating at the light-emitting element mounting surface of a mounting substrate is secured, better heat dispersal characteristics can be obtained than by simply placing a large-volume heat sink at the surface opposite the light-emitting element mounting surface. The present invention, created according to this new knowledge, secures a heat dispersal pathway originating at the light-emitting element mounting surface of the mounting substrate by providing a second heat sink. According to this structure, a bulb-type lighting source with better heat dispersal characteristics than the conventional technology can be obtained.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows an exploded perspective view of the structure of the lamp pertaining to the embodiment of the present invention.
FIG. 2 shows a cross-section of the structure of the lamp pertaining to the embodiment of the present invention.
FIG. 3 shows a top view explaining the contact zone between the heat sink member and the mounting substrate.
FIG. 4 shows the heat dispersal pathways of the lamp pertaining to the embodiment of the present invention.
FIG. 5 schematically shows the experimental system for the heat dispersal characteristics.
FIGS. 6A through 6E show graphs of the temperatures measured at each position as well as the junction temperatures.
FIGS. 7A through 7D schematically show the experimental system for the heat dispersal characteristics.
FIG. 8 shows a graph of the temperatures measured for each version.
FIG. 9 shows a cross-section of the structure of the lamp pertaining to a variation of the present invention.
FIG. 10 shows a top view explaining the contact zone between the heat sink member and the mounting substrate.
FIG. 11 shows a cross-section of the structure of the lamp pertaining to a variation of the present invention.
FIGS. 12A and 12B show cross-sections of the structure of lamps pertaining to variations of the present invention.
FIGS. 13A through 13C show cross-sections of the structure of lamps pertaining to variations of the present invention.
FIG. 14 shows a cross-section of the structure of the lamp pertaining to a variation of the present invention.
FIG. 15 shows a cross-section of the structure of the lamp pertaining to a variation of the present invention.
FIG. 16 shows a cross-section of the structure of the lamp pertaining to a variation of the present invention.
FIG. 17 shows a cross-section of the structure of the lamp pertaining to a variation of the present invention.
FIG. 18 shows a cross-section of the structure of the lamp pertaining to a variation of the present invention.
DESCRIPTION OF EMBODIMENTS
A preferred embodiment of the present invention is described below with reference to the drawings.
(Structure)
FIG. 1 is an exploded perspective view showing the structure of the lamp pertaining to the present embodiment. FIG. 2 is a cross-sectional diagram showing the structure of the lamp pertaining to the present embodiment.
As shown in FIG. 1 , the lamp 1 includes a bowl-shaped case 15 to which the an Edison screw 16 is attached, a heat sink member 11 that closes the mouth of the case 15 , a mounting substrate 21 placed on the top surface (the surface opposite the surface that closes the mouth) 14 of the heat sink member 11 , a light-emitting unit 24 placed on the top surface (the surface opposite the surface that is in contact with the heat sink member 11 ) of the mounting substrate 21 , a heat sink member 31 that is placed on the top surface 14 of the heat sink member 11 , and a globe 41 that is fixed to the heat sink member 31 and covers the light-emitting unit 24 in the light emission direction thereof. Further, as shown in FIG. 2 , the inside of the case 15 accommodates in an inner space thereof a power supply circuit 18 that supplies commercial power through the Edison screw 16 to the light-emitting unit 24 . The power supply circuit 18 is made up of several electronic components mounted on a printed circuit board 17 . The printed circuit board 17 is fixed to the interior of the case 15 . The power supply circuit 18 and the light-emitting unit 24 are electrically connected through a wire 19 . The wire 19 is passed through a through-hole 13 in the heat sink member 11 and through a through-hole 33 in the heat sink member 31 . The case 15 is made of plastic, ceramic, or similar electrically insulating material. It should be noted that the bowl shape here designates any shape such that the end opposite the end from which the Edison screw 16 protrudes forms a mouth and is not particularly limited to a shape with a round mouth.
The heat sink member 11 is made of a metal such as anodized aluminum in an approximately circular truncated cone shape where the side portions form fins 12 and where the top surface 14 is flat. In addition, a through-hole 13 is provided to allow a wire to be introduced.
The mounting substrate 21 is constructed from a metal substrate 22 that is made of aluminum, copper, or other metal and an insulating layer 23 that is made of plastic, ceramic or other insulator and which is layered on the top surface (the surface opposite the surface that is in contact with the heat sink member 11 ) of the metal substrate 22 . The light-emitting unit 24 and electrode pads 27 are mounted on the insulating layer 23 . The perimeter 28 of the top surface of the mounting substrate 21 is the region in which the light-emitting unit 24 is not placed. The perimeter 28 has no insulating layer 23 and so the top surface of the metal substrate 22 is exposed.
The light-emitting unit 24 is composed of an LED 25 and a silicone resin body 26 (see FIG. 2 , enlargement A). The LED 25 is a light-emitting element that emits blue light. The silicone resin body 26 contains yellow phosphors and functions as a wavelength conversion element by converting blue light into yellow light.
The heat sink member 31 is made of a metal such as anodized aluminum and is shaped like a roughly circular flat disc where the bottom surface has a recess 34 . A portion of the recess 34 continues through to the top surface of the disc, thus forming an aperture 32 . The bottom surface of the heat sink member 31 is in surface contact with the top surface 14 of the heat sink member 11 . The recess 34 of the heat sink member 31 is shaped so that the mounting substrate 21 can be accommodated therein while the perimeter 28 of the top surface of the mounting substrate 21 remains in surface contact. Also, the aperture 32 of the heat sink member 31 is shaped so as to accommodate the light-emitting unit 24 .
The globe 41 is made of a translucent material such as plastic or glass, and is attached to the heat sink member 31 in such a manner that the light-emitting unit 24 and the mounting substrate 21 are covered from the top in order to protect the light-emitting unit 24 and the mounting substrate 21 from direct contact by a user and from scattered water or the like. It should be noted that attaching the globe 41 to the top surface of the heat sink member 31 is accomplished by joining the two with a thermally conducting joining material, or else by inserting a screw into a screw groove in the heat sink member 31 . The perimeter 35 of the heat sink member 31 is the portion that is not covered by the globe 41 and that is in contact with outside air (see FIG. 2 ).
The relationship between the heat sink member 31 and the mounting substrate 21 is explained below.
FIG. 3 is a diagram showing a top view of the contact zone between the heat sink member 31 and the mounting substrate 21 .
According to the present embodiment, the contact area between the mounting substrate 21 and the heat sink member 31 is greater than the area on which the heat source, namely the light-emitting unit 24 , is placed. The rise in temperature of the light-emitting unit 24 can be substantially inhibited by widening the contact area between the mounting substrate 21 and the heat sink member 31 in this way.
In addition, the mounting substrate 21 is a quadrilateral when seen from above. The heat sink member 31 is in surface contact with three sides of the perimeter 28 of the mounting substrate 21 . Using a metal-based mounting substrate as the mounting substrate on which to place the light-emitting unit, better heat dispersal characteristics can be obtained in comparison to using a ceramic base. However, a metal-based mounting substrate has a drawback in that, when there is a temperature difference between the top surface and the bottom surface, internal stresses caused by differential thermal expansion lead to warpage. Should warpage of the mounting substrate occur, the contact area between the bottom surface of the mounting substrate and the heat sink member will be reduced, and the heat dispersal characteristics deteriorate. According to the present embodiment, the heat sink member 31 is in surface contact with the top surface of the mounting substrate 21 and thus, temperature differences between the top surface and the bottom surface of the mounting substrate 21 are inhibited, and even if internal stresses are caused by a difference in temperature, warpage can be controlled by the downward press on the top surface of the mounting substrate 21 . Furthermore, according to the present embodiment, the heat sink member 31 is in surface contact with three sides of the perimeter 28 of the mounting substrate 21 and thus can enhance the effective control of any warpage in the mounting substrate 21 .
In addition, according to the present embodiment, the thickness T 2 of the portion of the heat sink member 31 that is in surface contact with the top surface of the mounting substrate 21 is greater than the thickness T 1 of the mounting substrate 21 (see FIG. 2 , enlargement A). Increasing the thickness T 2 of the heat sink member 31 in this way can enhance the stiffness of the heat sink member 31 which in turn can further enhance the effective control of any warpage in the mounting substrate 21 .
In addition, according to the present embodiment, the heat sink member 31 is in direct contact with the metal substrate 22 without involving the insulating layer 23 (see FIG. 2 , enlargement A). Accordingly, thermal resistance at the interface between the mounting substrate 21 and the heat sink member 31 can be reduced, and thus better heat dispersal characteristics can be achieved.
FIG. 4 is a diagram showing the heat dispersal pathways of the lamp pertaining to the present embodiment.
The mounting substrate 21 has the following heat dispersal pathways: a pathway which originates at the bottom surface and in which heat is conducted to the heat sink member 11 (reference sign 51 ) and the heat sink member 11 is naturally cooled (reference sign 52 ); a pathway which originates at the top surface and in which heat is conducted to the heat sink member 31 (reference sign 53 ) and the heat sink member 31 is naturally cooled (reference sign 54 ); and a pathway which originates at the top surface and in which heat is conducted to the heat sink member 31 (reference sign 53 ), then heat is conducted by the heat sink member 31 to the heat sink member 11 (reference sign 55 ) and the heat sink member 11 is naturally cooled (reference sign 52 ). Thus, according to the present embodiment, not only the bottom surface but also the top surface of the mounting substrate 21 are both at the origin of heat dispersal pathways.
The heat dispersal characteristics of the heat dispersal pathway originating at the top surface of the mounting substrate 21 are validated below according to experimental results.
(Validation)
The inventors first conducted an experiment concerning changes in the heat dispersal characteristics exhibited along with changes in the enveloping volume of a heat sink member placed at the bottom surface of a mounting substrate.
FIG. 5 is a diagram schematically illustrating the experimental system for the heat dispersal characteristics.
The sample LED module is prepared by placing a light-emitting unit 64 on a mounting substrate 62 . The heat sink member 61 is placed at the bottom surface of the mounting substrate 62 . An aluminum substrate is used for the mounting substrate 62 and an LED chip 1.0 mm square is used as the light-emitting element of the light-emitting unit 64 . Twelve LED chips are flip-chip mounted on the aluminum substrate.
In this experimental system, four types of heat sink member, differing by enveloping volume, were prepared (enveloping volumes: 54 cm 3 , 208 cm 3 , 1108.8 cm 3 , 2625 cm 3 ). When current was applied to the light-emitting unit 64 , the temperature was measured at each of four positions (Pos. 1 at the top surface of the sample, Pos. 2 at the top surface of the heat sink member next to the sample, Pos. 3 at the edge of the top surface of the heat sink member, Pos. 4 at the bottom surface of the heat sink member) and the LED chip junction temperature T j was also measured. The current applied to the light-emitting unit 64 was one of three types, measuring 100 mA, 150 mA, and 200 mA, respectively.
FIGS. 6A through 6E show graphs indicating the temperatures measured at each position as well as the junction temperatures, where FIG. 6A shows the temperatures at Pos. 1 at the top surface of the sample, FIG. 6B shows the temperatures at Pos. 2 at the top surface of the heat sink member next to the sample, FIG. 6C shows the temperatures at Pos. 3 at the edge of the top surface of the heat sink member, FIG. 6D shows the temperatures at Pos. 4 at the bottom surface of the heat sink member, and FIG. 6E shows the LED chip junction temperatures.
From these results, it is understood that the temperature at each position decreases as the enveloping volume of the heat sink member that is placed at the bottom surface of the mounting substrate increases. However, the effect of the drop in temperature obtained by increasing the enveloping volume diminishes along with the increasing enveloping volume. For example, a tremendous drop in temperature can be obtained at Pos. 1 at the top surface of the sample by changing the enveloping volume of the heat sink member from 54 cm 3 to 208 cm 3 . Yet, hardly any drop in temperature can be obtained by changing the enveloping volume of the heat sink member from 1108.8 cm 3 to 2625 cm 3 . This trend can be observed at Pos. 2 next to the sample, at Pos. 3 at the edge of the top surface of the heat sink member, and at Pos. 4 at the bottom surface of the heat sink member, but is particularly striking at Pos. 1 at the top surface of the sample. Also, the same trend seen at Pos. 1 at the top surface of the sample can be seen in the junction temperature T j .
From the above, it is understood that while it is possible to obtain a decrease in temperature by increasing the enveloping volume of the heat sink member that is placed at the bottom surface of the mounting substrate, there is a limit to this effect. Given that the heat dispersal effect is constrained by the enveloping volume of the heat sink member when that volume is small, it can be surmised that when the enveloping volume reaches a certain value, the heat dispersal effect is constrained by the contact area between the mounting substrate and the heat sink member. Upon reaching these results, the inventors conducted an experiment concerning changes in the heat dispersal characteristics exhibited along with changes in the contact area between the mounting substrate and the heat sink member while the enveloping volume of the heat sink member is held constant.
FIGS. 7A through 7D are diagrams schematically illustrating the experimental system for the heat dispersal characteristics, where FIG. 7A shows the sample dimensions of the LED module, FIG. 7B shows version 1 of the system, FIG. 7C shows version 2 of the system, and FIG. 7D shows version 3 of the system.
In version 1 , the heat sink member is placed only at the bottom surface of the mounting substrate, and the enveloping volume of the heat sink member is 200 cm 3 . In version 2 , the heat sink member is placed only at the bottom surface of the mounting substrate, and the enveloping volume of the heat sink member is 300 cm 3 . In version 3 , the heat sink member is placed at the bottom surface and at the top surface of the mounting substrate, and the enveloping volume of the heat sink member is 300 cm 3 .
FIG. 8 is a graph showing the temperatures that were measured for each version.
Comparing version 1 to versions 2 and 3 , it is understood that changing the enveloping volume of the heat sink member from 200 cm 3 to 300 cm 3 caused a drop in sample top surface temperature. Further comparing version 2 and version 3 , it is understood that even when the enveloping volume of the heat sink member is held constant at 300 cm 3 , a greater drop in sample top surface temperature occurs in version 3 , where the heat sink member is placed at the bottom surface and at the top surface of the mounting substrate, in contrast to version 2 , where the heat sink member is placed only at the bottom surface of the mounting substrate. That is, it is understood that when a heat dispersal pathway (thermal transmission pathway) originating at the top surface of the mounting substrate is secured, better heat dispersal characteristics can be obtained than by simply increasing the enveloping volume of a heat sink member placed at the bottom surface of the mounting substrate.
Version 1 and version 2 above correspond to conventional technology, and version 3 corresponds to the present embodiment. Thus, according to the present embodiment, better heat dispersal characteristics than those of conventional technologies can be obtained, and this can in turn contribute to the miniaturization of the lamp.
The lamp pertaining to the present invention was described above according to a single embodiment, but the present invention is not limited to this embodiment. For example, the following variations are plausible:
1) In the present embodiment, the electrode pads 27 are placed on the top surface of the mounting substrate 21 , and the wire 19 is connected to the electrode pads 27 on the top surface of the mounting substrate 21 . However, the present invention is not limited in this way. For example, as shown in FIG. 9 , the electrode pads 27 may be placed on the bottom surface of the mounting substrate 21 , the wiring pattern 29 and the electrode pads 27 may be electrically connected through a through-hole, and the wire 19 may be connected to the electrode pads 27 on the bottom surface of the mounting substrate 21 . This arrangement makes possible the enlargement of the region of the top surface of the mounting substrate 21 in which the light-emitting unit is not placed, as shown in FIG. 10 . This in turn allows the heat sink member 31 to be placed in quadrilateral surface contact with the mounting substrate 21 . Also, as shown in FIG. 11 , there may be a through-hole going through the mounting substrate 21 from the top surface to the bottom surface, and the wire 19 may be passed through this through-hole.
2) In the present embodiment, the heat sink member 31 has no fins. However, the present invention is not limited in this way. For example, as shown in FIG. 12A , the side portions of the heat sink member 31 may have fins 36 . Also, in the present embodiment, the side portions of the heat sink member 11 have fins. However, the present invention is not limited in this way. For example, as shown in FIG. 12B , the inside of the heat sink member 11 may have fins 12 .
3) In the present embodiment, the globe 41 is in a shaped to resemble a light bulb. However, the present invention is not limited in this way. For example, as shown in FIGS. 13A through 13C , the globe 41 may be made as small as possible in order to increase the portion of the heat sink member 31 that is in contact with ambient air.
4) In the present embodiment, the inner circumference of the aperture of the heat sink member 31 is uniform at all points. However, the present invention is not limited in this way. For example, as shown in FIG. 14 , the aperture may have an inner surface 37 that widens as it approaches the top surface of the heat sink member. In this manner, light output efficacy may be increased.
5) In the present embodiment, a metal-based mounting substrate is used. However, the present invention is not limited in this way. For example, a ceramic substrate equivalent to the aluminum substrate may be used to produce the same effect.
6) In the present embodiment, the top surface of the heat sink member 11 is flat and the bottom surface of the heat sink member 31 has a recess to accommodate therein the mounting substrate 21 . However, the present invention is not limited in this way. For example, the top surface of heat sink member 11 may have a recess to accommodate therein the mounting substrate 21 , and the heat sink member 31 may only have an aperture to accommodate the light-emitting unit 24 and allow light output. Also, the top surface of the heat sink member 11 and the bottom surface of the heat sink member 31 may both have a recess so that the mounting substrate 21 can be accommodated in both recesses.
7) In the present embodiment, the light-emitting unit 24 is accommodated completely within the aperture of the heat sink member 31 . However, the present invention is not limited in this way. For example, as shown in FIG. 15 , the surface 39 of the top part of the light-emitting unit 24 may protrude beyond the surface 38 of the heat sink member 31 in a perpendicular direction from the insulating base 21 . In this manner, the light output efficacy may be increased. It should be noted that in this configuration, the stiffness of the heat sink member 31 can be enhanced by making the thickness T 2 of the heat sink member 31 greater than the thickness T 1 of the mounting substrate 21 which can in turn preserve the effective control of any warpage in the mounting substrate 21 .
8) In the present embodiment, nothing is stated about the gas in the inner space of the globe 41 . This gas may be air, or else a nitrogen gas may be sealed inside. As nitrogen gas is a better thermal conductor than air, even better heat dispersal characteristics can be achieved with a nitrogen gas sealed inside. Also, luminous deterioration due to moisture absorption by the LEDs and the phosphors can be prevented.
Note that the LED and phosphors may be prevented from absorbing moisture by evacuating all gas and creating a vacuum in the inner space of the globe 21 .
The sealing of the inner space of the globe 41 may be realized as shown in FIGS. 16 , 17 , and 18 . In FIG. 16 , the seal is realized via a sealer 43 that is applied to the opening of the through-hole 13 in the heat sink 11 plus a seal valve 42 on the globe 41 . In FIG. 17 , a seal valve 42 is placed at the opening of the through-hole 13 . Also, in FIG. 18 , a seal valve 42 is placed at the opening of the through-hole 33 . A mechanical vacuum valve or similar part may, for example, be used as the seal valve 42 . Glass, plastic, cement, or similar materials may be used as the sealer 43 .
9) In the present embodiment, the LED 25 is sealed by a silicone resin body 26 . However, the present invention is not limited in this way. For example, as shown in FIG. 18 , the LED 25 may be exposed. In this configuration, the inner surface of the globe 41 has a phosphor layer 44 which allows white light to be produced, much like in the present embodiment. Also, in order to prevent moisture absorption by the LED and phosphors, it is desirable to seal nitrogen gas or dry air into the inner space of the globe 41 , or else to evacuate all gas from inside and create a vacuum.
[Industrial Applicability]
The present invention can be used widely and generally in lighting applications.
[Reference Signs List]
1 lamp
11 heat sink member
12 fins
13 through-hole
14 top surface
15 case
16 Edison screw
17 printed circuit board
18 power supply circuit
19 wire
21 mounting substrate
22 metal substrate
23 insulating layer
24 light-emitting unit
25 LED
26 silicone resin body
27 electrode pads
28 perimeter
29 wiring pattern
31 heat sink member
32 aperture
33 through-hole
34 recess
35 perimeter
36 fins
37 gradually-widening inner surface
38 surface of the heat sink member
39 top surface of the light-emitting unit
41 globe
42 seal valve
43 sealer
44 phosphors
61 heat sink member
62 mounting substrate
64 light-emitting unit
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A bulb-type lighting source employs a light-emitting element in a structure that facilitates heat dispersal. The lighting source includes a first heat sink member mounted in a bowl shaped case supporting a power supply circuit. A mounting substrate is positioned in surface contact with a surface of the heat sink member and is capable of supporting a light-emitting unit. A globe covers the light-emitting unit to permit light emission. A second heat sink member has a surface in contact with a perimeter of the mounting substrate and offset from the light-emitting unit to provide a second part in surface contact with the first heat member to facilitate the release of heat.
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FIELD OF THE INVENTION
[0001] This invention relates generally to aircraft, and, more specifically, to determining aircraft altitude.
BACKGROUND OF THE INVENTION
[0002] For aircraft certification and modeling for simulation, the actual height of the aircraft during flight must be determined accurately within a threshold value typically of a few feet. This is required in order to pass various certifications. One method for calculating aircraft height uses a barometric loop (baro loop) of inertial reference sensor data. However, the baro loop produces some errors that reduce the accuracy when determining actual aircraft altitude.
[0003] Other current methods use height derived from inertial vertical speed with corrections for ambient pressure and temperature. However, these methods may not have desired accuracy for these applications. This is due to designs of aircraft inertial systems, which bias their vertical calculations with pressure inputs from the aircraft's sensors.
[0004] Therefore, there exists an unmet need to more accurately determine aircraft height for post-flight testing and aircraft modeling.
SUMMARY OF THE INVENTION
[0005] Embodiments of the present invention provide a method, apparatus, and computer program product for accurately determining aircraft altitude, impact pressure, and calibrated air speed. The determined results may be used for analysis in certification processes, used for building flight testing or simulation models that also may used in certification processes, or used for other purposes such as data to be used in a flight simulator.
[0006] According to an embodiment of the present invention, altitude information of an aircraft is determined based on recorded altitude information generated by an inertial navigation system (INS) of the aircraft and altitude information generated by a global positioning system (GPS) of the aircraft. A static pressure value is generated based on the determined altitude information.
[0007] In one aspect of the invention, the altitude information is adjusted based on known aircraft position defined by a system other than the INS and the GPS.
[0008] In another aspect of the invention, an integration is performed of a temperature adjusted vertical velocity value produced by the INS or a double integration is performed of a vertical acceleration value produced by the INS, and the result of either integration is adjusted according to aircraft pitch, roll, and yaw. A least squares fit is performed between the INS altitude information and the GPS altitude information.
[0009] In still another aspect of the invention, impact pressure is generated based on the generated static pressure and previously recorded pressure information from a pitot static system of the aircraft. Calibrated airspeed is generated based on the generated impact pressure and aircraft performance data or a simulation model is built based on the calibrated airspeed
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
[0011] FIG. 1 is a block diagram of an exemplary system for performing aircraft height determination;
[0012] FIGS. 2 and 3 are flow diagrams of an exemplary process performed by the system shown in FIG. 1 ; and
[0013] FIG. 4 is a perspective view of an aircraft performing a test flight.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Embodiments of the present invention provide a system and method for accurately determining aircraft altitude for use in a simulation model for testing various aspects of an aircraft relative to an actual flight test. Referring now to FIG. 1 , a system 20 is illustrated for generating aircraft altitude information in accordance with the present invention. The system 20 includes a computer 24 that receives data obtained by components of an aircraft 30 . The aircraft 30 includes a data acquisition system 34 that stores data in a memory 36 . The stored data is received from an Inertial Navigation System (INS) 40 , a Global Position System (GPS) 42 , a Radar Altimeter (RADAlt) 44 , and various aircraft sensors 46 , such as without limitation a pitot static system, and aircraft pitch, roll, and yaw sensors. After the aircraft 30 has completed a designated test, the computer 24 retrieves the data stored in the memory 36 . The computer 24 retrieves the data from the memory 36 by a direct connection or a wireless connection. In another embodiment, the memory 36 includes a removable memory device that includes the stored data. The computer 24 receives the memory device in a receiving port.
[0015] The computer 24 is a general purpose computer, such as without limitation a personal computer, a laptop, a mainframe, or a hand-held computer. The computer 24 includes memory, a processor, various user interfaces, such as without limitation a keyboard, a mouse, and a display. The computer 24 determines aircraft altitude or pressure that the aircraft 30 is experiencing at various points in time during a test scenario according to an exemplary process described in more detail below with respect to FIGS. 2 and 3 .
[0016] Referring now to FIG. 2 , an exemplary process 80 is illustrated for generating highly accurate aircraft altitude information, pressure information, and calibrated airspeed (CAS) for use in post-flight test analysis. The process 80 begins at a block 82 where barometric pressure is measured at the ground in the vicinity of where the flight test is taking place. The barometric pressure measurement is performed shortly before or soon after the flight test, or both. This measurement is taken in order to get an accurate measurement of barometric pressure throughout the period of the flight test. At a block 84 , during the test flight, the total pressure is measured by the aircraft 30 at a pre-defined sampling rate. Total pressure P T is measured by the aircraft's pitot system. At a block 86 , a history of static pressure values at altitude during the test flight are suitably generated after the test flight has occurred. Generation of a history of static pressure values is described in more detail below with regards to FIG. 3 . At a block 88 , for each sample period of time the static pressure P S is subtracted from the total pressure P T in order to get impact pressure. In one embodiment, CAS is determined from the impact pressure using Bernoulli's equation. At a block 92 , a simulation model is built using the CAS and data from other aircraft sensors 46 .
[0017] Referring now to FIG. 3 , generation of static pressure values P S is shown as performed at the block 86 in FIG. 2 . The exemplary process 86 begins at a block 104 wherein the computer 24 determines change in height values (Δh) using INS information. The change in height Δh is determined by double integrating an INS vertical acceleration value or taking a single integration of a temperature adjusted INS vertical velocity value. Equation 1 below is an example equation for generating the temperature adjusted INS vertical velocity value.
VZIC = VZI * 504.7446 * TAMB [ 145442.2 - HP ] ( 1 )
[0018] where:
[0019] VZI is raw inertial vertical speed in ft/sec;
[0020] HP is pressure altitude in feet;
[0021] TAMB is ambient air temperature in deg. K; and
[0022] VZIC is vertical speed from the INS 40 that has been corrected to give tapeline vertical velocity.
[0023] At a block 106 , GPS altitude information along a test flight is determined. At a block 108 , the GPS information is compared to the INS information during an appropriate test period. At a block 110 , improved height values of the aircraft 30 are determined based on the comparison. At a block 112 , the determined improved height values are adjusted based on a known aircraft location point. At a block 114 , static pressure P S is generated based on the determined height values.
[0024] The following calculations are suitably performed to correct INS height data (i.e., generating improved height values of the aircraft 30 ). A relatively stable period of flight is selected for generating the improved height values. Equations 2 and 3 below are two different methods for calculating an INS Δh according to aircraft position.
DZ 2=(trapezoidal) integration of VZIC from [fit time start] to [now]−sin(YAW)*cos(PITCH)* DX −(sin(YAW)*sin(ROLL)*sin(PITCH)+cos(YAW)*cos(ROLL))* DY +(sin(YAW)*cos(ROLL)*sin(PITCH)−cos(YAW)*sin(ROLL))* DZ (2)
DZ 3=second order (trapezoidal) integration of AZ from [fit time start] to [now]−sin(YAW)*cos(PITCH)* DX −(sin(YAW)*sin(ROLL)*sin(PITCH)+cos(YAW)*cos(ROLL))* DY +(sin(YAW)*cos(ROLL)*sin(PITCH)−cos(YAW)*sin(ROLL))* DZ (3)
[0025] One method for comparing the GPS information to the INS information is shown in Equations 4 and 5.
DZI=ZPDGPS−DZ 2 (4)
or
DZI=ZPDGPS−DZ 3 (5)
where: DX, DY, and DZ are the distances between the inertial sensor and the vehicle reference points in an appropriate body axes system; AZ is vertical acceleration (from the INS 40 ); PITCH, ROLL, and YAW are Euler attitude angles of the aircraft 30 ; and ZPDGPS is the height given by the differential GPS (DGPS) system 42 , corrected for pitch, roll, and yaw to a reference point.
[0031] A second order least squares fit of DZI versus time is calculated:
DZIFIT=C 0 Z+C 1 Z*TFIT+C 2 Z*TFIT*TFIT
where: TFIT is time.
[0034] In one embodiment, a second order least squares fit equation is used if 4 or more DGPS points are available, a first order fit equation is used if 3 points are available, and a zero order fit equation is used otherwise. If no DGPS data exists, then C0Z=C1Z=C2Z=0.
T =[time now]−[start time of inertial vertical fit]
ZPINTU=DZ 2+ C 0 Z+C 1 Z*T+C 2 Z*T*T
or
ZPINTU=DZ 3+ C 0 Z+C 1 Z*T+C 2 Z*T*T
where: T is a running time used in the correction; it can extend beyond either or both ends of the fit time period; and ZPINTU is the unsynchronized height change produced by this method from the INS 40 data.
[0038] A point (in time) for synchronizing to a reference height is identified. In this embodiment, the reference height is known terrain, where radar altimeter data is used.
[0039] A synchronization constant at time T1 is calculated:
DZ 1= ZPREF 1 −ZPINTU
[0040] Then, for all times of interest:
ZPINT 1= ZPINTU+DZ 1
where: T1 is the time of synchronization, T1 is used only to identify the point for the above equation above; ZPREF1 is the reference height at time T1, obtained by various means, such as without limitation from GPS information, corrected radar altimeter data, laser altimeter data, stable ground location, position fix with an known object (visual or photographic); and ZPINT1 is the DGPS-corrected inertial sensor height of the aircraft 30 .
[0045] This synchronization can be repeated for different segments of time in a flight test. These segments, along with time segments of height data computed by other means, can be combined to give a history of aircraft height for the duration of the test period.
[0046] Static pressure P S is determined according to Equation 6:
ⅆ ( P S ) ⅆ Z = - P S * ( 0.010413 ) TAMB ( 6 )
where: Z is the height determined above. Z is the tapeline altitude.
[0049] Referring now to FIG. 4 , a perspective view of an aircraft 200 on approach to landing on a runway 202 is shown. This is an example test flight that may be analyzed by embodiments of the present invention in order to produce accurate altitude values in a post-test analysis of the aircraft 200 after having flown a flight path 204 to touchdown on the runway 202 . A calculation of the height data performed by the process of the block 86 ( FIG. 3 ) is performed twice. The first time is at the block 108 ( FIG. 3 ) when the GPS information is compared to the INS information. The initial starting location of the INS information is irrelevant to actual aircraft height, so therefore it is adjusted to the start point of the GPS information. The second adjustment occurs at the block 112 ( FIG. 3 ), where a known aircraft location point is used to further adjust the height values that are determined in the block 110 ( FIG. 3 ). FIG. 4 illustrates one example for determining a known aircraft location point. In the test flight shown, the aircraft 200 is at some threshold distance from the runway 202 (not to be confused with the runway threshold) where the ground under the flight test profile (i.e., flight path 204 ) has been mapped so that its true surface height is known. The computer 24 ( FIG. 1 ) uses stored radar altimeter information at the threshold point to determine the height of the aircraft 200 at the threshold point. The determined height information at the threshold point is used in the second adjustment. This process may be likewise performed for a takeoff from the runway 202 .
[0050] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.
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A method, apparatus, and computer program product for accurately determining aircraft altitude, impact pressure, and calibrated air speed are provided. The determined results may be used for analysis in certification processes, used for building flight testing or simulation models that also may used in certification processes, or used for other purposes such as data to be used in a flight simulator. Altitude information of an aircraft is determined based on recorded altitude information generated by an inertial navigation system (INS) of the aircraft and altitude information generated by a global positioning system (GPS) of the aircraft. A static pressure value is generated based on the determined altitude information.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a current integrator for generating an output voltage in response to an input current to be integrated, comprising: an input terminal for receiving the input current; an integration capacitor; charging means for charging the integration capacitor in response to the input current; and an output terminal coupled to an electrode of the integration capacitor at which the output voltage is produced.
2. Description of the Related Art
Such a current integrator is shown in FIG. 1 and is generally known from handbooks, application notes etc. The charging means comprise an operational amplifier 2, which has its inverting input connected to the input terminal 4 for receiving the input current Ii to be integrated and having its non-inverting input connected to a reference voltage source 6 which supplies a reference voltage Vr relative to signal ground. Owing to the high voltage gain of the operational amplifier 2 the voltage difference between the inverting input and the non-inverting input is small, as a result of which the voltage at the input terminal 4 is also equal to the reference voltage Vr. The output of the operational amplifier 2 is at the output terminal 8 connected to an electrode 10 of an integration capacitor 12 which has its other electrode 14 connected to the inverting input of the operational amplifier 2. Owing to the high input impedance of the inverting input the current Ii to be integrated flows almost wholly into the integration capacitor 12, as a result of which the output voltage Vo at the output terminal 8 changes.
This known current integrator has various drawbacks. The integration capacitor 12 is comparatively difficult to realize on an integrated circuit. The voltage across the integration capacitor 12 is not exactly known and, moreover, it may become equal to zero volts. This means, for example, that it is not possible for the capacitance between gate and channel of an MOS transistor to be used as a capacitor. Instead special constructions are necessary such as improper use of a PMOS transistor in the accumulation mode, in which the gate-source voltage is smaller than the threshold voltage and electrons accumulate underneath the gate, instead of in the inversion mode, in which a channel is formed. Another possibility is to use capacitances between metal layers, but that requires a large area of the integrated circuit. The output voltage Vo should be processed by means of a circuit referred to the reference voltage Vr, because the current integrator is also referred to this voltage. This requires a differential circuit with a comparatively large number of components.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a current integrator which is easier to fabricate on an integrated circuit. To this end a current integrator of the type defined in the opening paragraph is characterized in that the charging means comprise a current-current converter having a first current terminal coupled to the input terminal to receive the input current and having a second current terminal coupled to said electrode of the integration capacitor to supply to the integration capacitor an output current proportional to the input current.
FIG. 2 illustrates the principle such a current integrator. The input current Ii is applied to the integration capacitor 12 via the current-current converter 16, the input terminal 4 being held at the desired reference voltage Vr by means of a reference voltage source 18. The current-current converter 16 supplies an output current Io to the second current terminal 20, which current is proportional to the input current Ii which flows in the first current terminal 22. One side of the integration capacitor 12 may now be connected to a supply voltage, which enables the use of a capacitor formed by a MOS transistor, which occupies a comparatively small area.
An embodiment of the current integrator in accordance with the invention is characterized in that the ratio between the output current of the current-current converter and the input current is smaller than 1. A ratio smaller than 1 allows the use of a smaller capacitance value to obtain the same effect for a given voltage excursion across the integration capacitor 12. This saves additional area.
A practical embodiment of a current integrator in accordance with the invention is characterized in that the current-current converter comprises: a differential amplifier having an output, a non-inverting input connected to receive a reference voltage, and an inverting input coupled to the first current terminal; a first transistor having a control electrode coupled to the output of the differential amplifier, and having a main current path; a current mirror having an input branch coupled to the first current terminal via the main current path of the first transistor; a first bias current source coupled to the first current terminal to supply a first bias current to the first current terminal; and a second bias current source coupled to the second current terminal to supply a second bias current to the second current terminal.
The differential amplifier and the first transistor provide a low impedance at the first current terminal and keep the first current terminal at the reference voltage. The current mirror reflects the input current in attenuated or non-attenuated form, to the second current terminal, which is coupled to the integration capacitor and the output terminal. The first and the second bias current sources provide a quiescent current through the input branch and the output branch of the current mirror and permit a bidirectional input current.
If the ratio between the currents of the first bias current source and the second bias current source is not approximately equal to the current transfer ratio of the current mirror there will be an output current to the integration capacitor even when the input current is zero and so there will be an offset in the output voltage. This is undesirable in many fields of use. In order to preclude this, an embodiment of the integrator circuit in accordance with the invention is characterized in that the second bias current source comprises: a second transistor having a control electrode and having a main current path of which one electrode is coupled to the second current terminal; a first switch connected between the control electrode of the second transistor and said electrode of the main current path of the second transistor; and the current-current converter further comprises: a second switch connected between the first current terminal and the input terminal; a third switch connected between said electrode of the integration capacitor and the second current terminal; and control means for closing the first switch and opening the second and the third switch during a first period and for opening the first switch and closing the second and the third switch during a second period following the first period.
The second bias current is replaced by a calibrated current source, which is calibrated by temporarily arranging the second transistor as a diode by means of the first switch, the input terminal being decoupled from the first current terminal by means of the second switch, and the integration capacitor being decoupled from the second current terminal by means of the third switch. If desired, calibration may be repeated at regular intervals depending on the rate at which the charge on the control electrode of the second transistor leaks away.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention will now be described and elucidated with reference to the accompanying drawings, in which
FIG. 1 shows a prior-art current integrator;
FIG. 2 shows the basic circuit diagram of a current integrator in accordance with the invention;
FIG. 3 shows a first variant of a current integrator in accordance with the invention; and
FIG. 4 shows a second variant of a current integrator in accordance with the invention.
In these Figures parts having the same function or purpose bear the same reference numerals.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows the basic circuit diagram of a current integrator in accordance with the invention. The current integrator comprises a current-current converter 16 having a first current terminal 22 connected to an input terminal 4 for receiving an input current Ii to be integrated. By means of a reference voltage source 18 the operating voltage at the first current terminal 22 is kept equal to a reference voltage Vr relative to signal ground. The current-current converter 16 also comprises a controllable current source 24, which supplies an output current Io to a second current terminal 20, said output current being proportional to the input current Ii. The proportionality factor or current gain is K, so that Io=K*Ii. The current integrator further comprises an integration capacitor 12 having an electrode 10 connected to an output terminal 8 and having a further electrode connected to a fixed voltage, in the present case earth. The second current terminal 20 of the current-current converter 16 is connected to the output terminal 8, so that an output voltage Vo becomes available by charging or discharging the integration capacitor 12 with the output current Io from the controllable current source 24.
Since the integration capacitor 12 has one electrode connected to a fixed voltage it can be implemented by a MOS transistor, which occupies a small area, for example a PMOS transistor if the fixed voltage is the positive supply voltage. The source, drain and backgate of this PMOS transistor are then connected to the positive supply voltage and the gate of this PMOS transistor is connected to a voltage equal to positive supply voltage minus at least the threshold voltage V T . If, in addition, the current gain K of the current-current converter 16 is selected to be smaller than unity a capacitance which is a factor K smaller can be used to obtain for the same voltage excursion across the integration capacitor 12. This saves additional area.
FIG. 3 shows an embodiment of the current integrator of FIG. 2. A differential amplifier 26 has a non-inverting input 28 connected to a first supply terminal 32 via a reference voltage source 30, which supply terminal functions as signal ground. The inverting input 34 of the differential amplifier 26 is coupled to the first current terminal 22, which is again connected to the input terminal 4 to receive the input current Ii to be integrated. The output 36 of the differential amplifier 26 is connected to the control electrode or gate of a PMOS transistor 38, which has its source connected to the first current terminal 22 and which has its drain coupled to an input branch 40, 42 of a current mirror 44. The source and drain form the main current path of the PMOS transistor 38, which provides a current path between the first current terminal 22 and the input branch 40, 42 of the current mirror 44. The current mirror 44 has an output branch 46, 48 coupled to the second current terminal 20.
The current mirror 44 comprises, by way of example, two NMOS transistors 50 and 52, whose sources are connected to the first supply terminal 32, whose gates are connected to the drain of the NMOS transistor 50, the gate of the NMOS transistor 50 being connected to the drain of the PMOS transistor 38 and the drain of the NMOS transistor 52 being connected to the second current terminal 20. The current gain K of the current mirror 44 is determined, in known manner, by the geometry ratio of the NMOS transistors 50 and 52.
The integration capacitor 12 is connected between the output terminal 8 and a second supply terminal 54, to which a positive supply voltage is applied. The integration capacitor 12 may comprise a PMOS transistor 72, whose source, drain and backgate are connected to the supply terminal 54 and whose gate is connected to the output terminal 8. The output terminal 8 and the electrode 10 of the integration capacitor 12 are also connected to the second current terminal 20. The gate capacitance of the PMOS transistor 72 acts as a capacitor and may take the place of or may be arranged in parallel with the integration capacitor 12. A first bias current source 56 between the second supply terminal 54 and the first current terminal 22 supplies a first bias current Ib1 to the series arrangement of the main current path of the PMOS transistor 38 and the input branch 40, 42 of the current mirror 44. A second bias current source 58 between the second supply terminal 54 and the second current terminal 20 supplies a second bias current Ib2 to the output branch 46, 48 of the current mirror 44. The bias current sources 56 and 58 bias the current mirror 44 and enable a bidirectional drive of the input terminal. The bias currents Ib1 and Ib2 are in a ratio equal to the current gain K of the current mirror 44, i.e. Ib2=K*Ib1.
The differential amplifier 26, the PMOS transistor 38 and the reference voltage source 30 hold the first current terminal 22 at a fixed voltage Vr relative to signal ground and also provide a low impedance at the first current terminal 22. The sum Ii+Ib1 of the first bias current Ib1 and the input current Ii flows to the input branch 40, 42 of the current mirror via the main current path of the PMOS transistor 38. A current K*(Ii+Ib1), which has been attenuated by a factor K, flows through the output branch 46, 48 to the second current terminal 20. Since Ib2=K*Ib1, a current K*Ii will flow in the integration capacitor 12 and an output voltage Vo will be available at the output terminal 8.
If Ib2 is not equal to K*Ib1 an offset current will flow in the integration capacitor 12 in the case of an input current Ii equal to 0. FIG. 4 shows an embodiment which precludes this offset current. The second bias current source is a calibrated current source with a PMOS transistor 60 having its source connected to the second supply terminal 54 and its drain to the second current terminal 20. The gate of the PMOS transistor 60 may be connected to the drain of the PMOS transistor 60 by means of a first switch 62 under control of a switching signal S1 from control means 64. Furthermore, a second switch 66 is arranged between the input terminal 4 and the first current terminal 22, controlled by a second switching signal S2 from the control means 64, and a third switch 68 is arranged between the second current terminal 20 and the node between the integration capacitor 12 and the output terminal 8, which third switch is controlled by a third switching signal S3 from the control means 64. During calibration of the PMOS transistor 60 the first switch 62 is closed and the second and the third switch 66 and 68 are opened by means of suitable switching signals S1, S2 and S3. Now only a bias current Ib1 flows through the input branch 40, 42 of the current mirror 44. The current in the output branch 46, 48, which has been attenuated or amplified by a factor K, flows wholly through the diode-connected PMOS transistor 60, producing a gate-source voltage to match this current. After the first switch 62 has been opened and the second and the third switch 66 and 68 have been closed by suitable switching signals, S1, S2 and S3 the circuit is ready for use. The gate-source voltage built up in the PMOS transistor 60 is preserved in the internal gate-source capacitance Cgs of this transistor. However, for this purpose an external capacitor (not shown) may be connected to the gate of the PMOS transistor 60, if required. Since the gate-source capacitance Cgs is ultimately discharged by leakage currents, calibration should be repeated at regular intervals. For this purpose the control means further include a clock pulse generator 70, which ensures that recalibration is effected at regular intervals.
The embodiment shown in FIG. 4 is particularly suitable for use in digital-to-analog converters and switched capacitor filters which effect time-discrete signal processing.
FIGS. 3 and 4 show embodiments comprising MOS transistors. However, these transistors may be replaced by bipolar transistors, in which case drain, source and gate should read emitter, collector and base. The base is the control electrode of a bipolar transistor and the main current path is the path between the emitter and the collector. The switches 62, 66 and 68 preferably comprise MOS switching transistors, which are known to those skilled in the art. The control means 64 can be implemented by means of known digital techniques for the generation of suitable switching signals S1, S2 and S3.
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A current integrator for generating an output voltage (Vo) in response to an input current (Ii) to be integrated. The input current is applied to an integration capacitor via a current-current converter. This enables one end of the integration capacitor to be connected to a fixed voltage and to be implemented by means of a MOS transistor which occupies a comparatively small area. A further area reduction is possible by making the current gain (K) of the current-current converter smaller than 1.
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BACKGROUND
Various devices have heretofore been proposed for providing heated air for persons having respiratory problems as disclosed, for example in U.S. Pat. Nos. 398,991; 427,179; 438,464; 603,021; 3,200,819; 3,249,108; 3,333,585; Re. 20,135; 3,139,885; and 3,707,966.
Despite the many attempts that have been made in the past to provide devices and appliances for warming or heating air for personal breathing, there is a definite need for an improved portable conditioned air breathing device containing a heating unit which will condition the air and which can be worn without discomfort by the user and utilized over a long period of time.
OBJECTS
One of the objects of the present invention is to provide a new and improved portable conditioned air breathing device which is compact and simple in structure.
Another object of the invention is to provide a breathing device of the type described containing a collapsible hose in a storage compartment which is adapted to be withdrawn from and coupled to the storage compartment and use in conjunction with a face mask.
Another object of the invention is to provide a portable conditioned air breathing device of the type described in which there is a heating compartment in heat exchange and air-tight relationship with respect to an air conditioning compartment wherein the heating compartment contains a metal flame tube with a burner at one end and heat exchange elements extending from the flame tube into the air conditioning compartment.
Still a further object of the invention is to provide a new and improved device of the type described containing means to mix conditioned air with an additive to increase the humidity or for medicinal purposes.
Another object of the invention is to provide a portable conditioned air breathing device of the type described having means for mixing fresh air with heated air and for controlling the flow of fresh air.
Still another object of the invention is to provide a portable conditioned air breathing device of the type described wherein the heating compartment has an opening at the top comprising a weather cap which covers said opening and is axially adjustable and removable.
Other objects and advantages of the invention will appear from the following description in conjunction with the accompanying drawings.
THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view illustrating in general the manner in which a portable conditioned air breathing device embodying the invention is used;
FIG. 2 is a top plan view of a portable conditioned air breathing device embodying the invention;
FIG. 3 is an elevational section taken along the line 3,3 of FIG. 2;
FIG. 4 is a sectional view taken along the line 4,4 of FIG. 2;
FIG. 5 is a sectional view taken along the line 5,5 of FIG. 3;
FIG. 6 is a sectional view taken along the line 6,6 of FIG. 3;
FIG. 7 is a sectional view taken along the line 7,7 of FIG. 3;
FIG. 8 is a bottom plan view taken along the line 8,8 of FIG. 3;
FIG. 9 is a front elevational view showing the exterior of the portable conditioned air breathing device embodied in FIGS. 1 to 8;
FIG. 10 is a detailed sectional view of the weather cap at the top of the canister and also showing the fresh air inlets to the air conditioning compartment;
FIG. 11 is a detailed sectional view of a portion of the apparatus showing the manner in which the flame tube is installed;
FIG. 12 is a detailed view of means for automatically holding open the fuel valve after flame has been established and for closing it when the flame is extinguished;
FIG. 13 is a detailed view of an alternate structure for electrical ignition;
FIG. 14 is a detailed view of the valve stem for a main fuel control valve and a valve control knob with a spring for frictionally holding the valve stem and the knob;
FIG. 15 is a detailed view of a snap-in button type prefilter which is disposed in the fresh air inlets at the bottom of the canister; and
FIG. 16 is a side sectional view taken along the line 16,16 of FIG. 15.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention a portable conditioned air breathing device is provided comprising a compartmented canister having a plurality of compartments running from the top toward the bottom thereof, including a collapsible hose storage compartment, an air conditioning compartment having one or more fresh air inlets and a heating compartment in heat exchange relationship with the air conditioning compartment, the hose storage compartment having coupling means at one end thereof for a collapsible hose and an opening in a side wall for transmitting conditioned air from the air conditioning compartment to said storage compartment and to a collapsible hose connected to said storage compartment. A compartment can also be provided in said canister for holding an additive for the conditioned air with means for ejecting said additive into the air conditioning compartment. The heating compartment preferably comprises an elongated metal flame tube having a combustion unit in one end and extending upwardly to an opening in the top of the canister where combustion exhaust gases are discharged through said opening, said flame tube containing metal fins which project into the air conditioning compartment. Means are also provided for introducing fresh air through inlets at the bottom of the canister and passageways to inlets in the sides of the upper part of the air conditioning compartment. In addition, means are provided on the side of the canister for igniting the burner and for controlling the flow of fuel to the burner. Means are also provided for mixing fresh air with heated air and for filtering the air. Another feature is the provision of means for stopping the flow of fuel to the burner automatically when the flame is extinguished. A further feature is the provision of a weather cap which is adjustable and also removable.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, FIG. 1 illustrates the use of the device herein which is embodied in a canister generally indicated at 1 connected by a flexible collapsible hose 2 to a face mask 3 which is held on the head of the user by a strap 4. The canister 1 is supported by shoulder straps generally indicated at 5 and a belt generally indicated at 6 which are fastened to the canister in any suitable manner.
As illustrated in FIGS. 2 to 4, the canister 1 comprises a top portion 7, sides 8 and bottom 9 and is generally eliptical in cross section, although the cross sectional shape is subject to variation and modification.
Within canister 1 and running from the top toward the bottom thereof are a hose storage compartment 10, an air conditioning compartment 11, a heating compartment 12 and a compartment 13 which contains means for introducing moisture or other additive for medical purposes into the air conditioning compartment 11. In compartment 10 the collapsible flexible tube 2 is retained by a coupling means 14 in opening 15 in the top of canister 1. Preferably the coupling means is secured by threads 16 or other suitable means in the sides of the opening 15 so that the flexible tube 2 can be released from the position shown in FIG. 3, pulled out of the storage compartment 10 and recoupled by means of threads 17 or in any other suitable manner to the opening 15 in the top of canister 1.
Fresh air is introduced into passageways 18, 19, 20 and 21 through inlets 22, 23, 24 and 25 in the bottom 9 of canister 1, as shown in FIG. 8, flows upwardly through the passageways 18, 19, 20 and 21 and through inlets 26, 27, 28 and 29 to air conditioning compartment 11. In air conditioning compartment 11 the air flows downwardly through a heat exchanger generally indicated at 30 which preferably comprises a series of metal fins 31 attached to the outer wall of flame tube 32 which is also made of metal. The walls of flame tube 32 are heated by flame 33 from burner 34 and the heat is conducted to the heat exchanger 30 which in turn transmits it to the fresh air flowing downwardly through compartment 11. A filter 35 is disposed in compartment 11 in concentric relationship with flame tube 32 in order to remove any solid particles which may be carried in the air. Filter 35 is mounted on flame tube 32 and held in place by means of threads at 36, or in any other suitable manner, so that it can be removed and replaced. After passing through the filter 35, the conditioned air passes through opening 37 to compartment 10 and thence through the flexible tube 2 to a mask on the face of the user as shown in FIG. 1.
Flame tube 32 is mounted in compartment 11 by cross member 38 secured to the inner sides of compartment 11 and a ground joint seal at 39, as illustrated in FIG. 11. Thus, the air conditioning compartment 11 is air-tight with respect to the heating compartment 12 so that the gases of combustion must all pass through opening 40 in the top of the canister and no gases of combustion can enter the air conditioning compartment 11.
The flame tube 32 contains a heat economizer 41 in the form of a spiral metal strip which causes the combustion gases to move in a tortuous path thereby increasing the efficiency of the heat exchange between compartment 12 and compartment 11. For the purpose of the invention it is preferable to use liquefied butane or similar gas fuel which is contained in a disposable and replaceable type container 42 made of transparent nylon or metal, or other suitable material, and seated on bumpers 43 made of rubber or other suitable resilient material and resting on the inside of the bottom 9 of canister 1. Container 42 is removable by unscrewing cap 44 which is threadedly connected to the bottom 9 at 45 and contains a cross bar 46 which may be grasped by the hand for the purpose of rotating cap 44. Main fuel control valve 47 is threadedly secured to container outlet 48 and is threadedly mounted at 49 on cross member 50 which is welded or otherwise secured to the inside of the prolongation of compartment 11. The burner 34 is of the jet type. Valve 47 is a needle-type valve controlled by rotating a knob 51 as shown in FIG. 4 which is disposed on the outside of canister 1 so that it can be readily grasped by the hand of the user. By rotating knob 51 the size and intensity of flame 33 can be controlled. Burner 34 is threadedly secured to valve 47 at 52 so that the burner jet can be removed and cleaned when desired.
As a safety precaution a valve 53 is provided having a valve stem 54 with a groove 55 therein a shown in FIG. 12. A bi-metallic strip 56 containing a slot 57 is connected to the inside wall of flame tube 12 by means of rivets 58 or in any other suitable manner so that the slot 57 is disposed in groove 55 of valve stem 54. Valve 53 is a spring-type normally closed thermostatically operated and manual start-up valve. A manual start button 59 is depressed to open valve 53. When flame is established, heat from the flame flexes bi-metallic strip 56 which acts against the valve spring in valve 53 to hold the valve open. When the flame is extinguished for any reason, bi-metallic strip 56 flexes in the opposite direction, thereby allowing the spring in valve 53 to close the valve.
The burner is ignited initially in a conventional manner by rotating the knurled wheel 60 which projects through an opening 61 in canister 1. When wheel 60 is rotated it creates a spark by friction against flint 62. At the same time, button 59 is depressed and valve 47 is opened so that fuel from storage unit 42 can enter burner 34 and be ignited to create flame 33. After the burner has been ignited, button 59 can be released and valve 53 will be held away from the passageway to the burner by metallic strip 56. The size of the flame can be controlled by turning knob 51 of valve 47. Combustion air and ventilation of the fuel storage and main fuel compartment is provided through holes 63 in canister 1 (see FIG. 9).
Compartment 13 contains a container 64 for liquids such as water or solutions used as inhalants for medical purposes. Container 64 can be inserted and removed through removable cover 65 which is threadedly secured to the bottom of the canister and can be rotated by grasping bar strip 66. A sponge-type rubber, or other resilient retainer disc 67 is cemented to the inside surface of cover 65. Liquids in container 64 are ejected through opening 68 into air conditioning compartment 11 by pressing downwardly on pump stem 69 thereby causing the liquid to be forced upwardly through tube 70 and to be discharged through orifice 71 when it reaches the dotted line position shown in FIG. 3.
The openings 40 in the top of compartment 12 are provided by perforations in plate 72 and a weather cap 73 made of metal, or other suitable material, is threadedly secured to plate 72 at 74 so that it can be rotated axially in order to provide a space between the top of canister 1 and the inside of the weather cap for outward flow of combustion gases during inclement weather conditions. The weather cap 73 can also be completely removed. Perforated plate 72 is threadedly secured at 75 to the outer part of flame tube 12 so that it can be removed and cleaned.
Another important feature of the invention is the provision of an adjustable damper 76 which is mounted in the bottom of canister 1 and contains openings 77 which can either partially or completely be opened and closed by rotating damper 76 and thereby permit the addition of fresh unheated air to the previously conditioned air for the purpose of adjusting the temperatue of the conditioned air and/or the humidity to suit the needs of the user. A filter 78 is provided in order to filter out any solid particles which may be present in the air admitted through the adjustable damper 76. The filter may consist of filter pads or cloth screens which are effective to keep out insects and also to keep the larger particles in the air from entering the device.
The four perforated inlets 22, 23, 24 and 25 are of the snap-in type and contain snap-in members 79 as shown in FIG. 16 and also include a filter disc 80 made from non-allergic filter material which fits in the ridge 81 of the inlet members.
As illustrated in FIG. 13, an alternate system of electric ignition can be used by employing a crystal-type electric generator (Piezo Electric) 82 having insulated electric wire leads 83 and operated by a push button 84 which has a spring return. Actuation of push button 84 generates a spark between high temperature electrodes 85 and 86 which are carried by porcelain insulators 87 and 88.
Where a transparent container is used for the fuel, the level can be observed through a transparent opening 89 in the outside of the canister 1 as shown in FIG. 9.
MODE OF OPERATION
The fresh air (air for breathing) enters the canister through for intake openings 22, 23, 24 and 25 at the bottom of the canister and passes upwardly through passageways 18, 19, 20 and 21 and openings 26, 27, 28 and 29 into air conditioning compartment 11. The air is heated by passing through the perforated fin heat exchangers generally indicated at 30, heat being supplied to the heat exchanger elements by conduction and radiation from the flame tube 12 which in turn receives heat from the flame 33. Hot gases flow upwards in the combustion tube 12 and around the metal strip heat economizer 41. The burner 34, through a system of control valves, and a feed system burns liquefied gas supplied by fuel container 42. The burner is equipped with an orifice plate 90 which is designed to pass only the required fuel to the burner thereby eliminating possible excess fuel supply and the consequent over-heating of the device. Modulation of the fuel supply from the safe maximum amount as determined by the orifice, down to complete shutoff of the fuel supply is controlled by the main fuel control valve 47.
By the time fresh air leaves the bottom row of the perforated fin heat exchanger 30 it is heated to maximum temperature as determined by the intensity of the burner flame. At this point, humidification of the fresh air may be accomplished by adding water in the form of a spray or mist to the hot fresh air through opening 68 ahead of the entering side of the main air filter and evaporator cartridge 35.
When necessary, as prescribed by a physician, medication may be substituted instead of water by removing the water from the liquid bottle 64 and replacing it with medication, or exchanging the water bottle with a matching bottle containing the medication. It is also possible to replace the standard main filter cartridge 35 with one containing medication saturated into the filter cartridge thereby passing the fresh heated air through the medicated filter to provide medicated vapors for therapeutic treatment.
The main air filter and evaporator cartridge 35 is preferably made up of two sections, the first section located at the air-entering side of the cartridge containing high efficiency non-allergic air filtering media, and the second section containing activated carbon granules for a limited degree of air purification. The casing containing the two sections is preferably made of waterproof material such as plastic material with the top and bottom perforated for the air passing through the unit. The cartridge is removable and replaceable.
During warm summer weather the device can be used to provide some relief by cooling the air by evaporation of water sprayed into the vaporizor air chamber and trickling into the filter cartridge 35 thereby saturating the filter media and the activated carbon granules which will then cool the air by evaporation. The degree of cooling will depend upon the dryness or humidity of the ambient air. This cooling will provide some comfort and lower the effects of heat prostration.
The invention is especially intended for portable use by out-patients susceptible to attacks of sundry cardio-respiratory ailments when such persons are exposed to cold outside air. Also, use by normal persons suffering from the common cold may find relief in the home or office or in transit by the use of this device. Older people, suffering from cardiovascular or pulmonary disease may find comfort by the use of this device, especially when exposed to cold outdoor weather while walking or engaging in outdoor sports such as hunting, snowmobiling, or watching football. Normal persons using this device outdoors during severe cold weather will find comfort as well as endure the severe weather longer while participating in active winter sports such as skiing, tobogganing or skating.
It is thought that the invention and its numerous attendant advantages will be fully understood from the foregoing description, and it is obvious that numerous changes may be made in the form, construction and arrangement of the several parts without departing from the spirit or scope of the invention, or sacrificing any of its attendant advantages, the forms herein disclosed being preferred embodiments for the purpose of illustrating the invention.
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A portable conditioned heated air breathing device is provided comprising a compartmented canister with a collapsible hose storage compartment, an air conditioning compartment and a heating compartment and which also contains an ejector for ejecting an additive into the conditioned air as well as a structural arrangement for mixing fresh air with heated air, a filter for filtering the air and a device for igniting a burner from the outside of the canister and a manually controllable valve for controlling the flow of fuel to the burner.
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FIELD OF THE INVENTION
[0001] This invention relates to a stapler and a stapler positioning member used for document binding, etc.
BACKGROUND OF THE INVENTION
[0002] In a stapler, an object (for example, a bundle of paper) is filed for example with a U-shaped staple, and the staple used must have a length according to the thickness of the bundle of paper.
[0003] For this reason, the user of the stapler needs to be aware of the thickness of the bundle of paper somewhat correctly before performing the binding operation.
SUMMARY OF THE INVENTION
[0004] However, as there was no determining criterion for judging the thickness of the bundle of paper in the conventional stapler, it could not be said that the user of the stapler could correctly determine the thickness of the bundle of paper and select a suitable staple.
[0005] This invention was conceived in view of the above problems, and aims to provide a stapler and stapler positioning member having a construction such that the thickness of the bundle of paper can be easily determined.
[0006] In order to achieve above the objects the present invention provides a stapler provided with a positioning member in contact with a binding object which specifies the position of the binding object, comprising a step part on at least one side face of the positioning member, wherein it is possible to determine the height of the binding object by comparison of the height of each steps of this step part with the height of the binding object.
[0007] The present invention further provides a stapler positioning member in contact with a binding object which specifies the position of the binding object, comprising a step part on at least one side face, wherein it is possible to determine the height of the binding object by comparison of the height of each steps of this step part with the height of the binding object.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a perspective view showing the overall construction of one embodiment of this invention.
[0009] [0009]FIG. 2 is a plan view showing a base.
[0010] [0010]FIG. 3 is a cross-sectional view showing a base and a positioning member.
[0011] [0011]FIG. 4 is a front view showing the positioning member.
[0012] [0012]FIG. 5 is a plan view showing the positioning member.
[0013] [0013]FIG. 6 is a base plan view also showing the positioning member.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] [0014]FIG. 1 shows the overall construction of the stapler. The base 1 of the stapler is shown in FIG. 2.
[0015] The stapler comprises a base 1 , a staple case 2 and a handle 3 etc., as shown in the figure.
[0016] The staple case 2 is attached free to rotate via a shaft 5 to a frame 4 fixed to the rear end side (right-hand side of FIG. 1 and FIG. 2) of the base 1 .The handle 3 is attached free to rotate via a shaft 6 to this staple case 2 . Due to this construction, if the user of the stapler pushes the handle 3 downwards, the staple case 2 rotates downwards, and a staple stamping part 7 is pushed against a binding object (for example, bundle of paper) installed on the base 1 . A cutting edge 8 coordinated with the handle 3 stamps out the staple held in the staple case 2 from the staple stamping plate 7 , and the bundle of paper is filed with the staple.
[0017] The base 1 is a lengthwise member which comprises the lowermost part of the stapler, the stapler being installed in a usage position (for example, on a table) in this base 1 . Rubber slip stop members 11 , 12 are attached at both ends in the longitudinal direction of the base 1 , and the position of the stapler in use is fixed.
[0018] A staple bending plate 13 is attached approximately in the center of the upper surface of the base 1 so that it is situated under the staple stamping plate 7 . Two types of staple bending parts 13 A, 13 B are provided in this staple bending plate 13 . The direction of the staple bending plate 13 is changed according to the kind of staple used, either the staple bending part 13 A or 13 B (the staple bending part 13 A or 13 B on the right-hand side of FIG. 1 and FIG. 2) being selected for staple bending immediately under the staple stamping plate 7 .
[0019] At the rear of the staple bending plate 13 (right-hand side of FIG. 1 and FIG. 2), a long hole 14 extending in front of the frame 4 is formed in the longitudinal direction of the base. A positioning member (hereafter referred to as a first member) 20 is attached in this long hole 14 such that it is free to slide along the long hole 14 . Plural female parts 15 A, 15 B are formed at a predetermined spacing on both sides of the long hole 14 , respectively.
[0020] As shown in FIG. 3 - FIG. 6, the first member 20 has step parts 30 A, 30 B on both sides of a U-shaped body part 41 . The first member 20 is provided with a shaft part 21 extending downwards from its lower end side. The first member 20 is set so that the staple case 2 is sandwiched by the body part 41 . The bundle of paper is positioned when the edge of the bundle of paper contacts a front part 22 which is oriented towards the side of the stamping plate 13 .
[0021] The shaft part 21 of the first member 20 fits into the long hole 14 . In this fitting state, an upper ring 23 , a spring 24 and a lower ring 25 are disposed sequentially on the circumference of the shaft part 21 from the underside of the base 1 . The lower ring 25 is fixed to the end of the shaft part 21 by screwing a screw 27 into a hole 26 formed coaxially with the long hole 21 . Due to this construction, the first member 20 is permanently pushed against the base 1 by the spring force of the spring 24 sandwiched between the upper ring 23 and the bottom ring 25 .
[0022] A pair of male parts 28 A, 28 B for positioning are formed on both sides of the shaft part 21 of the first member 20 . These male parts 28 A, 28 B fit into the female parts 15 A, 15 B of the base 1 , respectively, so that the motion of the first member 20 can be adjusted in the front-back direction (longitudinal direction of the long hole 14 ). Hence, the first member 20 can be set in a desired position by selecting the female parts 15 A, 15 B for positioning into which the male parts 28 A, 28 B fit. When it is desired to change the position of the first member 20 in the front-back direction, if the first member 20 is pushed forwards and backwards, the first member 20 floats up slightly against the spring force of the spring 34 , the male parts 28 A, 28 B separate from the female parts 15 A, 15 B, and the first member 20 can then be moved forward and backward.
[0023] Step-like parts 30 A, 30 B are formed symmetrically to the left and right on both sides of the first member 20 . These step parts 30 A, 30 B both have three steps, and are respectively provided with three upward-facing steps 31 A, 32 A, 33 A and 31 B, 32 B and 33 B.
[0024] The height of each step is marked on the steps 31 A to 33 A and 31 B to 33 B, respectively. Specifically, the numeral “10” which shows that the height is 10 mm is marked on the steps 31 A, 31 B, the numeral “15” which shows that the height is 15 mm is marked on the steps 32 A, 32 B and the numeral “20” which shows that the height is 20 mm is marked on the steps 33 A, 33 B.
[0025] The marking on the steps 31 A- 33 A, 31 B- 33 B need only correspond to the height of the step, and is not necessarily the actual height of the step. For example, the kind of staple corresponding to the height may be shown.
[0026] The markings on the steps 31 A- 33 A, 31 B- 33 B can also be Braille points.
[0027] From the body part 41 of the first member 20 to the step parts 30 A, 30 B, the inside is a hollow part 42 .
[0028] The first member 20 is made of resin, and is manufactured by mold forming, etc.
[0029] The operation of the device will now be described.
[0030] When a binding operation is performed with the stapler, the first member 20 is set to a suitable position, and the bundle of paper is set on the base 1 so that the edge of the bundle is in contact with the front part 22 of the first member 20 .
[0031] In this case, the bundle of paper is in contact with the front part 22 of the first member 20 , and since it is adjacent to the step parts 30 A, 30 B of the first member 20 , the height can easily be visually compared with the steps 31 A- 33 A and 31 B- 33 B of the step parts 30 A, 30 B. Therefore, based on a comparison of the thickness of the bundle of paper and the height of the steps, the user of the stapler can determine the thickness of the bundle of paper exactly, and can choose the staple corresponding to the thickness of the bundle of paper correctly.
[0032] Moreover, as markings corresponding to the height of the step are respectively displayed on the steps 31 A- 33 A and 31 B- 33 B, the user of the stapler can determine the height of each step at a glance based on this display, and can easily judge the thickness of the bundle of paper based on a comparison with the height of the step. Therefore, a suitable staple according to the thickness of the bundle of paper can be selected still more easily and correctly.
[0033] In this case, as the steps 31 A- 33 A and 31 B- 33 B are upward-facing surfaces, even when the bundle of paper is brought in contact with the first member 20 and set, the display on the steps 31 A- 33 A and 31 B- 33 B is not hidden by the bundle of paper, and can always be easily seen from above during operation.
[0034] The steps 31 A- 33 A and 31 B- 33 B are effectively flat upward-facing surfaces, so the marking can be easily made (for example, by stamping).
[0035] Moreover, as the step parts 30 A, 30 B are formed in the side parts of the first member 20 and the markings are provided on the upward-facing steps 31 A- 33 A and 31 B- 33 B, the first member 20 may be used in the same way whether the front face or the rear face of the first member 20 is used as the surface (front part 22 ) in contact with the bundle of paper. Therefore, it is not necessary to be concerned about which is the front or rear of the first member 20 during installation of the first member 20 on the base 1 , and installation is easy.
[0036] Moreover, as the shape of the step parts 30 A, 30 B is simple, it is easy to appreciate the shape also by touching the step with the finger. Therefore, the height of the bundle of paper can easily be compared with the steps 31 A- 33 A and 31 B- 33 B by touching the first member 20 , so the thickness of the bundle of paper may be determined and the exact staple selected even by a visually handicapped user, for example. In this case, if the markings on the steps 31 A- 33 A and 31 B- 33 B are Braille points, a visually handicapped user can use the stapler even more easily.
[0037] Also, if the user holds the stapler, as the step parts 30 A, 30 B are easy to hold, the step parts 30 A, 30 B do not interfere with the operation of the first member 20 .
[0038] Moreover, as the step parts 30 A, 30 B are formed on both sides of the first member 20 , the thickness of the bundle of paper can be judged at a glance by comparison with the step parts 30 A, 30 B whether viewed from the left or right of the stapler (whether viewed from the side or the rear shown in FIG. 1).
[0039] Moreover, since the hollow part 42 is formed inside the first member 20 , although the step parts 30 A, 30 B are provided for determining the thickness of the bundle of paper, the materials required for forming the first member 20 can be reduced, and cost reduction is achieved.
[0040] As the first member 20 has a simple shape comprising only the step parts 30 A, 30 B, it is easy to carry out mold forming, and it is easy to manufacture.
[0041] In the above embodiment, although the step parts 30 A, 30 B were formed symmetrically on the both sides of the first member 20 , this invention is not limited to such a form. For example, the step parts may be provided only on one side. Moreover, when the step parts are provided on both sides of the first member 20 , the left and right step parts may have different shapes.
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Step parts 30A, 30B are formed on both sides of a first member 20 attached to a base 1 of a stapler such that the member is free to slide, and the thickness of a binding object (for example, a bundle of paper) is determined by comparing with the height of steps 31A-33A, 31B-33B of the step parts 30A, 30B. Markings are made on the steps 31A-33A, 31B-33B corresponding to their height. A hollow part 42 is formed inside the first member 20.
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TECHNICAL FIELD
The invention is in the field of brushes for application of mascara to the eyelashes, mascara applications systems, and a method.
BACKGROUND OF THE INVENTION
Mascara both lengthens and thickens lashes. In order to obtain optimal results, ideally each lash should be liberally and uniformly coated with mascara, and the lashes should not clump together. In general, the more thickly mascara is applied, the greater the tendency is for the lashes to clump together. Brushes which are designed to provide thick application of mascara often have bristles spaced so closely together that the lashes cannot penetrate the bristle face to exert a combing effect on the lashes as the mascara is applied. This contributes to clumping. On the other hand, brushes with fewer bristles permit eyelashes to pass through the bristle face as mascara is applied, and thereby exert a combing effect. However, due to the reduced bristle density on such brushes, they are often not capable of thickly coating mascara onto the eyelashes because there are fewer bristles onto which mascara is loaded. A number of patents exist that address different ways of improving the application of mascara onto eyelashes while minimizing difficulties such as lash clumping and uneven distribution.
U.S. Pat. No. 5,063,947 teaches mascara brushes made from a variety of filaments, which are then subjected to rotary grinding which causes the fiber ends to become “shredded”. The patentee claims that the shredded fiber ends provide hooks, which are additional reservoirs for mascara. Then, when the brush is used to apply mascara to the lashes, the additional mascara in the reservoirs will be applied to the lash also causing heavier application. While the additional reservoirs provided by the hooks may theoretically hold additional mascara, it has been found that the mascara does not readily release from such reservoirs when the brush is stroked against the lashes. In addition, shredded ends, or hooks, provide safety issues in that they could cause eye damage if accidentally poked into the eye, particularly if the fiber used to make the brush has a larger, hence stiffer, cross-section.
U.S. Pat. No. 4,927,281 teaches mascara brushes made from fibers which have capillary channels. The patentee claims that the capillary channels provide additional reservoirs for mascara. When the brush is dipped into the mascara, it fills the reservoirs. When the brush is stroked against the lashes, the mascara in the reservoirs is alleged to deposit onto the lashes. While the theory behind such a brush design is good, as a practical matter the mascara tends to become lodged into the channels, and does not release the desired bigger load of mascara to the lashes.
A variety of other patents deal with mascara brush designs that allegedly provide better application of mascara to the lashes without the drawback of lash clumping or uneven distribution. However, none of the current brush designs is optimal for this purpose.
The object of the invention is to provide a mascara brush which is capable of applying a liberal coat of mascara to the eyelashes, yet with reduced clumping of the lashes and uneven distribution of product.
The object of the invention is to provide a mascara brush made of fibers having two or more different cross sectional diameters causing the resulting brushes to provide excellent combing and application of mascara to the lashes.
The object of the invention is to provide a mascara brush made of at least two different types of fibers, where one fiber type provides a combing effect to the lashes and the other fiber type provides improved application of mascara bulk to the lashes.
The object of the invention is to provide a mascara brush made from larger cross-section fibers which are capable of providing a combing effect to lashes, yet do not pose a safety hazard.
SUMMARY OF THE INVENTION
The invention is directed to a brush for the application of mascara to the eyelashes comprised of a central core of twisted metal wire, having gripped therebetween at least two types of fibers which extend radially from the core, wherein the first fiber has a cross-sectional diameter of less than 4 mils and the second fiber has a cross-sectional diameter of greater than 10 mils.
The invention is also directed to a mascara application system comprising, in combination;
a) a reservoir for mascara containing one opening,
b) a closure for said reservoir, said closure having and inner surface and an outer surface,
c) a wand having a proximal end comprised of a stem which is affixed to the inner surface of said closure and a distal end having affixed thereto a brush comprised of twisted metal wire having gripped therebetween at least two types of fibers which extend radially from the core, wherein the the first fiber has a cross-sectional diameter of less than 4 mils and the second fiber has a cross-sectional diameter of greater than 10 mils.
DESCRIPTION OF THE DRAWINGS
FIG. 1 : is a cross-sectional view of the mascara brush and container in accordance with the invention.
FIG. 2 : is an illustration of one intermediate step in the manufacture of mascara brushes in general.
FIG. 3 : is a close up illustration of the twisted metal wire brush containing two types of fibers.
FIG. 4 : illustrates the cross-sectional shapes of some of the types of fibers that may be used to make the brushes of the invention.
DETAILED DESCRIPTION
FIG. 1 shows a cross-sectional view of the mascara container and brush of the invention. Typically, the container comprises a reservoir for mascara 1 containing one opening 2 . There is a closure 3 for the reservoir for mascara 1 . Attached to the closure 3 is a wand 4 . The proximal end 5 of the wand 4 is attached to the inner surface 6 of the closure 3 . The distal end 7 of the wand 4 has affixed thereto a brush 8 comprised of twisted metal wire 9 having gripped therebetween at least two types of fibers 10 . One type of fiber has a cross-sectional diameter of less than 4 mils, preferably about 2 to 3.9 mils, more preferably about 2.5 to 3 mils. The term “mil” means thousandths of an inch. The second type of fiber has a cross-sectional diameter that is greater than 10 mils, preferably 10.1 to 14 mils, more preferably 11 to 12 mils. Most preferred are mascara brushes made from a mixture of fibers having a cross sectional diameter of 3 mils and 11 mils. The fibers used may be circular solid or hollow, or have varying cross-sectional shapes such as square, oblong, quadrilobal or tetralocular, trilocular, seahorse, and so on. FIG. 4 illustrates the various types of cross-sectional shapes, e.g. solid circular 3 and 11 mil, 20 , oblong 21 , and tetralocular 22 , and trilocular 23 . The tetralocular and trilocular fibers used are those described in U.S. patent application Ser. No. 09/294,107, filed Apr. 19, 1999, entitled Mascara Brush, Container and Method, which is hereby incorporated by reference in its entirety. In the case where the fiber cross-section has an irregular shape, the cross-sectional diameter of the fiber is measured at its widest point. The fibers may be made of any thermoplastic polymeric material such as nylon, polyester, polytetrafluoroethylene, polyethylene, polypropylene, and so on. Preferably the fibers are made of nylon, in particular nylon 6-10 or nylon 6-12.
When the closure 3 is attached to the reservoir for mascara 1 so that the container is in the closed position, the brush 8 is immersed in the mascara bulk 11 . Generally, the reservoir for mascara 1 , which is preferably a vial, contains a wiper 12 which is is formed from a synthetic thermoplastic material that has memory, i.e. is capable of flexure to permit removal of the brush and which returns to its original size and shape, and has a diameter slightly less than that of the brush 8 such that when the brush 8 , is pulled through the wiper 12 , excess mascara is removed from the brush. Typically, the closure 3 is affixed to the reservoir for mascara 1 by mating screw threads 13 on the closure 3 with similarly sized and shaped screw threads on the neck of the reservoir 14 thereby forming an air tight seal.
The mascara brush 8 is made using traditional machinery known in the art for this purpose. One type of machine that may be used to make such brushes is a Zahoransky MA1, made by Zahoransky GmbH in Todtnau Germany. The cut fibers used to make the brush are purchased in the form of small bundles of fibers which are cut into sections and contained in containers called pucks. The fibers in the puck are loaded into a retaining device in the machine called a magazine (not shown), which has a floor that slides back and forth (not shown) to permit the fibers to fall from the magazine into a device referred to as a rake 15 as depicted in FIG. 2 . The rake 15 contains depressions 19 into which the fibers 18 fall. The machine bends a metal wire 16 into a bobby pin or U-shape 17 . The fibers 18 in the rake 15 are then slipped between the arms of the U shaped metal wire 17 . The two ends of the wires are gripped by the machine, and the wires are twisted to form the brush. Another type of machine that may be used to make the brush is a Zahoransky MA100 which operates in essentially the same fashion except that the fibers are purchased on spools having a certain number of fibers per spool. The spooled fibers are fed into the machine and positioned between the U-shaped wire, then cut. The ends of the U-shaped wire are then twisted in the same manner to yield a brush. The brush is then trimmed to the desired shape and is ready for affixing to the wand 4 . In the case where the Zahoransky MA1 is used, the magazine is loaded with the contents of two different pucks containing fibers having the two different cross-sectional diameters specified. In the case where the Zahoransky MA100 is used, there will be at least two different spools of fiber used, one of each spool having the fiber of the cross-sectional diameter specified. Fibers 18 may be made from any synthetic material such as nylon, polyester, polytetrafluoroethylene, or a similar synthetic material.
The wire 16 used to make the brush 8 generally has a diameter from 15 to 33 mils, preferably 20 to 30 mils. The brush 8 may have a fiber density ranging from about 20 to 800 fibers per ¼ inch of brush length, preferably 25 to 500 fibers per ¼ inch brush length. Most preferred is where the brush has a fiber density of about 60 to 200 fibers per ¼ inch of brush length, i.e. so that in a brush having a length of 1 inch, there would be about 240 to 800 total fibers. Preferred fibers are a mixture of 3 mil and 11 mil fibers. Generally, the brush will contain from about 10-90% 3 mil fiber and 90-10% 11 mil fiber. In general, the brush will contain more 3 mil fibers than 11 mil fibers because the smaller fiber diameters tend to fill the rake more readily than those with larger fiber diameters. Preferably, the brush contains about 30-50% 11 mil fibers and about 50-70% 3 mil fibers, both fibers being nylon 6-12. Fibers having these specifications are available from various suppliers including DuPont. Preferred brushes will have about 10 to 22 turns of the wire helix, the turns holding the fibers in place.
The mascara brushes made according to the invention provide better application of mascara and improved combing of the lashes. The result is more thickly applied mascara with no clumping.
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A brush for the application of mascara to the eyelashes comprised of a central core of twisted metal wire, having gripped therebetween at least two types of fibers which extend radially from the core, wherein the first fiber has a cross-sectional diameter of less than 4 mils and the second fiber has a cross-sectional diameter of greater than 10 mils; and a mascara application system.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent application No. 61/383,656, filed Sep. 16, 2010, the entire content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention generally relates to manually operated finishing tools, and, more particularly, to concrete finishing tools having a trowel or a surface finishing attachment in combination with a cordless power tool and a light.
Freshly poured concrete begins to cure immediately, and may be formed, smoothed, and finished to achieve its final form using hand-held, manually operated tools that may include a trowel and a brush that may be attached to a long boom handle for finishing larger surface areas. Some finishing tools are not suitable for use on smaller surface areas and surfaces having hard to reach areas. Some finishing tools require significant manual effort to achieve a smooth or finished surface and thus result in considerable fatigue when working with larger surface areas and heavier concrete. Some finishing tools are bulky and are cumbersome when maneuvering around difficult to reach places. Some finishing tools only allow linear patterns or finishes to be applied to a concrete surface.
As can be seen, there is a need for an improved apparatus for finishing freshly poured concrete surfaces that reduces fatigue on a user, provides an ability to maneuver into hard to reach areas, and provides an ability to apply non-linear, circular or wave-like finishes to the concrete surface.
SUMMARY OF THE INVENTION
In one aspect of the present invention, a cordless concrete finishing tool comprises a body having a chassis, a guard, and frame supports; an extension handle attached to the body; a motor assembled to the body and operatively connected to a driving gear; a driven gear interconnected to the driving gear, and disposed to rotate blades that are connected to the driven gear by a quick-change coupling mechanism; an integral handle configured on the body and disposed to house a switch for the motor; and a power supply disposed to provide power for the motor.
In another aspect of the present invention, a cordless concrete finishing tool comprises a body including an injection molded polymer formed as a chassis, wherein the chassis has an integrated handle'and frame supports that support a guard; a threaded socket formed in, the body and disposed on an outside surface thereof; a rotating blade assembly housed by the guard; a motor operably connected to the rotating blade assembly by a driving gear and a driven gear; a variable speed switch operable to activate the motor; a light disposed on an outside of the body and operable to illuminate a working surface of the concrete finishing tool; and a removable power supply configured to power the motor.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side perspective view of a tool according to an embodiment of the present invention;
FIG. 2 shows a top plan view of the tool shown in FIG. 1 ; and
FIG. 3 shows a bottom plan view of the tool shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
Various inventive features are described below that can each be used independently of one another or in combination with other features.
Broadly, embodiments of the present invention generally provide a cordless concrete finishing tool that uses cordless motor technology to reduce the labor of the troweling process by reducing both a fatigue of a laborer and a time needed to trowel or finish a freshly poured surface. The finishing tool may be more practical for typical size jobs that may be more common than larger size jobs. The finishing tool may be portable and sized to make finishing hard to reach places possible and easy.
Referring to FIGS. 1-3 , side perspective, top plan, and bottom plan views of an exemplary embodiment of the present invention are shown respectively. A cordless concrete finishing tool 10 may have a body 12 , a chassis 14 , and a guard 15 held or supported by frame supports 17 . A motor 16 , which may run on a battery 24 , may be provided for the tool 10 , along with an extension handle 18 that may have a threaded stud 20 that assembles to a socket 22 that may have a threaded hole 23 . The tool 10 may also include an integral handle 25 , which may house a variable speed switch 26 . One or more lights 28 may be provided for the tool 10 . A quick-change coupling 30 may be provided for blades 32 , along with a driving gear 34 and a driven gear 36 for rotating the blades 32 , which may include a plurality of blades on a carrier, to form a rotating blade assembly.
The body 12 , chassis 14 , and guard 15 may be made from an injection molded polymer or stamped metal, and may be capable of providing a rigid body construction. According to an exemplary embodiment, an overall size of the tool 10 may be about 5 inches wide, about 4 inches tall, and about 12 inches long. The tool 10 may include a handle 25 for gripping, and may include an extension handle 18 , which may be a pole or boom, for using the tool 10 in areas that may be out of arms reach. The handle 25 and extension handle 18 may be placed on the tool 10 at any suitable position, location, or angle. The blades 32 may comprise a set of four trowel blades, for example, and may be stainless steel or any other suitable rigid material. The tool 10 may include a cordless motor 16 , which may be a battery powered motor connected to one or more high voltage (e.g., 36 volt) batteries 24 (e.g., part of a removable power pack) that may have a battery transfer switch for when the battery 24 becomes drained, along with a low battery warning indicator. The tool 10 may be water proof, and may have one or more lights 28 , which may be disposed on the body 12 or the chassis 14 , and which may be activated by the variable speed switch 26 . The tool 10 may include a guard 15 for safety, which may contain and follow a contour of the rotating blade assembly, and may be configured in various shapes or sizes to prevent debris from being thrown by the rotating blade assembly and prevent from items from interfering therewith. A quick change coupling 30 may secure the blades 32 and may provide a tool-free replacement for possible optional attachments (e.g., float trowels or finish trowels).
The blades 32 may comprise a suitable blade configuration for troweling and may include a suitable connection means to attach the trowels to the motor 16 . The guard 15 may enclose the blades 32 , and may attach to the body 12 of the tool 10 . One or more gears may be provided on the inside of the body 12 , which may be configured to transfer power from the motor 16 to the driven gear 36 , which in turn may spin the trowels. An on/off switch may be provided which can allow power to get to the motor and drive the gears. The trowels may be configured to spin in either direction for smoothing the concrete.
To make an embodiment of the present invention, the body 12 may be molded or stamped and the motor 16 may be mounted thereto. The gears 34 , 36 may be mounted to the body 12 and interconnected to the motor, which may be connected to all electrical connections and switch 26 . The trowels may be manufactured and welded.
In an alternative embodiment, the trowel heads may be changed from a float trowel to a finish trowel. The battery may be located in various locations, and the location of the lights may vary. The drive gears 34 , 36 may vary in configuration to suit a particular purpose. The drive gears 34 , 36 may be interconnected by a belt (e.g., toothed, V-belt, or flat belt) or chain. The body 12 may be configured in different styles having different types of guards 15 in various colors.
To use an embodiment of the tool 10 , a user may install a battery or batteries into the tool 10 , select the type of trowel needed for the job, and assemble the trowel on the quick change coupling 30 . The user may then place the tool on a slab of concrete and activate the switch 26 , which may allow the rotating motion of the trowels of the blades 32 to finish the concrete.
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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A concrete finishing tool includes a body having a chassis, a guard, and frame supports. An extension handle is attached to the body, and a motor is attached to the body and operatively connected to a driving gear and driven gear to rotate blades having a quick change coupling mechanism. An integrated handle is configured on the body and houses a switch for the motor that is powered by a power supply.
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FIELD OF THE INVENTION
[0001] The present invention relates to a base paper (raw paper), which can be made into various processed paper, such as the paper sheet of a textbook, the thin layer of a notebook or wrap paper, the flake structure of household paper or the base layer of office paper. The present invention also relates to a preparation method of the base paper.
BACKGROUND OF THE INVENTION
[0002] In the prior art, there exist the problems of stimulation to eyes caused by the whiteness of textbook, notebook and duplicating paper, and the use of a large number of chemicals resulting in environmental pollution.
[0000] No other dyes, pigments or dyeware are added into the base paper of the present invention. In most cases, the base paper is not bleached or just lightly bleached, and the resulting base paper per se has a natural yellow color which is beneficial to the vision, so as to achieve the purpose of protecting eyes and preventing myopia. At the same time, by employing 100% of the base paper, the damage of chemicals such as dioxin to humans can be avoided, that is to say, the base paper of the present application is environment-friendly.
SUMMARY OF THE INVENTION
[0003] A primary object of the present invention is to provide a base paper;
[0004] Another object of the present invention is to provide a preparation method of the base paper.
[0005] A further object of the present invention is to provide the use of the base paper in paper production.
[0006] In order to achieve the objects mentioned above, the invention takes the following technical scheme:
[0000] A base paper, which is made from mixed pulp comprising straw pulp and industry pulp, wherein the weight percent of the straw pulp is 10-100 wt. % of the mixed pulp, preferably 30-90 wt. %, more preferably 40-80 wt. %; the straw pulp has a hardness with potassium permanganate value of 10-17, an average fiber length of 0.1-2.5 mm, a tensile index of 23-57 Nm/g, a tear index of 3.0-6.0 mN·m 2 /g, and a folding number of 2-6 kPa·m 2 /g; and the straw pulp has a whiteness of 28-50%, preferably 30-45%, more preferably 25-43%.
[0007] A method for preparing the base paper, wherein the method comprises: putting the grass material into a cooker, adding cooking liquor, and then heating the cooking liquor to 100-200°, increasing pressure to 0.3-0.9 MPa, keeping cooking for 150-250minutes, and obtaining the straw pulp after pressing and washing; and in the cooking liquor, ammonium sulfite is used in an amount of 5-20% of bone dry raw material by weight, sodium hydroxide is used in an amount of 0-15% of the bone dry raw material by weight, and the liquor ratio is 1:2-15.
[0008] Preferably, the method comprises: putting the grass material into the cooker, adding cooking liquor, and then heating the cooking liquor to 156-173°, increasing pressure to 0.6-0.75 MPa, keeping cooking for 180-220 minutes, and obtaining the straw pulp after pressing and washing; and in the cooking liquor, ammonium sulfite is used in an amount of 9-15% of the bone dry raw material by weight, sodium hydroxide is used in an amount of 0-8% of the bone dry raw material by weight, and the liquor ratio is 1:6-10.
[0009] The method further comprises oxygen delignification after washing, which comprises: pumping the pulp after cooking or washing to an oxygen delignification reaction tower for a reaction of 60-90 minutes and obtaining the straw pulp, wherein, a temperature and a pressure of the pulp is respectively 90-100° and 0.9-1.2 MPa at the inlet of the reaction tower, and 95-105° and 0.2-0.4 MPa at the outlet; and the alkali used in the oxygen delignification is 2-4% of bone dry pulp based on sodium hydroxide, and oxygen is added in an amount of 20-40 kg per ton of bone dry pulp.
[0010] The method further comprises oxygen delignification, which comprises: 1) regulating concentration of high-hardness pulp which is obtained after cooking; 2) pumping the high-hardness pulp to an oxygen delignification reaction tower and adding sodium hydroxide and oxygen; 3) the high-hardness pulp being subjected to delignification reaction in the oxygen delignification reaction tower, wherein the concentration of high-hardness pulp refers to regulating the concentration of high-hardness pulp to 8-18%; the oxygen delignification is preferably single stage and carried out in the oxygen delignification reaction tower.
[0011] Preferably, during the oxygen delignification, a temperature and a pressure of the pulp is respectively 95-100° and 0.9-1.2 MPa at an inlet of the reaction tower, and 100-105° and 0.2-0.4 MPa at an outlet.
[0012] Alkali used in the oxygen delignification is 2-4% of bone dry pulp based on sodium hydroxide, oxygen is added in an amount of 20-40 kg per ton of bone dry pulp; and the straw pulp reacts in the reaction tower for 60-90 min.
[0013] Preferably, the pulp is heated to 70° and conveyed to a pulp pipe before the oxygen delignification.
[0014] Preferably, a magnesium salt is added in amount of 0.2-1% of the bone dry raw material by weight as a protective agent in the oxygen delignification.
[0015] Preferably, a bleacher is added in an amount of 1/10˜¼ the one of the prior art.
[0016] The invention has the following advantages:
(1) Textbook made from the base paper of the invention as material can form the yellow vision environment to people without adding other dyes, pigments or colorant, which achieves the purpose of protecting the eyes, prevention and treatment of myopia; (2) The straw pulp without bleaching in the invention avoids health threats caused by dioxins and other environmental problem; (3) Products made by the base paper are not added dye, pigment or colorant, and the straw pulp is not need to be bleached, which reduces the cost of manufacturing.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] The following embodiments further illustrates the technical solution of the present invention. It will contribute to understand the advantages and effect of the invention. The embodiments do not limit the scope of protection of the invention, and the scope of protection of the invention is decided by the claims.
Example 1
[0021] The present example relates to the preparation method of the straw pulp.
[0022] The straw pulp of the present example is obtained after cooking and washing, or obtained after cooking, washing and oxygen delignification.
[0023] The cooking of the invention can employ a common cooking method in the prior art, such as ammonium sulfite, sodium hydroxide, anthraquinone-sodium hydroxide, sulfate, or anthraquinone-alkali sodium sulfite cooking methods.
[0024] The method preferably comprises: putting the grass material into a cooker, adding cooking liquor to the cooker and heating to 100-200°, increasing pressure to 0.3-0.9 MPa, keeping cooking for 150-250 minutes, and obtaining the straw pulp after pressing and washing. Wherein, in the cooking liquor, the ammonium sulfite is used in an amount of 5-20% of the bone dry raw material by weight, the sodium hydroxide is used in an amount of 0-15% of the bone dry raw material by weight, and the liquor ratio is 1:2-15.
[0025] More preferably comprises: putting the grass material into a cooker, adding cooking liquor to the cooker and heating to 156-173°, increasing pressure to 0.6-0.75 MPa, keeping cooking for 180-220 minutes, and obtaining the straw pulp after pressing and washing. Wherein, in the cooking liquor, the ammonium sulfite is used in an amount of 9-15% of the bone dry raw material by weight, the sodium hydroxide is used in an amount of 0-8% of the bone dry raw material by weight, and liquor ratio is 1:6-10.
[0026] The oxygen delignification is carried out after washing to get the straw pulp of the invention, and the pulp is obtained.
[0027] The oxygen delignification of the present invention comprises: pumping the pulp after cooking or washing to an oxygen delignification reaction tower, in which the temperature and pressure of the pulp is respectively 90-100° and 0.9-1.2 MPa at an inlet of the reaction tower, and 95-105° and 0.2-0.6 MPa at an outlet.
[0028] Wherein, alkali is used in the oxygen delignification in an amount of 2-4% of bone dry pulp based on sodium hydroxide, and oxygen is added in an amount of 20-40 kg for every ton of bone dry pulp for keeping reaction for 60-90 min to obtain the straw pulp.
[0029] The straw pulp of the invention has a hardness with potassium permanganate number of 10-17, an average fiber length of 0.1-2.5 mm, a tensile index of 23-57 Nm/g, a tear index of 3.0-6.0 mN·m 2 /g, and a folding number of 2-6 kPa·m 2 /g.
[0030] The straw pulp of the invention has a whiteness of 28-50%, preferably 30-45%, more preferably 25-43%.
[0031] The straw pulp of the present example is obtained from one or more of wheat straw, rice straw, cotton stalk, giant reed and reed, preferably wheat straw and rice straw.
[0032] The example also relates to a mixture of pulp which contains other industrial paper pulp. The industrial paper pulp comprises one or more of bagasse pulp, wood pulp, cotton pulp, bamboo pulp or secondary fiber.
[0033] The secondary fiber is made from recycled waste paper pulp fibers.
[0034] The straw pulp has a weight ratio of 10-100% of the mixed pulp, preferably 30-90%, more preferably 40-80%.
Example 2
[0035] The present example relates to a straw pulp which is the same as that of example 1 except the following difference: the base paper is made from the straw pulp with content of 100% which has a hardness with potassium permanganate value of 10-17, an average fiber length of 0.1-2.5 mm, a tensile index of 23-57 Nm/g, a tear index of 3.0-6.0 mN·m 2 /g, a folding number of 2-6 kPa·m 2 /g.
[0036] The present example also relates to an anti-myopia base paper of textbooks which is made from the mixed pulp, wherein, the pages of textbooks with a whiteness of 40-76%, preferably 50˜76%, more preferably 60˜76% are made from straw pulp without adding dyes, pigments or colorant. Further, the pages have an opacity of 70˜100%, preferably 80˜99%, more preferably 85˜95%.
[0037] The present example also relates to a base paper of publications which is made from the mixed pulp, wherein, the base paper refers to the page here. The paper made from the mixed pulp without adding any dye, pigment or colorant has a whiteness of 40-76%, preferably 50˜76%, more preferably 60˜76%. Further, the page has an opacity of 70˜100%, preferably 80˜99%, more preferably 85˜95%.
Example 3
[0038] This example is the same as example 1, except that straw pulp fiber and wood pulp fiber obtained by following method are interweaved each other to form a network structure which makes the page multi porous, rough, has large area of optical joint surface and high opacity.
[0039] The preparation method and properties of writing paper are as follows: putting the straw into a cooker, adding cooking liquor to the cooker and heating to 165°, increasing pressure to 0.7 MPa, keeping cooking for 240 minutes, and obtaining the straw pulp after pressing and washing. Wherein, in the cooking liquor, ammonium sulfite is used in an amount of 15% of the bone dry raw material by weight, sodium hydroxide is used in an amount of 5% of the bone dry raw material by weight, and liquor ratio is 1:8. The straw pulp has a hardness with potassium permanganate value of 16, a tensile index of 28 Nm/g, a tear index of 3.9 mN·m 2 /g, a folding number of 3.4 kPa·m 2 /g, and a whiteness of 35%. The straw pulp and wood pulp are mixed to make the writing paper (base paper) with dirt count of 75/·m 2 per 0.3-1.5 mm 2 , opacity of 91%, whiteness of 51%.
[0040] The preparation method and properties of food wrap paper are as follows: putting the straw into a cooker, adding cooking liquor to the cooker and heating to 160°, increasing pressure to 0.65 MPa, keeping cooking for 200 minutes, and obtaining the straw pulp after pressing and washing. Wherein, in the cooking liquor, ammonium sulfite is used in an amount of 10% of the bone dry raw material by weight, sodium hydroxide is used in an amount of 5% of the bone dry raw material by weight, and liquor ratio is 1:8. The straw pulp has a hardness with potassium permanganate value of 16, a tensile index of 38 Nm/g, a tear index of 4.8 mN·m 2 /g, a folding number of 4.6 kPa·m 2 /g, a whiteness of 35%. The pulp is used to make the food wrap paper (base paper) with dirt count of 120/·m 2 per 0.3-2.0 mm 2 , bursting strength of 75 kPa, and whiteness of 28-60%.
[0041] The dirt count of the invention is measured by the testing method of national standard GB/T 1541-1989 (Paper and board-Determination of dirt).
Example 4
[0042] The straw pulp fiber of the invention is defined as the straw pulp fiber which is obtained by the method of the prior art, such as cooking and washing, or cooking, washing and oxygen delignification. The cooking of the invention comprises, but not limited to, ammonium sulfite and alkaline method. The alkaline method comprises anthraquinone-sodium hydroxide, sulfate or basic sodium sulfite cooking methods.
[0043] The preferable cooking method of the present example is as follows: putting the straw material into a cooker, adding cooking liquor to the cooker and then heating to 100-200°, increasing pressure to 0.3-0.9 MPa, and keeping cooking for 150-250 minutes, and obtaining the straw pulp after pressing and washing. Wherein, in the cooking liquor, ammonium sulfite is used in an amount of 5-20% of the bone dry raw material by weight, sodium hydroxide is used in an amount of 0-15% of the bone dry raw material by weight, and liquor ratio is 1:2-15.
[0044] An oxygen delignification can be carried out after cooking or washing, wherein the oxygen delignification comprises:
1) regulating concentration of high-hardness pulp obtained after cooking; 2) pumping the high-hardness pulp to an oxygen delignification reaction tower and adding sodium hydroxide and oxygen; 3) carrying out delignification reaction in the oxygen delignification reaction tower .
[0048] Wherein, the concentration of high-hardness pulp is regulated to 8-18%. In other words, the oxygen delignification is carried out under a high concentration.
[0049] Preferably, the oxygen delignification is single stage and executed in the oxygen delignification reaction tower, in which, the temperature and pressure of the pulp is respectively 95-100° and 0.9-1.2 MPa at an inlet of the reaction tower, and 100-105° and 0.2-0.4 MPa at an outlet.
[0050] Wherein, alkali used in the oxygen delignification treatment is 2-4% of bone dry pulp based on sodium hydroxide, and oxygen is added in an amount of 20-40 kg for every ton of bone dry pulp; and the straw pulp reacts in the reaction tower for 60-90 min.
[0051] Preferably, the pulp is heated to 70° and conveyed to a pulp pipe before the oxygen delignification.
[0052] Preferably, magnesium salt with amount of 0.2-1% of the bone dry raw material by weight is added as protective agent.
[0053] Preferably, high-hardness of the pulp obtained after the oxygen delignification is potassium permanganate value of 10-14, which is equivalent to 13-19.8 Kappa number, more preferably potassium permanganate value of 11-13, which is equivalent to 14.5-17.9 Kappa number.
[0054] The straw pulp of the present example is obtained from one or more of wheat straw, rice straw, cotton stalk, giant reed and reed, preferably wheat straw and rice straw.
[0055] The example also relates to a mixture of pulp which contains other industrial paper pulp, wherein the industrial paper pulp comprises one or more of bagasse pulp, wood pulp, cotton pulp, bamboo pulp or secondary fiber which is made from recycled waste paper pulp fibers.
[0056] Wherein the straw fiber preferably has a ratio of 10˜100 wt. %, more preferably 30˜97%, further preferably 51˜95%, most preferably 71˜93%.
[0057] The household paper of the present example can be prepared only by straw pulp fibers or by straw pulp fibers with other plant pulp fiber, such as wood pulp fiber, bamboo pulp fiber and so on.
[0058] The base paper of household paper has a tensile index of 1.5˜4 N·m/g, preferably 2˜3.5 N·m/g, more preferably 2.3˜3.2 N·m/g, and the visible dust of 0.3 mm 2 ˜2.0 mm 2 is 10˜500/m 2 , preferably 20˜400/m 2 , more preferably 30˜250/m 2 , and the visible hole of 2˜5 mm on the household paper is 2˜100, preferably 5˜80, more preferably 20˜60.
[0059] The dust and hole of the present example are all meet with the national standard definition, such as GB/T20808-2006. The base paper of the household paper of the present example has a basis weight of 10˜70 g/m 2 , preferably 15˜50 g/m 2 , more preferably 20˜40 g/m 2 . The color of the base paper is same as that of the straw pulp fiber and other plant pulp fiber themselves. The household paper of the invention refers to toilet paper, towel paper, wiping paper or tissue paper. Following is the specific embodiments:
[0060] A flake tissue paper, which is made up by one base layer manufactured by 50% straw pulp fibers and 50% of the unbleached wood pulp fibers, wherein the base paper has an basis weight of 10 g/m 2 , a whiteness of 45%, the color of the base paper is the color of the straw fiber and wood pulp fiber themselves, and the base paper has a tensile index of 1.5 N·m/g, particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 50 per square meter, and holes of 2˜5 mm of 3˜10.
[0061] A flake tissue paper, which is composed by three base layers manufactured by 100% of the straw pulp fibers, wherein the base layer has an basis weight of 70 g/m 2 , a tensile index of 4 N·m/g, a whiteness of 35%, particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 400-500 per square meter, holes of 2˜5 mm of 50˜100, and the color of the paper is the color of the straw fiber itself.
[0062] A flake towel paper, which is composed by two base layers manufactured by 30% of the straw pulp fibers and 70% of the wood pulp fibers, wherein the base layer has a basis weight of 15 g/m 2 , a tensile index of 2 N·m/g, a whiteness of 55-70%, particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 20 per square meter, and holes of 2˜5 mm of 70˜90, and the color of the paper is the color of the straw fiber and wood pulp fiber themselves.
[0063] A flake wiping paper, which is composed by four base layers manufactured by 60% of the straw pulp fibers and 40% of the wood pulp fibers, wherein the base layer has an basis weight of 50 g/m 2 , a tensile index of 3.5 N·m/g, a whiteness of 40%, particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 300 per square meter, and holes of 2˜5 mm of 30˜50, and the color of the paper is the color of the straw fiber and wood pulp fiber themselves.
[0064] A drum toilet paper, which is composed by three base layers manufactured by 80% of the straw pulp fibers and 20% of the wood pulp fibers, wherein the base layer has an basis weight of 20 g/m 2 , a tensile index of 2.5 N·m/g, a whiteness of 38-40%, particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 450 per square meter, and holes of 2˜5 mm of 10˜20, and the color of the paper is the color of the straw fiber and wood pulp fiber themselves.
[0065] A flake toilet paper made into long strip and folded, which is composed by two base layers manufactured by 10% of the straw pulp fibers and 90% of the bleached wood pulp fibers, wherein the base layer has a basis weight of 30-40 g/m 2 , a tensile index of 3-3.2 N·m/g, a whiteness of 65-75%, particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 20 per square meter, and holes of 2˜5 mm of 3˜15.
Example 5
[0066] This example is the same as example 4 except that, the composite layer of the office paper has a breaking length of 1.5˜5 km, preferably 2˜4.5 km, more preferably 2.5˜4 km, an opacity of 70˜100%, preferably 80˜99%, more preferably 85˜95%, a visible dust of 0.3 mm 2 ˜2.0 mm 2 of 10˜500/m 2 , preferably 20˜400/m 2 , more preferably 30˜250/m 2 , a whiteness of 35˜75%, preferably 35˜65%, more preferably 40˜60%, a basis weight of 20˜160 g/m 2 , preferably 30˜80 g/m 2 , more preferably 40˜70 g/m 2 , wherein, the base layer of the office paper has a Hue L values of 65-95, preferably 70-94, more preferably 80-91, a value of 0-5, preferably 0-4.5, more preferably 0-3, and b value of 0-40, preferably 0-35, more preferably 0-30.
[0067] At least one side of the base layer of office paper is coated by adhesive layer. It means that one side or both two sides can be coated by adhesive layer. The adhesive layer can be set by the method of the prior art, such as taking one or more of starch, animals glue and polyolefin to set adhesive layer, for example, using oxidized starch, polyacrylamide, polyethylene-maleic anhydride polymers, acrylic latex, modified polyvinyl alcohol, sodium carboxymethyl cellulose or styrene-acrylate and so on, wherein, the method of prior art comprises press sizing, tube sizing, off-machine sizing, spray sizing, roller press sizing or calendar sizing, wherein the amount of adhesive can be same as that of the prior art, preferably 1˜20 kg per ton of paper, more preferably 5˜15 kg per ton of paper, most preferably 7˜12 kg per ton of paper, wherein, the specific embodiments are as follows :
[0068] A flake offset printing paper has a basis weight of 20˜50 g/m 2 , a breaking length of 1.5˜2.5 km, a particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 300 per square meter, and an opacity of 100%, width of 10 cm, and length of 38 cm, which comprises a base layer manufactured by 50% of the straw pulp fibers and 50% of the unbleached wood pulp, wherein, both sides of the base layer are coated with adhesive, and the base layer has a whiteness of 45-50%, Hue L values of 50-89, a value of 0-2 and b value of 0-20.
[0069] A flake writing paper has a particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 500 per square meter and an opacity of 95%, which comprises a base layer manufactured by 100% of the straw pulp fibers, wherein, the base layer has a whiteness of 35-45%, one side of the base layer is coated with adhesive, and the color of the base layer is the color of straw fiber itself.
[0070] A flake writing paper has a particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 200 per square meter and an opacity of 80%, which comprises a base layer manufactured by 60% of the straw pulp fibers and 40% of the unbleached wood pulp fibers, wherein, the base layer has a whiteness of 40%, Hue L values of 65-75, a value of 2.5-3 and b value of 20-35.
[0071] A typing paper has a particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 450 per square meter, an opacity of 92% and width of 10 cm, length of 20 cm, wherein, the middle base layer is manufactured by 80% of the straw pulp fibers and 20% of the wood pulp fibers, which has a whiteness of 38-45%, Hue L values of 70-80, a value of 3.5-5, and b value of 30-35, wherein, two surface of the base layer are coated by adhesive layer of modified PVA, with the adhesive used of 10 kg per ton of paper.
[0072] A sheet typing paper with a particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 20 per square meter, and an opacity of 94%, which comprises a base layer manufactured by 10% of the straw pulp fibers and 90% of the wood pulp fibers, wherein, the base layer has a whiteness of 55-65%.
[0073] The base paper of office paper in the present invention is manufactured by straw pulp fibers and/or other plant pulp fibers, wherein the manufacturing refers to any manufacturing in the prior art, for example, mixing the straw pulp and other plant pulp after beating respectively, or mixing the straw pulp and other plant pulp before beating, which makes the straw fiber and other plant pulp fiber has a certain space structure, such as the space structure of the prior art.
[0074] The office paper refers to electrostatic copy paper, writing paper, offset printing paper or typing paper.
Example 6
[0075] This example is the same as example 4 and example 5 except that steps of cooking, washing and bleaching with small amount of bleacher can be carried out, wherein the bleacher with a small amount used in the present invention is 1/10˜¼ of the prior art. The base paper made by the straw pulp fiber obtained after oxygen delignification or bleaching with small amount of bleacher can be made into household paper and office paper.
[0076] The special embodiment is as follows: an electrostatic copy paper with a basis weight of 130˜160 g/m 2 , a breaking length of 2˜4.5 km, a particulate matter of 0.3 mm 2 ˜2.0 mm 2 of less than 20 per square meter, and an opacity of 92%, which comprises a base layer made by 30% straw fiber and 70% bleached wood pulp fiber, wherein the straw fiber is obtained after cooking, washing and bleaching with a small amount of ¼ of the prior art of bleacher, wherein both sides of the base layer are coated with adhesive, and the base layer has a whiteness of 65˜75%, Hue L values of 55-80, a value of 1.5-5, and b value of 9-35. Wherein, the electrostatic copy paper of the invention has a sizing of polyacrylamide.
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A raw paper prepared by a mixed pulp including straw pulp, which can be used to prepare textbooks, writing papers and office paper with good performance, and the producing method of said raw paper are provided. The weight proportion of the straw pulp in the mixed stock is from 10% to 100%, and the straw pulp has a hardness of KMnO 4 value 10-17, an average fiber length of 0.1-2.5 mm, a tensile index of 23-57 Nm/g, a tearing index of 3.0-6.0 mN·m2/g, a folding endurance index of 2-6 kPa·m2/g and a whiteness of 28-50%. Either, the L value of the hue of said raw paper is 65-95, a value is 0-5, and b value is 0-40. The KMnO 4 value of hardness of the pulp after oxygen delignification is 10-14. The method includes: adding grass-series raw material into a digester, then adding cooking liquor, heating the cooking liquor to 100-200°, pressurizing to 0.3-0.9 MPa, cooking for 150-250 min, extruding the pulp, washing and obtaining the straw pulp. The amount of the ammonium sulfite of the cooking reagent is 5-20% of the absolute dry material, and the amount of the sodium hydroxide is 0-15% of the absolute dry material, the liquor ratio is 1:2-15.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/581,018, filed 16 Oct. 2009, now U.S. Pat. No. 8,116,225 which application claims priority to U.S. provisional patent application Ser. No. 61/110,257 filed 31 Oct. 2008, each of which application is incorporated herein in its entirety by this reference thereto.
BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates to data transmission. More particularly, the invention relates to channel bandwidth estimating methods on hybrid technology wireless links.
2. Description of the Prior Art
Peak and sustainable data rates achievable in mobile broadband radio access networks have evolved by three orders of magnitude over the last decade. In many cases, three generations of radio technologies co-exist in the same geography, presenting data rates from few kbps to few hundred kbps to few mbps, all supported by same mobile device and same radio access network.
In addition to static attributes that differentiate three generations of radio access technologies, such as fundamental channelization characteristics of radio interfaces, dynamic variations introduced by multi-user loading and changing propagation conditions can make the per-user perceived bandwidth vary substantially very quickly.
These dynamic variations pose challenges to any application that relies on accurate channel estimation for bandwidth and data rate calculations, particularly if the task needs to be performed at the TCP/IP level. Accurate bandwidth and data rate calculations are needed for such scenarios as streaming video, voice over IP (VOIP), quality of service (QoS) enforcement, network characterization, network tuning, load estimation, and network optimization.
Prior art approaches to bandwidth estimation include such techniques as straight averaging, in which a determination is made of bytes received over a particular time interval. Such approaches use packet trains, where an a priori known packet sequence is sent, i.e. both the sender and the receiver know about this packet sequence. One disadvantage of sending a priori packet trains is that such technique is fundamentally disruptive to the network because it takes time to make the measurement, i.e. it does not provide a real-time value of available bandwidth, and because it adds overhead to network bandwidth by consuming such bandwidth during packet train network transit time.
It would be advantageous to provide a solution to the problem of accurately estimating channel bandwidth.
SUMMARY OF THE INVENTION
An embodiment of the invention provides a bandwidth estimation algorithm. A primary objective of the algorithm is to detect peak and/or average per-user bandwidth of data communication networks, such as narrowband and broadband wide-area radio access networks. The estimation can be performed at the TCP/IP layer with no lower layer (PHY, MAC, etc.) information assumed to be available. However, the bandwidth estimation algorithm can be applied to anywhere bandwidth needs to be estimated as well, such as DSL, cable networks, or satellite systems.
In particular, a bandwidth estimation algorithm on shared links detects peaks and/or average per-user bandwidth. Estimating is performed at the transport or IP layer with no assistance from lower layer (PHY, MAC, etc.) and the techniques can be used for any of adjusting the level of video optimization to the available bandwidth; driving QoS decisions at the transmitter based on available bandwidth; improving QoS enforcement during transitions among hybrid technologies on a wireless links; and correcting estimates on devices delivering bursty payload.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the phenomena of dynamic variations in the inter-packet arrival times;
FIG. 2 shows that dynamic packet variations can happen in any scenario in which the sender needs to send packets to a receiver;
FIG. 3 is a flow chart that describes the general flow of the logic in a channel bandwidth estimation mechanism according to the invention; and
FIG. 4 is a block schematic diagram of a machine in the exemplary form of a computer system within which a set of instructions may be programmed to cause the machine to execute the logic steps of FIG. 3 according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates the phenomena of dynamic variations in the inter-packet arrival times. As can be seen from FIG. 1 , the packet arrival pattern and the packet sender pattern are not always correlated. In particular, in the EVDO family and the HSPA family, the most dominant mobile broadband networks today, the users share a ‘big fat pipe’ model, or a ‘large shared channel’ model, of a radio channel in time-divided manner, as opposed to dedicated radio channels for each user. The architecture shown in FIG. 1 is typical of the environment in which the invention here disclosed may be practiced and those skilled in the art will appreciate both how to implement such an environment and the many variations available in constructing such an environment. For example, while FIGS. 1 and 2 show an architecture in which unidirectional bandwidth estimation may be made from a server to a client (or from a client to a server), those skilled in the art will appreciate that the invention is applicable to bandwidth estimation bidirectionally as well, e.g. from a client to a server and from a server to a client.
FIG. 1 illustrates the usage scenario for sending packets through a radio access network. However, dynamic packet variations can happen in any scenario in which the sender needs to send packets to a receiver, as illustrated in the FIG. 2 .
A common approach toward bandwidth estimation taken by many applications and algorithms involves accumulating received bytes over time, using some pre-determined criteria, and deriving the perceived bandwidth. This approach works well when the radio channel is dedicated or semi-dedicated. Examples of such radio access network (RAN) technologies include 1xRTT, GRPS, and EDGE. However, when such solutions are applied in shared channel cases, as shown in FIG. 2 , those calculations can yield incorrect estimations. Depending on specific criteria, such as accumulation period and packet types used for those calculations, these estimates can vary from being below the long-term temporal average to values above the peak instantaneous theoretical throughput. For example, if the instantaneous bandwidth is calculated by dividing the total number of bytes by the accumulation period, and if a number of packets arrive at the same time within a very short period, then the reported bandwidth can be inaccurately characterized as very high. This then has a detrimental impact on such things as the TCP layer send window and the QoS enforcement policy.
In the invention presented here, these drawbacks are avoided. A key contribution of the invention is the ability to detect a burst of packets delivered to a client device by the radio channel and to use that burst to calculate a bandwidth estimate sample. Several such samples are then used to compute a filtered average, which then becomes the reportable bandwidth estimate. A key assumption for this algorithm is that the algorithm is operating in the TCP/IP layer, either in application (user) space or kernel space, and that the underlying radio modem drivers delivers packets in a temporally correlated pattern relative to that of the actual arrival of constituent payload over the radio interface. Those skilled in the art will appreciate that many variations on this approach are possible within the confines of the invention herein.
Algorithm
FIG. 3 is a flow chart that describes the general flow of the logic of the channel bandwidth estimation algorithm according to a presently preferred embodiment of the invention. An embodiment of the algorithm goes through the following steps for every packet that is received, as denoted in FIG. 3 :
1. A new packet is received. The timestamp of the packet is noted. 2. Calculate the inter-arrival time, which is the elapsed time between the timestamp noted for a previously received packet and the current packet. 3. Calculate the minimum inter-burst time, which must be re-calculated for every packet that arrives. Inter-burst time is defined as the time between bursts of packets, and the minimum inter-burst is the time that is used to determine if the inter-arrival time between packets is sufficiently long to determine two respective packets are not part of the same burst but are related to separate bursts for the purpose of bandwidth estimation.
The calculation of the minimum inter-burst time is a function of the current average of packet inter-arrival times, the average number of packets in a burst at the sender, and a pair of configurable rails (a set of configurable parameters) for maximum and minimum values.
In one embodiment of the invention, for purposes of calculating the minimum inter-burst time, the minimum inter-burst time is directly proportional to the average inter-arrival time. In another implementation of this function, the minimum inter-burst time is three times the average inter-arrival time. Other approaches may be used as well, as will be appreciated by the skilled person when practicing the herein disclosed invention.
The minimum inter-burst time is useful for detecting different bursts, as well as for adapting to changing channel conditions and in particular different radio interfaces. For example, HSDPA typically has 50-100 ms inter-burst time and 1-5 ms inter-arrival time, while 1X RTT typically has 150 ms inter-burst time and 60-80 ms inter-arrival time. By using the inter-arrival of the packets, which can be measured, and calculating the minimum inter-burst time in this way, the algorithm can automatically adapt to the use of HSDPA or 1XRTT in a hands-off approach without having to specify the network in use and without having to manually set parameters.
4. Check the inter-arrival time to see if it is greater than a minimum configurable value and less than a configurable upper limit, and also check to see if the packet length is greater than a configurable minimum packet size. If all conditions are satisfied, then go to step 5 . Otherwise, skip step 5 and go to step 6. 5. Calculate the average packet inter-arrival time. The calculation of the average packet inter-arrival time can be a moving average and/or a weighted average. 6. Determine how many back-to-back, closely spaced packet arrivals the algorithm should be able to tolerate. Two packets are considered closely spaced if their inter-arrival time falls below a configurable minimum inter-arrival time.
High-speed network packets arrive on the order of few tens of milliseconds on average, which justifies occasional back-to-back zero ms inter-arrivals. Therefore, the algorithm tolerates a number of back-to-back closely spaced packet arrivals. However, due to the nature of underlying OS and device drivers, packets are not always delivered with the same relative inter-arrival pattern as that of their actual arrival patterns over the air interface. For this reason, an upper bound is set on the tolerable number of closely spaced packet arrivals within a packet burst. However, narrowband networks are in the several tens of milliseconds to the few hundred milliseconds range. Therefore, the algorithm is adaptive and can recalculate this upper bound every time a packet arrives.
7. Check to see if the inter-arrival time is less than a configurable minimum. If it is, the packet is closely spaced; go to step 8 . Otherwise, go to step 9 . 8. Adjust the count of closely spaced packets. Go to step 10 . 9. Reset the count of closely spaced packets. Go to step 10 . 10. Check the following for criteria, all of which have to be true for the current packet to be part of a packet burst for use in the bandwidth calculation:
The inter-arrival time is less than the minimum inter-burst time calculated in Step 3 . The number of back-to-back closely spaced packets counted in steps 7 through 9 is less than the tolerable number computed in Step 6 . The number of packets accumulated in the current burst is less than a configured maximum. The size of this packet is greater than a configured minimum. Techniques, such as multiplexing data entry from multiple application layer connections served through a gateway server, may be applied to create packet sizes greater than a configured minimum. Multiplexing of data can thus lead to better bandwidth estimates without having to discard a significant number of samples.
If all these conditions are true, then go to step 11 . Otherwise, go to step 14 .
11. Check to see if burst tracking is currently on. If tracking is on, go to step 13 . Otherwise, go to step 12 . 12. Start burst tracking. Go to step 13 . 13. Update burst tracking counters. Go to step 19 . 14. Check to see if burst tracking is currently on. If tracking is on, go to step 15 . Otherwise, go to step 19 . 15. Check to see if the tracking duration, i.e. the elapsed time between the first and last packet of the burst, is greater than a configurable minimum tracking duration, and the number of packets within the burst is greater than a configurable minimum number of packets. If both conditions are true, go to step 18 . Otherwise go to step 16 . 16. Estimate the bandwidth for this burst by dividing the number of accumulated bytes by the tracking duration. The bandwidth value is checked whether it falls within the minimum and maximum bandwidth values. This sample is added to a running set of previous samples. The running set is of configurable length. 17. Estimate the average reportable bandwidth value, from the running set of previous bandwidth samples. The average can be a weighted average, with fixed coefficients or variable coefficients. 18. Stop burst tracking. Update the appropriate counters. 19. Wait for another packet to arrive.
Configuration
A presently preferred embodiment of the herein disclosed bandwidth estimation algorithm introduces the following configuration parameters. These attributes are parameterized to give flexibility to fine-tune the system into an optimal operating point that is robust across a variety of radio access networks and loading conditions. Those skilled in the art will appreciate that some or all of these parameters may comprise part of an implementation of the invention, that the designation given these parameters is arbitrary, that the default values are not mandatory (hence, the fact that they are configurable) and that other parameters not described below may be used in connection with the invention as well.
bw4_min_iat
This configurable parameter specifies a minimum threshold for the inter-arrival time between two consecutive packets. The purpose of this parameter is to detect closely spaced inter-arrival times between consecutive packets resulting from client side context switching. Default value: 0 ms
bw4_min_iat_count
This configurable parameter specifies an upper limit for the number of consecutive packets that have inter-arrival times less than or equal to bw4_min_iat. If the upper limit is reached, the most recently arrived packet stops the packet burst tracking process. Default value: 1 (allows two consecutive packets of bw4_min_iat time between them).
bw4_max_iat
This configurable parameter specifies the maximum threshold for inter-arrival time between two consecutive packets. The purpose is to detect long inter-arrival time resulting from “no sending time,” e.g. a web-browsing user clicks a link and waits for two minutes before clicking another link. Default value: 100 ms
bw4_max_pkts
This configurable parameter specifies the maximum number of valid packets after which the current packet trace is stopped for calculating bandwidth, and a new trace is potentially started. Default value: 10
bw4_min_pkts
This configurable parameter specifies the minimum number of valid packets needed in a packet trace for a valid bandwidth calculation. If this minimum is met, when other criteria/conditions flag an end to a packet trace, a bandwidth calculation is made on that packet trace. Default value: 3
bw4_min_pkt_size
This configurable parameter specifies the minimum number of bytes needed inside a packet to qualify that packet as a valid packet for bandwidth estimation purpose. The purpose is to use only packets of reasonable size for bandwidth calculation. Default value: 512 bytes
Applications
The output of the above-described algorithm is a metric that is useful for many purposes. Thus, the estimated value can be fed into various entities on the sender side, among others, for example to identify the transmit rate to apply. The metric can also be used for various other applications such as, for example, load estimation. In a presently preferred embodiment of the invention, the metric is used to provide a transmit rate value. The metric may also be used, for example, for video content optimization, for example it may be used as a parameter that dynamically alters compression levels and image quality, based upon bandwidth.
The metric may be collected and stored as historical information and used to prepare reports that a system manager can review to understand bandwidth use patterns in a network. Thus, the metric produced by the invention is useful for reporting such things, for example, as traffic usage patterns, instantaneous values, trends over time, hot times of day, hot times of week, if there was a failure in the system, the effect a failure had on the system, and other diagnostic information. For the purpose of delivering prioritized traffic over a single connection to/from the user device, traffic may be separated into multiple parallel channels. The channel estimation techniques described herein can be applied in connection with link bandwidth sharing.
The metric can also be used in connection with throttling, i.e. setting up thresholds for different application flows, and for enhancing quality of service (QoS) across different application flows. The metric can also be used for setting a priority for a particular application or to find the bandwidth available for a particular user who is in a particular sector.
In connection with load estimation, the load considered need not be the entire mobile network. The invention may be used to localize the load to a particular antenna, for example. That gives great advantage to the application, because however the bandwidth information is used, it is not necessarily for the entire network, e.g. it can be for an individual user. Further, for load estimation there are various levels of granularity from atomic, which would be the individual user, to system-wide.
The metric also allows an operator to troubleshoot the network. For example, an operator can measure the bandwidth for a five-minute period, or send packets for five minutes, and then measure how much is actually sent to determine the bandwidth. However, there may be some interval of time in between where the conditions over the network are changing. This change is captured in real-time, using the metric developed using the invention herein, at a granular interval that tells an operator what happened between these five minutes.
The invention allows for operator adjustable parameters, such as optimization levels based on various bandwidth conditions. Typically, the end-user or consumer end-user has no direct visibility into these parameters. For example, in connection with a video optimization product the operator may notice that available bandwidth is 200 kilobits per second. In this example, the operator has the option to set parameters which, in effect, tell the system “If you see available bandwidth is 200 kilobits per second, set the video rate to be this level.” Thus, the operator can define, for example, low, medium, and high levels of bandwidth use. The user, on the other hand, may then have the option to select low, medium, or high, but low, medium, and high are dynamically changed based on the available bandwidth that the server determines is the available bandwidth. Therefore, the meaning of low, medium, and high to the user is dynamically adjusted in response to bandwidth estimation and, optionally, based upon operator determined thresholds.
Those skilled in the art will appreciate that the invention is applicable to all wireless technologies, starting from 2G, 2.5G, 3G, 4G, variations such CDMA, WCDMA, Edge technology, HSPA, and even non-wireless mediums. Thus, the invention may be used in connection with bandwidth estimation on any shared medium, e.g. cable bandwidth estimation. For example, in transitioning from one technology to another, e.g. from Edge to 3G, bandwidth needs change, and the algorithm herein likewise adapts to such changing bandwidth in those conditions.
Computer Implementation
FIG. 4 is a block schematic diagram of a machine in the exemplary form of a computer system 1600 within which a set of instructions may be programmed to cause the machine to execute the logic steps of FIG. 3 according to the invention. In alternative embodiments, the machine may comprise a network router, a network switch, a network bridge, personal digital assistant (PDA), a cellular telephone, a Web appliance or any machine capable of executing a sequence of instructions that specify actions to be taken by that machine.
The computer system 1600 includes a processor 1602 , a main memory 1604 and a static memory 1606 , which communicate with each other via a bus 1608 . Those skilled in the art will appreciate that the processor may comprise one or more individual processors which may be situated in the same location or in disparate locations. The computer system 1600 may further include a display unit 1610 , for example, a liquid crystal display (LCD) or a cathode ray tube (CRT). The computer system 1600 also includes an alphanumeric input device 1612 , for example, a keyboard; a cursor control device 1614 , for example, a mouse; a disk drive unit 1616 , a signal generation device 1618 , for example, a speaker, and a network interface device 1620 .
The disk drive unit 1616 includes a machine-readable medium 1624 on which is stored a set of executable instructions, i.e. software, 1626 embodying any one, or all, of the methodologies described herein below. The software 1626 is also shown to reside, completely or at least partially, within the main memory 1604 and/or within the processor 1602 . The software 1626 may further be transmitted or received over a network 1628 , 1630 by means of a network interface device 1620 .
In contrast to the system 1600 discussed above, a different embodiment uses logic circuitry instead of computer-executed instructions to implement processing entities. Depending upon the particular requirements of the application in the areas of speed, expense, tooling costs, and the like, this logic may be implemented by constructing an application-specific integrated circuit (ASIC) having thousands of tiny integrated transistors. Such an ASIC may be implemented with CMOS (complimentary metal oxide semiconductor), TTL (transistor-transistor logic), VLSI (very large systems integration), or another suitable construction. Other alternatives include a digital signal processing chip (DSP), discrete circuitry (such as resistors, capacitors, diodes, inductors, and transistors), field programmable gate array (FPGA), programmable logic array (PLA), programmable logic device (PLD), and the like.
It is to be understood that embodiments may be used as or to support software programs or software modules executed upon some form of processing core (such as the CPU of a computer) or otherwise implemented or realized upon or within a machine or computer readable medium. A machine-readable medium includes any mechanism for storing or transmitting information in a form readable by a machine, e.g. a computer. For example, a machine readable medium includes read-only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; electrical, optical, acoustical or other form of propagated signals, for example, carrier waves, infrared signals, digital signals, etc.; or any other type of media suitable for storing or transmitting information.
Challenges
As network speeds reach another order of magnitude (approaching 10 Mbps), measuring bandwidth accurately using inter-packet arrival time becomes challenging. Primarily, this has to do with device operating systems delivering packets with zero-millisecond clusters. Microsecond accuracy is needed to measure speeds at this rate. Another emerging issue is the OFDM based RANs that are likely to exhibit less ‘bursty’ patterns and more ‘smoothed’ pattern of packet arrivals. The invention is considered sufficiently robust to meet each and every one of these challenges.
Although the invention is described herein with reference to the preferred embodiment, one skilled in the art will readily appreciate that other applications may be substituted for those set forth herein without departing from the spirit and scope of the present invention. Accordingly, the invention should only be limited by the Claims included below.
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A bandwidth estimation algorithm on shared links detects peaks and/or average per-user bandwidth. Estimating is performed at the transport or IP layer with no assistance from lower layer (PHY, MAC, etc.) and the techniques can be used for any of adjusting the level of video optimization to the available bandwidth; driving QoS decisions at the transmitter based on available bandwidth; improving QoS enforcement during transitions among hybrid technologies on a wireless links; and correcting estimates on devices delivering bursty payload.
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FIELD OF THE INVENTION
This invention relates to a mixing apparatus used in mixing two fluids such as two liquids, a liquid and a solid, or a liquid and a gas, within a culture fermenter for microorganisms, waste water treatment systems, and other chemical processes.
BACKGROUND OF THE INVENTION
In known mixing apparatus used in mixing two fluids such as a liquid and a solid, or a liquid and a gas within a fermenter for beer, a fermenter for microorganisms, waste water disposal plants, and other chemical processes, the mixing apparatus contains different parts that are necessary for the process of mixing.
One of the known apparatus used in mixing two liquids contained a fan within the mixing tank, and the rotating force of the fan was used to mix the liquids.
FIG. 1 shows a mixing apparatus using the rotating force of a fan to mix two liquids. FIG. 4 shows the same mixing apparatus for a liquid and a gas.
The apparatus in FIG. 1 utilizes rotational force to mix two liquids, wherein motor 3 rotates the two liquids within the tank 2 by means of a rotating fan 1. However, as this machine utilizes mechanical rotation energy to mix the two liquids, there are problems of low energy efficiency and frequent breakdown of parts.
In FIG. 2 and FIG. 3, there is shown an apparatus which provides provided oxygen to the waste water treatment systems in the prior art. This apparatus is currently being produced and utilizes a pipe with minute holes in the form of a connective body 11, a joint piece or cap 12, and a pipe 13. This apparatus is activated when a gas from the outside enters the connective body 11 and passes through the minute air holes of the pipe 13 held fast by the joint piece 12. Small air bubbles are formed and dispersed into the water. The pipe is made of ceramic or polyethylene with the minute holes formed therein. With the mixing apparatus mentioned above, there is a possibility of the holes becoming clogged with underwater vegetation and can also breed there. Aeration may decrease as a result. Therefore, routine cleanup of the pipes to remove underwater vegetation and maintain optimum aeration is necessary.
Another type of aeration apparatus, shown in FIG. 4 and FIG. 5, utilizes a ball and a net. In this apparatus, the gas enters an inlet valve 21 and passes through an air passageway 22. Through the ball motion within the container the air bubbles are initially divided again as the bubbles pass through a net 24. However, this mixing apparatus 25 also has the problem of clogging in the net holes.
SUMMARY OF THE INVENTION
Therefore, it is an object of this invention to provide a mixing apparatus which has a high level of mixing efficiency and easy maintenance and repair during the process of mixing two fluids such as two liquids, a liquid and a solid, or a liquid and a gas within a fermenter for beer, a culture fermenter for microorganisms, waste water treatment systems, and other chemical processes.
The objective of the present invention is to provide a mixing apparatus that can dissolve oxygen in a gas or pure oxygen with high oxygen transfer efficiency and without the problems of previous mixing apparatus, such as clogging with and breeding of underwater vegetation.
The mixing apparatus provided in accordance with this invention comprises a fluid influx tube which induces one of the fluids to be mixed, and an acoustic resonance part that forces a fluid emitted from the fluid influx tube to move toward the other external fluid by means of pulsation energy. The fluid from the fluid influx tube induces acoustic resonance in the acoustic resonance part and is emitted outside of the mixing apparatus to mix with the external fluid. This invention has high mixing efficiency because, unlike prior technologies which use mechanical energy, the apparatus of the invention uses sound wave energy created by acoustic resonance to mix two fluids together. Also, there is the advantage of having the two fluids mix in a relatively static state, with little external shaking.
More specifically, the mixing apparatus creates a pressure pulse from a high pressure gas or liquid with a reflective plate or reflective groove or vibrating plate. This pressure pulse energy reflective groove or vibrating plate. This pressure pulse energy increases the dissolution rate of the gas or liquid. When a gas is dissolved in water, the pressure pulse greatly increases gas solubility. When a liquid is mixed with another liquid in this mixing apparatus using acoustic resonance, the pressure pulse increases the expansion rate of the formed and thus increases the mixing rate.
According to the preferred embodiment of this invention, a reflective plate that emits pulsation is placed at a desired distance from the fluid influx tube. Also, reflective grooves can be formed on the reflective plate, and the shape of these reflective grooves is preferably cylindrical.
According to another embodiment, the outlet of the fluid influx tube is preferably annular in shape, and a pole shaped column is placed in the middle of the outlet to form the annular shape.
Preferably, the ratio between the diameter of the outlet of the fluid in flux tube and the distance between the fluid influx tube and the reflective plate is 0.1-5. The fluid in flux tube has a check valve to prevent the reverse flow of fluid.
According to yet another embodiment of this invention, a vibrating plate may generate pulsation by means of the pressure difference between the fluid flowing from the influx tube and a spring adhered to the vibrating plate. Preferably, a protrusion or a reflective groove is formed in the center of the reflective plate. The protrusion provides the outlet of the fluid influx tube with an annular shape. Also, a rubber tube may be placed between the vibrating plate and the outlet of the fluid influx tube to prevent the fluid from flowing backward.
In this invention, the term "fluid" means gases and liquids. Also, the mixing apparatus that dissolves gases into fluids is called an aeration apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section view of a mixing apparatus mixing two fluids in the prior art.
FIG. 2 is a perspective view of the prior art mixing apparatus which uses a pipe.
FIG. 3 is a cross-section view of the apparatus illustrated in FIG. 2.
FIG. 4 is a section view of a mixing apparatus which uses a ball and net.
FIG. 5 is a top plan view of the apparatus in FIG. 4. FIG. 6 is a schematic view illustrating an example of the present invention which uses a reflective plate.
FIGS. 7A and 7B are detailed side and end views illustrating the combining means of FIG. 6, respectively.
FIGS. 8 and 8B are respectively side and end views illustrating the reflective plate in FIG. 6.
FIG. 9 is a cross-section view of another example of this invention which uses a reflective plate.
FIGS. 10A and 10B are detailed side and end views illustrating the reflective plate of FIG. 9.
FIG. 11 is a cross-section view of an example of this invention which uses a vibrating plate.
FIGS. 12A and 12B are detailed end and side views illustrating the rubber ring of FIG. 11.
FIGS. 13A and 13B are detailed end and side views illustrating the vibrating plate of FIG. 11.
FIGS. 14A and 14B are detailed end and side views illustrating a different form of the vibrating plate of FIG. 11.
FIG. 15 is a cross-section view illustrating another example of this invention which uses a vibrating plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments of an apparatus of this invention that uses sound wave energy to mix two fluids will now be described by way of examples with reference to the accompanying drawings.
FIG. 6 is a schematic view of the mixing apparatus which includes a fluid influx tube leading a fluid, a fluid supplying means, a reflective plate, and a combining means for said fluid influx tube and said reflective plate. FIG. 6 and FIG. 9 illustrate examples of a mixing apparatus that use a reflective plate according to this invention. The fluid influx tube 31 primarily includes an entrance through which fluid from the outside fluid supplying means, such as compressor (not shown), enters, and an exits through which the fluid is discharged to the reflective plate. Also, as illustrated in FIG. 6, a check valve 35 can be installed within the fluid influx tube 31 to prevent the fluid from flowing backwards within the mixing apparatus. At the exit end of the fluid influx tube 31, the reflective plate 34 is separated at a desired distance by a securing bolt 33. When installing the check valve 35, in order to make installation easier, the fluid influx tube 31 can be separated into two parts and recombined by various means such as with bolts and nuts as well as other forms of combination. The check valve 35 and valve spring 36 are therefore easily installed. Also, the fluid influx tube 31 and the reflective plate 34 can be combined by many different methods. For example, in this invention one combining means 33 for the fluid influx tube and the reflective plate has a female screw on both ends thereof, and the outlet end of the fluid influx tube and the reflective plate have a male screw. Finally, the combining means 33 is used to provide the desired distance between the exit of the fluid influx tube and the reflective plate 34, and can be combined in many different ways. As illustrated in FIG. 7, the combining means 33 has a hollow cylindrical shape with several long, narrow fluid-emitting slots. The reflective plate 34, as shown in FIGS. 8A and 8B is a solid cylindrical shape with screw-like grooves along the outer side. It is preferable to form a circular reflective groove 40 in the center of the front side facing the influx tube, if possible, as will be further explained later. The reflective plate 34 is inserted in the securing bolt 33 and is placed a desired distance from the fluid influx tube 31.
In the apparatus mentioned above, fluid enters the fluid influx tube 31, after which the check valve 35 opens so that the fluid passes through the tube. The fluid then hits against the reflective plate 34, and a pressure pulse develops in the area between the reflective plate 34 and the end of the fluid influx tube 31.
As mentioned above, the frequency causing the pressure pulse is determined by the outlet diameter d 1 of the fluid influx tube 31, the distance between the fluid inlet tube and the reflective plate 34, the shape, the diameter D 2 and the depth hr of the reflective groove 40, air pressure, speed at which air passes through the fluid influx tube, water density, and water pressure. Due to this pulse energy, the supplied fluid is divided into many small parts, and is spread out into the outer fluid with pulsation energy, thereby increasing fluid mixing efficiency. The reflective grooves add mixing efficiency, and a cylindrical shape of the reflective grooves are both easy to make and have good pulse effect. Among many variables that determine the size and frequency of pulse, the most important is the ratio between the diameter d of the fluid influx tube and the distance between the fluid influx tube and the reflective plate. According to an experiment, pulsation occurs when the ratio d 1 \l=0.1-5 and if possible, the ratio d 1 \l=0.5-2. For example, when the ratio d 1 \D 2 is 1, the frequency f of acoustic resonance is found as follows: ##EQU1## wherein c is the sound velocity, and h r and d 1 are as mentioned above.
FIG. 9 shows another example of the mixing apparatus in FIG. 6, wherein a circular reflective groove 40 is formed on the exit side of the fluid influx tube 31 and a pole-shaped column 4 extends from the reflective plate into the outlet of the fluid influx tube to form the outlet into an annular shape. The function of column 41 is to disperse the fluid in the fluid influx tube 31. A conical shape of the frontal part of the column 41 will provide better dispersing results.
With the structure mentioned above, the fluid is driven by a fluid supplying means to pass through the fluid influx tube 31 and the check valve 35. The fluid is then dispersed to an annular shape by column 41 and hits against the reflective groove 40 of the reflective plate 34 causing a pressure pulse to develop in the area consisting of reflective plate 34, reflective groove 40, a column 41 and the outlet 39 of the fluid influx tube 31.
As mentioned above, the frequency causing the pressure pulse is determined by the diameter d 1 of the fluid influx tube 31, the diameter d 2 of the column 41, the diameter D 1 of the outlet 39 of the fluid influx tube, the diameter D 2 and the depth h r of the reflective groove 40, the distance l between the fluid influx tube and the reflective plate 34, the shape of the reflective groove 38, the pressure of the fluid, the speed of passing through of the fluid, and the density and pressure etc. of the outer fluid. The frequency f of acoustic resonance in this example is as follows: ##EQU2## wherein ΔP is the pressure difference of fluids between the fluid influx tube 31 and the external fluid, and the other terms are as mentioned above.
The fluid which has pulsation energy is mixed effectively with the outer fluid. In particular, the reflective groove adds efficiency and, because the fluid is emitted from the fluid influx tube in an annular shape, it is dispersed into smaller fluid particles and mixing efficiency is increased. In particular, in apparatus used in dissolving gas into fluid, the air bubbles receive pressure from the pulsation energy formed in the exit area of the fluid influx tube and become smaller, increasing the contact area between air and water. Thus, the air dissolubility is increased.
FIG. 11 and FIG. 14 illustrate examples of a mixing apparatus using vibrating plates. In the apparatus of FIG. 11, a securing bolt 52 is fastened to the end of a fluid influx tube 31 and a spring 55 is fastened to this securing bolt 52. The vibrating plate 54 successively adheres to the rubber plate 53, as shown in FIGS. 12A, 12B through the elasticity of the spring 55. Fluid which enters the fluid influx tube 31 pushes the vibrating plate 54 which is adhered to the outlet of the fluid influx tube 31 with the rubber ring 53 in the middle, and passes through the outlet of the fluid influx tube 31, the rubber ring, and the vibrating plate 54. Afterwards, the space that was created between the vibrating plate and the fluid influx tube 31 is closed by the spring 55. Through a continuation of this phenomenon, a pulsation force is developed, and as this pulsation force is spread to the outer fluid, the mixing efficiency of the two fluids increases. In particular, as shown in FIGS. 13A, 13B, a protrusion 56 in the middle of the vibrating plate changes the shape of the exit of the fluid influx tube outlet 57 to an annular shape. This shape, in comparison with the circular shape, creates smaller fluid particles which results in a higher mixing efficiency level. If a vibrating plate 54 with a reflecting groove 58 (see FIGS. 14A, 14B), instead of a protruding part in the middle is used, the pulsing effect is also increased.
FIG. 15 shows another example of a mixing apparatus using a vibrating plate, as shown in FIG. 11. The apparatus has a check valve 35, as shown in FIG. 6, to prevent the fluid from flowing backward.
The dispersion of a fluid in this invention can be accomplished by using a compressor from the outside to add the fluid to be mixed to the fluid inside the container. If a solid and a liquid are to be mixed, the mixed material can be fed into the fluid influx tube with a compressor and it can be mixed through circulation. In the case of mixing a gas or a liquid with another liquid, the gas or liquid can be fed into the fluid influx tube. The FIG. 15 embodiment also has the rubber ring 60 through which the securing bolt 52 extends to provide a gap between the vibrating plate 54 and the fluid influx tube 31.
The following is an explanation of this mixing apparatus using acoustic resonance through executed experiments.
Experiment 1
A test was performed using mixing apparatus illustrated in FIG. 6 to dissolve oxygen in air into waste water. The conditions of this experiment were: exit diameter of fluid influx tube d 1 =3 mm, distance between fluid influx exit and reflective plate e=3 mm, applied air pressure 4 Bar.
The calculation for oxygen transfer efficiency is as follows: ##EQU3##
The result was that the calculated oxygen transmission efficiency was 3.62%.
Experiment 2
A test was performed using mixing apparatus illustrated in FIG. 9 to dissolve oxygen in air in water. The conditions of this experiment were: exit diameter of fluid influx tube d 1 =depth of the reflective groove 38 d 3 =diameter of the reflective groove 38 D 2 =8 mm, diameter of pole shaped column d 2 =7, distance between fluid influx exit and reflective plate Δ=3 mm, applied air pressure 4 Bar.
The calculated oxygen transfer efficiency was 3.79%.
Experiment 3
A test was performed using mixing apparatus illustrated in FIG. 11 to dissolve oxygen in air in water. The conditions of this experiment were: exit diameter of fluid influx tube d 1 =3 mm, applied air pressure 4 Bar. The calculated oxygen transfer efficiency was 3.96%.
Comparison Experiment 1
In an experiment performed with the same conditions as that in Experiment 1 but using the mixing apparatus in the prior art illustrated in FIG. 4, the calculated oxygen transfer efficiency was 2.25%.
As illustrated above, the oxygen transfer efficiency level using this invention in mixing gas and water is relatively high. Advantageously, this mixing apparatus which uses acoustic resonance not only can make air bubbles very small using pulsation energy, but is different from previous mixing apparatus in that the air bubbles do not rise directly upwards, but side to side, resulting in longer exposure time in the liquid. Another reason that the oxygen transmission efficiency level is higher in this invention is that, due to the pulsations underwater, the material transmission resistance between the bubbles and water is minimized, resulting in easier dissolution of oxygen. Another benefit is that, because a pulse always exists in the vibrating sound source, there is little worry of the growth of underwater vegetation which makes the previous chore of routine cleaning unnecessary.
Furthermore, the excellence in efficiency of this invention in the mixing of two liquids has also been proved. Also, the quantity to be mixed in the mixing apparatus can be altered simply by changing the diameter of the fluid influx tube.
As examined, this mixing apparatus uses pulsation energy created by acoustic resonance. Two fluids are mixed by the pulsation created by acoustic resonance, not by mechanical energy as in previous mixing apparatus, resulting in high mixing efficiency. Also, in a mixing procedure based on mechanical action (e.g. the revolving fan blades) results not only in loud noise but also can cause the problem of fluid spillage. In contrast, this invention operates with little outer disturbance.
In particular, the invention has a superior oxygen transfer efficiency level as compared to other mixing apparatus that dissolve oxygen in air into water. Also, this invention also has a simple structure and relatively easy maintenance for the equipment. Finally, this apparatus does not have the problem of underwater vegetation growing inside it.
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A mixing apparatus is used in mixing two fluids, such as two liquids, a liquid and a solid, or a liquid and a gas, within beer fermenter, microorganism culture mediums, waste water disposal plants, and other chemical processes. It is high in efficiency and simple in maintenance and repair. In particular, this apparatus utilizes sound vibration which sends pulses through the apparatus and adds a fluid to the other fluid to be mixed. Therefore, the mixing efficiency level can be raised by using this fluid mixing apparatus.
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BACKGROUND
This invention concerns the characterisation, classification, identification and typing of different DNA containing organisms such as plants, animals, bacteria and their viruses.
The science of detecting genomic polymorphisms is quickly evolving, and several techniques have been developed to compare the genomes of different organisms. These techniques utilise the whole genome or segments thereof for comparison purposes and are often referred to as DNA fingerprinting techniques. The main application fields for these techniques are gene mapping, detection of bacterial strain diversity, population analysis, epidemiology, gene expression and the demonstration of phylogenetic and taxonomic relationships.
In the application areas of bacterial identification and typing, pulsed-field gel electrophoresis, random amplified polymorphic DNA (RAPD) and DNA sequencing of different genes are frequently discussed as methods of the future, compared to traditional methods based on biochemical and growth properties. The drawback with all these and other suggested DNA fingerprinting methods is the use of electrophoresis. This is because electrophoresis is a laborious separation technology and the time from start to finish is long, ranging from 30 minutes up to more than 20 hours for pulsed-field gel electrophoresis, followed by both detection of the DNA and analysis of the results.
Since ribosomes are present in all living organisms, and the ribosomes contain three kinds of rRNA (in bacteria 5 S, 16 S, and 23 S), DNA sequencing of the corresponding genes is frequently used for characterisation, identification and taxonomy relations of bacteria, fungi and other organisms. The most widely used of the ribosomal genes is 16 S rDNA. The DNA sequences of these genes contain well-defined segments of different evolutionary variability regions, which in the 16 S rRNA molecule are referred to as universal, semi-conserved and variable regions. Oligbnucleotide primers complementary to universal regions can be used for amplification of ribosomal RNA from any organism or bacteria, the generated ribosomal fragment being then sequenced. In a computer search against a database with all known ribosomal sequences the species can be assigned.
Random amplified polymorphic DNA (RAPD) is a process for detecting polymorphisms on the basis of nucleotide differences and is covered by U.S. Pat. No. 5,126,239 of Livak et al, 1992. RAPD analysis is one of the most sensitive, reproducible and efficient methods currently available in the research field for distinguishing different strains and isolates of a species. RAPD analysis is a technique that uses a single short oligonucleotide primer of arbitrary sequence in a low stringency amplification reaction (Welsh J and McClelland M, 1990, Nucleic Acids Research, 18 (24), 7213-7218; Williams J G et al (1990) Nucleic Acids Research, 18, 6531-6535). The generated DNA fragments are subsequently analysed by gel electrophoresis. Analysis can either be done automatically on line with an automated DNA sequencer or on any electrophoresis gel and stained with ethidium bromide or silver.
In arrayed primer extension techniques (APEX), primers which have hybridised with a template, having a free 3′-end and having a free hydroxyl group, can be extended with free dNTPs and a DNA polymerase. If ddNTPs or other chain terminators are added to the mixture the elongation will terminate at that point. A similar method to this was developed for mutation detection (WO 91/13075). The authors used a PCR template bound to wells of a microtitre plate, and the primers were added for extension after binding to the template.
Further development of this method was carried out where consecutive primers overlapping each other by one base were bound to a support in the form of an array (also called a DNA chip). These were bound to the surface by the 5′-end, so that the 3′-end was free for elongation after addition of template, ddNTP and a polymerase. The chain terminating molecules were labelled, with any type of chromophore, fluorophore, isotope or antibody reactive reagent. This technique is described in WO 95/00669.
BRIEF SUMMARY OF THE INVENTION
The present invention combines features of random amplified polymorphic DNA (RAPD) and of arrayed primer extension (APEX), techniques, so as to avoid the difficulty and delay of gel electrophoresis.
In one aspect, the invention provides a nucleic acid analysis method which comprises:
a) using a primer to amplify the nucleic acid,
b) providing an array of probes in which each probe comprises a primer sequence that is identical to (or complementary to) the sequence of the primer, and an adjacent sequence which is different in each probe of the array,
c) applying the amplified nucleic acid from a) under hybridisation conditions to the array of b),
d) effecting enzymatic chain extension of any probe where the adjacent sequence matches that of the hybridised amplified nucleic acid, and
e) observing the location of probes of the array where chain extension has taken place in d).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 depicts the general concept of the invention wherein a template DNA fragment has hybridized to an oligonucleotide probe and the oligonucleotide probe carries at its 3′ end a random 3-mer extension;
FIG. 2 depicts an array of oligonucleotide probes together with three fragments of template DNA where hybridisation and chain extension have taken place.
FIG. 3 depicts bacterial grouping data obtained by practice of the method of the invention;
FIG. 4 ( i-vi ) depicts the total internal reflection fluorescence (TIRF) data for six Listeria strains obtained by practice of the methods of the invention; and
FIG. 5 depicts four dendrograms illustrating the Listeria data of FIG. 4 ( i-vi ).
DETAILED DESCRIPTION OF THE INVENTION
The nucleic acid to be analysed may be genomic DNA or RNA e.g. mRNA of an organism such as a plant, animal, bacteria or virus. The method is expected to be useful for applications where RAPD analysis is currently used, including gene mapping, detection of strain diversity, population analysis, epidemiology, the demonstration of phylogenetic and taxonomic relationships, and gene expression studies.
In step a) the nucleic acid to be analysed is amplified using a single primer (or possibly several primers) in a low stringency amplification reaction e.g. by PCR. This primer is a chain of units capable of hybridising in a substantially sequence-specific manner to a suitable chain of the nucleic acid to be analysed; to form a hybrid in which the primer chain is capable of enzymatic chain extension. The primer is composed of units which are either nucleotides or nucleotide analogues.
Generally speaking, a nucleotide analogue is a compound which is capable of being incorporated in a chain of nucleotide residues; and which is capable of hybridising in a more or less base-specific manner with a base of a complementary nucleic acid chain; and which may be a substrate for chain-extending enzymes. A nucleotide analogue may be a nucleotide modified: in the base, e.g. so as to affect base-pairing properties; and/or in the sugar or backbone moiety, e.g. as in ddNTPs and in the amide linked backbones of PNA; and/or in the phosphate moiety.
For the primers for this invention, peptide nucleic acids are of interest. Preferably however the primer is an oligonucleotide. The primer preferably has from 7-40 residues. Usually a short primer with 8-10 residues is used, but primers with up to 20 or 40 residues are also possible. After amplification, all amplimers will have the same sequence at both ends, the length of that sequence depending on the primer.
In many techniques where amplification is involved, there is a need for standardised reagent supply. For this purpose it may be convenient to use Ready-To-Go™ (RTG) RAPD beads marketed by Amersham Pharmacia Biotech which provide the reagents for the reactions. The RTG RAPD beads contain thermostable polymerases, dNTPs, BSA and buffer for a 25 μl reaction.
Preferably the amplified nucleic acid is broken into fragments. Fragmentation is preferred because only small fragments may have access to a probe bound on a solid support. In the examples below, two different approaches have been used, restriction enzymes and the enzyme uracil-DNA-glycosylase (UDGase). To use UDGase, dUTP must be added to the amplification mix. UDGase activity is blocked by a UDGase inhibitor. Other enzymatic, chemical and physical methods of breaking the amplified nucleic acid are known and may be used.
An important feature of this invention is the use of an array of immobilised probes. These are herein called probes, although they also act as primers for chain extension. Each immobilised probe comprises a primer sequence that is identical to (or complementary to) the sequence of the primer used in a). Each probe also comprises an adjacent sequence, generally of 1-8 nucleotide (or nucleotide analogue) residues. The adjacent sequence of each probe of the array is different from that of every other probe of the array. Preferably the array consists of a complete set of probes having adjacent sequences of a particular length, that is to say: four probes where each adjacent sequence is 1 nucleotide residue; or 16 probes where each adjacent sequence is 2 nucleotide residues; or 64 probes where each adjacent sequence is 3 nucleotide residues; or 4 n probes where each adjacent sequence is n nucleotide residues.
Preferably the adjacent sequence is positioned at the 3′-end of the primer sequence of the probe. Preferably the probe is tethered to a support through the 5′-terminal residue of the primer sequence, either covalently or by means of strong binding agents such as the streptavidin-biotin system.
In step c), the fragments of the amplified nucleic acid from a) are applied under hybridisation conditions to the array. Because all probes of the array include a primer sequence complementary to the primer-derived sequence of the amplified nucleic acid, hybridisation takes place at every probe location of the array.
In step d) template-directed chain extension of probes of the array is effected. Preferably this chain extension is performed using a polymerase enzyme together with a supply of nucleotides or nucleotide analogues. Under these circumstances, chain extension only takes place where the nucleotide residues at the 3′-end of the probe accurately match those of the hybridised nucleic acid fragment.
For this purpose a nucleotide analogue may have a base analogue that is degenerate, by having the ability to base pair with two or three of the natural bases, or universal, by forming base pairs with each of the natural bases without discrimination. Also, chain-terminating ddNTPs may be used as nucleotide analogues, and are preferred.
Nucleotides or nucleotide analogues for addition during the chain extension step may be labelled for ease of detection. The nature of the label is not material to the invention. Examples are radioisotopes, fluorescent moieties, haptens, and components of chromogenic or chemiluminescent enzyme systems. Preferably the four ddNTPs are used, each labelled with a different fluorescent or other label, so that the four different signals can be read simultaneously.
Step e) of the method involves observing the location of probes of the array when chain extension has taken place in d). This observation can be made by standard means using the one or more labels added during chain extension. The result is a pattern which is characteristic of the nucleic acid being analysed.
In another aspect the invention provides a nucleic acid analysis kit comprising:
i) a primer for amplifying a nucleic acid,
ii) an array of probes in which each probe comprises a primer sequence that is identical to (or complementary to) the sequence of the primer, and an adjacent sequence which is different in each probe of the array,
iii) and reagents for effecting enzymatic chain extension of nucleic acid hybrids.
Description of the Ordered Arrangement of an Array of Oligonucleotide Probes
An oligonucleotide primer typically has 7 to 40 nucleotides; for example with 10 nucleotides: 5′-NNNNNNNNNN-3′-OH. Oligonucleotide probes generally comprise oligonucleotide primers and an additional 1-8 bases; for example with 2 additional bases a total of 16 (4 2 ) probes are needed:
NNNNNNNNNNAA NNNNNNNNNNCA
NNNNNNNNNNAC NNNNNNNNNNCC
NNNNNNNNNNAG NNNNNNNNNNCG
NNNNNNNNNNAT NNNNNNNNNNCT
NNNNNNNNNNGA NNNNNNNNNNTA
NNNNNNNNNNGC NNNNNNNNNNTC
NNNNNNNNNNGG NNNNNNNNNNTG
NNNNNNNNNNGT NNNNNNNNNNTT
for 3 additional bases 4 3 =64 probes are needed, etc. up to 4 8 ≈65,000.
After hybridisation and extension of an array of 64 probes, two different patterns can look like this;
Reference is directed to the accompanying drawings, in which:
FIG. 1 illustrates the principle of the invention. A template DNA fragment has a 10-mer oligonucleotide primer at its 3′ end. An oligonucleotide probe has been immobilised on a surface of a support through a T 12 anchor joined at the 5′-end of (the complement of) the 10-mer oligonucleotide primer sequence. The oligonucleotide probe carries at its 3′-end a random 3-mer extension, in this case TCA.
The template DNA fragment has hybridised to the oligonucleotide probe. By chance the sequence of the template DNA (AGT) complements the 3-mer extension at the 3′-end of the oligonucleotide probe. As a result, template-directed chain extension of the oligonucleotide probe has taken place, and a total of seven nucleotides (N) or labelled nucleotide analogues (*) have been added to its 3′-end.
FIG. 2 is a corresponding diagram showing an array of oligonucleotide probes, together with three fragments of template DNA where hybridisation and chain extension have taken place.
FIG. 3 shows bacterial genotyping data obtained in Example I on two different strains of E. coli using three different primers.
FIG. 4 ( i-vi ) shows TIRF data obtained on six different strains of Listeia in Example 3. For each strain, the upper four panels show images obtained with four different labelled ddNTPs; and the lower panels show the data expressed graphically (capital letters are strong signals, lower case letters are weak signals).
FIG. 5 comprises four dendograms and contains a comparison between strong and weak assigned spots from the images. Primer 2 was compared with primer 6 amplified Listeria DNA in combination with two polymerase enzymes.
In the examples below, the acronym RAPX is used to denote the method of the present invention comprising a combination of the random amplified polymorphic DNA (RAPD) and arrayed primer extension (APEX) techniques.
EXAMPLES
The first example shows the invention method performed in microtitre plates (MTP) with both fluorescein labelled dCTP and anti-fluorescein antibodies and detected by using para-nitrophenyl phosphate (pNpp). Two different bacterial DNA were used in order to show that different patterns could be generated.
The second example shows the method performed on a microscope slide with one of the bacterial DNA as template.
Fragmentation is an important step because only small fragments will have access to the bound primer on the solid support. For this step two different approaches were used, restriction enzyme cleavage and using the enzyme Uracil-DNA-glycosylase (UDGase). To use UDGase, dUTP must be added to the amplification mix. UDGase activity is blocked by a UDGase inhibitor.
The whole procedure consists of the following steps:
RAPD amplification
Digestion/Fragmentation
Purification and quantification
Array setup on chip or MTP
Hybridisation and chain extension
Detection of reacted products
Example 1
Genomic DNA was purified from E. coli strains according to standard protocols. Test DNA from Pharmacia Biotech RTG™ RAPD kit was used.
RAPD Amplification:
Each DNA was amplified generally according to the manufacturer's protocol and with the RTG RAPD beads. One reaction contained 25 pmol primer, 10 ng bacterial DNA and water to 25 μl.
Primers:
Primer 2: GGTGCGGGAA (SEQ ID NO:1)
Primer 6: CCCGTCAGCA (SEQ ID NO:2)
Primer 1283: GCGATCCCCA (SEQ ID NO:3)
Escherichia coli strains: BL21 and C1a
When large quantities of RAPD templates are needed several batches of the same sample were amplified, following the prescribed RAPD protocol.
Number
of Cycles
Temp
Time
1 cycle
50° C.
8 minutes
1 cycle
95° C.
3 minutes
45 cycles
95° C.
1 minute
36° C.
1 minute
72° C.
2 minutes
1 cycle
35° C.
30 minutes
Five microlitre of material from each tube were tested on a polyacrylamide gel.
Digestion
The generated RAPD products were fragmented according to two different methods, restriction enzyme cleavage or using the enzyme UDGase.
Cleavage with Restriction Enzymes
The RAPD product (DNA) was cleaved with Alu1 and Hha1.
Ingredient
1 Tube
Sterile water
240 μl
Restriction Buffer
40 μl
Alu1 Enzyme (3.5)
25 μl (75 units)
RAPD product (DNA)
95 μl
TOTAL
400 μl
Incubate tubes for 1 hour in a 37° C. oven.
Place 100 μl of the following master mix in each tube:
Ingredient
1 Tube
Sterile water
15 μl
Restriction Buffer
60 μl
Hha 1 Enzyme (3.6)
25 μl (75 units)
TOTAL
400 μl
Incubate for 2 hours in a 37° C. oven.
After cleavage 5 μl was tested on a polyacrylamide gel.
Cleavage with UDGase
Bacterial DNA was amplified with an addition of 80 mM dUTP before treatment with UDGase and UDGase inhibitor (UDI).
One RAPD reaction contained 25 pmol primer, 10 ng bacterial DNA, 80 mM dUTP (Pharmacia Biotech), water to 25 μl and one RTG RAPD bead, with the same amplification conditions as above.
UDGase Treatment, Set Up:
25 μl RAPD DNA
6.25 μl UDGase (1 U/μl New England Biolabs)
6.25 μl 10×UDGase mix
25 μl water
Incubate at 37° C. for 24 min.
Add 6.25 μl UDI
Incubate at, at least 75° C., for 10 minutes and test on polyacrylamide gel.
Purification and Quantification
Cleaved RAPD products were concentrated with a Centricon-10 Concentrator. The concentrated DNA was then filtered through an Amicon EZ filter to remove excess of primers, free nucleotides and enzymes.
Finally, the DNA concentration was measured using Optical Density at 260 nm and 280 nm using spectrophotometer and calculate the volume to get 2.5 μg DNA for the hybridisation and extension reactions.
Preparation of Array Plates
Three sets of 64 oligonucleotides with primer sequences from primers 2, 6 and 1283 extended with all possible combinations of three additional nucleotides (nt), giving them a total length of 13 nt, were bound to microtitre plate wells.
Reactions in Wells
RAPD DNA template (2.5 μg) was added to each well and heated to boiling temperature for 3 minutes.
Order
Component
Volume - 1 well
1
water
79.2 μl
2
5x TSP buffer
20 μl
3
Deoxy Mix
0.1 μl
4
Fl-dCTP (.5 mmol)
0.2 μl
5
Tba Polymerase
0.5 μl
Total
100 μl
Tba Polymerase is a DNA polymerase from the bacterium Thermococcus barrossi.
After adding the reaction mix, incubate at 72° C. for 45 minutes in a large oven.
5× Thermostable Polymerase Reaction Buffer (TSP)
Component
Volume
[Final]
1M Tris-HCl, pH 9.5
10 μl
100 mM
1M MgSO 4
5 μl
50 mM
10% Triton X-100
25 μl
2.5%
Milli Q ™ water
60 μl
100 μl
Mix. Sterile filter. Store at room temperature.
dNTP (Deoxy) Mix (dA, dG, & dT)
Component
Volume
[Final]
100 mM dATP
5 μl
1 mM
100 mM dGTP
5 μl
1 mM
100 mM dTTP
5 μl
1 mM
Milli Q ™ water
485 μl
500 μl
Store at −20° C.
Detection of Reaction Products
In order to enhance the signal, anti-fluorescein antibodies labelled with alkaline phosphatase were used. Before detection of the reaction, each well was blocked with a buffer containing bovine serum albumin. One hundred microlitre of anti-fluorescein antibody solution was pipetted in to each well and incubated 60 minutes at room temperature. The microtitre plate was washed several times before para-nitrophenyl phosphate reagent was added and a yellow colour was developed at room temperature.
The yellow signal output read from each well is a quantitative measure on the amount of the RAPD fragment for that particular RAPD-extended probe. All data from the reader (Spectra Max 3000) was used for generation of a graph for each organism, FIG. 3 .
This is a set of overlaid duplicate optical density readings. Signals have been determined by high values that have consistently shown up through four experiments that have compared these two strains of bacteria.
In the centre is a bar code that represents signals for the two strains.
Example 2
This experiment was performed to show that the method of the invention also works when the array of oligonucleotide probes is on a glass surface. For this purpose, silanised glass slides were procured and three sets of the three oligonucleotide probe families of Example 1 (3×64=192 probes) were synthesised to have amino-linked 5′-modified ends. These oligonucleotide probes were spotted on to the silanised surface of the glass slide, the experiment being performed in triplicate. Border controls (self-extending oligonucleotides capable of A, G, T or C addition) were spotted in a pattem that surrounded each of the four spotted grids.
Nucleic acid template material was prepared, as described in Example 1, starting from genomic DNA of the E. coli strain BL21. Template material was validated by running samples on polyacrylamide gel and staining with ethidium bromide. It was found that the material digested with the mixture of frequent cutting enzymes (Alu1 and Hha1) seem to average about 250 bp in size (50-500 bp range).
Hybridisation and extension reactions were performed generally as described in Example 1. The extension reaction mix was:
13.5 μl RAPD DNA fragments (2 pmol)
1 μl 17.5×Thermosequenase DNA polymerase buffer
1 μl unlabelled dNTPs (50 mM)
1 μl Cy5-ddCTP (50 mM)
1 μl Thermosequenase DNA polymerase (5 U/μl)
Incubate at 65° C. during 20 minutes. The Cy5-ddCTP was a sulphonated cyanine dye dideoxy nucleotide marketed by Dupont. Control reactions were first performed in order to ensure the presence of correctly spotted oligonucleotides and validate a successful enzyme reaction. In the presence of polymerase enzyme without any template, only the border controls appeared. The addition of three different oligonucleotides that would specifically hybridise to one of each of the primer families, resulted in the detection of the appropriate spots in the array. These control experiments demonstrated the ability to perform specific reactions on the microscope slide surface.
Template nucleic acid material (prepared as described in Example 1) that represents sequence information of the bacterial genome BL21 was then applied to the oligonucleotide probe array. Using a total internal reflection detection system, a specific pattern of signals was seen for template material from the BL21 source.
Example 3
Amplification:
Bacterial DNA: E. coli BL21 and E. coli C1a strains are from the Amersham Pharmacia Biotech RTG RAPD kit. Six Listeria monocytogenes strains are Listeria monocytogenes; serotype 1, serotype 2, serotype 4a, serotype 4b, ATCC 15313 and ATCC 35152.
Primers: Primer 2, 6 are from the Amersham Pharmacia Biotech RTG RAPD kit and primer 1283 is from Berg et al.
Amplification reagents: RAPD RTG beads from the Amersham Pharmacia Biotech RTG RAPD kit.
All samples were spiked with one microliter 2.5 mM dUTP
Enzymes for Fragmentation of RAPD Products:
Shrimp alkaline phosphatase (SAP)1 U/μl APB.
Uracil-DNA-glycosylase, (if from PE UDG=UNG) 1 U/μl NE
Biolabs
SAP will degrade (dephosphorylate) all free dNTPs and UDG will remove all dU from the DNA and after heating the strands will be broken at these points. This step is applicable to any DNA fragment.
Primers for Spotting:
All 192 primers were 25-mers with an amino-activated 5′-end.
The general sequence for the primers is
5′-NH 4 -TTT TTT TTT TTT-P-N 1 N 2 N 3 -3′, where P is the primer sequence from Primer 2, Primer 6 or Primer 1283; and N 1-3 is A, C, G or T. (See: SEQ ID NO: 5; SEQ ID NO: 6; and SEQ ID NO: 7).
For the arrangements of the primers see below.
In Primer 2 set up P=GTTTC GCTCC (SEQ ID NO: 4), Primer 6 set up P=CCCGT CAGCA (SEQ ID NO: 2), and in Primer 1283 set up P=GCGAT CCCCA (SEQ ID NO: 3).
N
N
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
TGA
TAA
GGA
GAA
CGA
CAA
AGA
AAA
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
TGC
TAC
GGC
GAC
CGC
CAC
AGC
AAC
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
TGG
TAG
GGG
GAG
CGG
CAG
AGG
AAG
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
TGT
TAT
GGT
GAT
CGT
CAT
AGT
AAT
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
TTA
TCA
GTA
GCA
CTA
CCA
ATA
ACA
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
TTC
TCC
GTC
GCC
CTC
CCC
ATC
ACC
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
TTG
TCG
GTG
GCG
CTG
CCG
ATG
ACG
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
T 12 P-
TTT
TCT
GTT
GCT
CTT
CCT
ATT
ACT
N
N
T
G
C
A
Cy2
Cy3
Cy5
A is a self extended primer that only extends with A;
C is a self extended primer that only extends with C;
G is a self extended primer that only extends with G;
T is a self extended primer that only extends with T;
N is a mix of A, C, G, and T, self extending primers.
Cy2, Cy3 and Cy5 are pre-labelled primers with respectively dye. (Can also be self extended in some cases.)
Extension Reagents for the APEX Reaction
Dyes:
Cy2 - ddCTP (equal to fluorescein)
50 μM
Cy3 - ddGTP
50 μM
Cy3 - ddATP
50 μM
Cy5 - ddUTP (often written as T in
50 μM
many of the reactions and results)
Dye mixes may vary from time to time, use normal stocks of 50 μM.
10×ThermoSequenase DNA polymerase buffer (TS): 260 mM Tris-HCl pH 9.5; 65 mM MgCl 2 , this buffer does not have high influence on the APEX reaction.
ThermoSequenase DNA polymerase (from Amersham Pharmacia Biotech (APB)) 4 U/μl. If needed dilute with T.S. dilution buffer (=10 mM Tris-HCl pH 8.0; 1 mM β-mercaptoethanol, 0.5% Tween-20 (v/v), 0.5% Nonidet P-40 (v/v)).
KlenTaq X DNA polymerase (WO 92/06188 with the same mutation for improved ddNTP incorporation as in Thermosequenase DNA polymerase) ˜5 U/μl.
Methods
Preparation of Glass Slides Before Spotting of Primer:
1. Arrange 25-30 cover slips (24×60 mm) in a stainless staining tray.
2. Immerse the tray in glass staining dish with acetone to fully immerse slides.
3. Place the glass staining dish in sonicator for 10 minutes.
4. Remove the tray from acetone bath, shake off excess of acetone and rinse several times (at least twice) in MilliQ water.
5. Immerse tray in 100 mM NaOH and sonicate for 10 minutes (a few more minutes, no problem).
6. Remove the tray and shake off the excess of NaOH and rinse several times (at least twice) in MilliQ water.
7. Immerse tray in silane solution and sonicate for 2 minutes.
8. Wash slides by immersion in 100% EtOH once. (Silane and silane contaminated EtOH in special container for silane discharge.)
9. Dry the tray with the slides in nitrogen with a high velocity (without breaking the slides).
10. Cure the slides in a vacuum oven at 100° C. over night or until they are used for spotting (at least 20 minutes vacuum is not needed).
Spotting of Oligos:
All spotting was done with a lab made spotter with 96 parallel capacity. Each slide was spotted with three replicas of the primers.
After spotting the slides were allowed to air dry for 5 to 15 minutes, when dried and marked. They were stored at room temperature, in a dry place, in the trays until used. Chips can be used for a few weeks, probably longer. Arrangements of oligos and sequences see above.
RAPD Amplification
The RAPD amplification were done according to the Ready-To-Go RAPD instruction. After 45 cycles (96° C., 1 min.; 36° C., 1 min.; 72° C., 2 min.), one microliter of the products was tested on a 4-20% premade PAGE, before the fragmentation step.
Fragmentation of RAPD (DNA fragment) Products:
Before RAPX (APEX) can be done all DNA fragments must be fragmented so all new fragments can get access to the primer on the chip.
Set Up:
20 μl DNA from RAPD reaction
0.5 μl SAP (Shrimp alkaline phosphatase) 1 U/μl
0.5 μl UDG (Uracil-DNA-glycosylase, if from PE UDG×UNG)
1 U/μl NE Biolabs
Total: 21 μl
Incubate 37° C. for 1 hour.
Inactivate enzymes at 100° C. for 10 minutes.
The samples can now be frozen and stored until they are used.
Extension Method for the APEX Reaction Slide Treatment:
Start with washing the slides in hot water (90-98° C., not boiling) for 2×5 minutes in a 50 ml Falcon tube. When the slides are ready, remove them from the tube with a forceps and place them on a dry heater block at 48° C. The slide (DNA chip) is now ready for adding the reactions.
RAPX Reactions Set Up:
1. 4-5 μl DNA from RAPD reaction (or from PCR reaction if an APEX slide has been used). Note that the DNA must be fragmented before this step.
2. 3μl 10×TS buffer (the rest of the buffer comes from PCR and DG cleavage)
3. Water to 38 μl for dry-down method or 18 μl for cover slip method.
4. Heat denature at 100° C. for 7-10 minutes, target 8 minutes, not longer.
5. Spin the tube quickly and add quickly
6. 1 μl ThermoSequenase DNA polymerase (4U)
7. 1 μl Dye-mix (up to three dyes at the same time and quick spin and load on the slide).
These three last steps must be done under 1 minute, in order not to let DNA fragments renaturate. If cover slips are used, each reaction needs 20 μl, but the dry-down method is preferred, where all 40 μl of the reaction is physically spread out over the primer array with help of the tip of a pipette tip.
8. Incubate at 48° C. for 20 minutes with cover slip. Alternatively, the so called dry-down method can be used were the spread mix is allowed to dry down until no trace of solution is seen. This takes about 8 minutes. The signals with cover slips were better and with lower background.
9. Wash with hot water for 2-5 minutes, 2 times.
10. Ready to read on TIRF instrument.
Detection
The detection system is a total internal reflection fluorescence (TIRF) , where microscopic slides are placed on top of a prism with oil on to link a laser beam in to the glass slide. The system has five different wave lengths from five different lasers to vary between. In this experiment only three were used. To detect Cy2 a laser with 488 nm was used, for Cy3 a 532 nm and for Cy5 a 635 nm laser was used. Image related software was based on Image Pro Plus 3.0.
Results
RAPD Amplification
The RAPD amplification was done with RTG RAPD beads in order to use a standardised method for further high reproducibility. The amplified products were analysed on an ethidium bromide stained polyacrylamide gel. The only reference to compare with was the RAPD manual from APB with the different primers and the two E. coli stains. The expected bands were seen, and correspond very well. In summary, all DNA were nicely amplified except the Listeria DNA with primer 1283, which contained too much broken DNA.
RAPX Reaction with E. coli DNA
DNA from the two E. coli stains BL21 and C1a were amplified and fragmented. The extension reaction is quick to set up and analyse. The extension can be done in two ways, either with or without a cover slip. If a cover slip is used the background is lower and was mainly used in the typing reactions, see below. But, in the first set up, the dry down method with no cover slip was used, which resulted in some circular shaped background.
In the set up of primers positive controls were used, in each corner of the matrix a mix of primers were added that always will be extended if the DNA polymerase is active. Below the matrix self extendible primers for the different bases were placed together with Cy-dyed primers for laser control. A self extended primer is a primer that has complementarily to it self or a neighbour, which then can be extended. The neighbour is seen in the cases with the 64 primers and the other control primers are fold back self extenders. The different pre-labelled primers gave expected signals showing that the detector and the imaging system is working. Taken together this show that the DNA polymerase is active and that the system is working perfectly with all positive signals.
After RAPD amplification and fragmentation the two E. coli stains BL21 and C1 were analysed on Primer 2 RAPX chips. The two different E. coli strains show clearly two different patterns, accordingly these two E. coli strains can be separated. Both E. coli strains gave four bands after RAPD analysis on PAA. Each band has two ends with the sequence from the primer, the sequence further in is not known. Accordingly, totally 8 spots can light up on a RAPX chip. Three panels with E. coli DNA have about 13 stronger signals and the control with no DNA has five signals, this corresponds well with the expected 8 spots. The position of the spots can not be predicted unless each fragment is sequenced or the whole genome of the organism is sequenced.
Typing of Six Listeria Strains with RAPX.
With the good tests with E. coli DNA in mind, the next step was to test if different patterns can be generated from several different strains, six strains from Listeria monocytogenes were then selected. The chosen strains had been typed with RAPD and analysed on silver stained gels by C. Ko, Hoefer see below, which will make it easier to interpret the results from the RAPX analysis.
Before the typing started the following two tests were done, firstly check of primer chips for self-extendible primers. Secondly, test two different thermostable enzymes, ThermoSequenase DNA polymerase and KlenTaqX DNA polymerase. The comparison of different Listeria strains was finally done.
During the work two different thermostable DNA polymerases was used. The majority of reactions were done with ThermoSequenase DNA polymerase, but also KlenTaqX DNA polymerase were used. The new enzyme KlenTaqX DNA polymerase, which is smaller in size than ThermoSequenase DNA polymerase gave stronger signals and lower background, which also made it easier to assign the base on the extended primers. All spots, even the weak ones where informative in the cluster analysis with elongation with KlenTaqX DNA polymerase, when the clusters from Primer 2 and Primer 6 were compared.
Each sample was analysed two times using two different dye mix systems, since not all terminators are available with dyes with separated spectrum. The two dye mixes were Mix1: Cy2-ddCTP, Cy3-ddGTP, Cy5-ddATP and Mix2:, Cy2-ddCTP, Cy3-ddGTP, Cy5-ddUTP. Thus, each sample generated six images, but the assembly of these six images gave a pseudo four dye system, by choosing the best of either “2” or “4”, and “3” or “5” to get C and G extendible primers, respectively. The A and T (ddUTP) extendible primers are from Cy5-labelled terminators, “1” and “6”.
The next step was to test all Listetia strains in the RAPX reaction. It was notable how quick the RAPX analysis is done, even though the reaction was done in duplicate, with two different dye mix combinations. The RAPX reaction takes about 30 minutes, including pipetting, set up and reading the images.
For the analysis of relation between the different strains the best of the triplicate signals on each slide were selected. All signals shown on the image were scored manually and the extended bases were assigned. FIG. 4 shows all six Listefa strains after analysis with Primer 6, these samples were extended with KlenTaqX DNA polymerase. The same type of data was also generated from Primer 2, but with ThermoSequenase DNA polymerase, data not shown. All assigned bases were stored in a spread sheet software for cluster analysis, which was done in two steps. In the first step all assigned bases were converted to figures and then a similarity table was calculated. Finally a dendogram was calculated as shown in FIG. 5 .
When cluster data from a poster made by Chris Ko at Hoefer Pharmacia in San Francisco were compared with the data generated with RAPX, the similarities are seen. Then the dendograms from Primer 6 and 2 data were compared with the dendogram generated by Chris Ko and were shown to be very similar. The small differences could be explained by the use of different primers in C Ko's experiments.
Conclusions
The RAPX method is shown to be a quick and accurate method. It takes approximately 30 minutes to perform the extension, and detection including hands on time and incubations. Different strains can be analysed with the RAPX method and the same cluster/groups can be identified when compared with ordinary gel electrophoresis. The speed and the easiness of the RAPX method guarantee for the future use of this array technology in bacterial typing as well as relationship studies of other organisms. An array format like this method could easily be highly automated.
7
1
10
DNA
Artificial Sequence
Description of Artificial Sequence primer 2
1
ggtgcgggaa 10
2
10
DNA
Artificial Sequence
Description of Artificial Sequence primer 6
2
cccgtcagca 10
3
10
DNA
Artificial Sequence
Description of Artificial Sequence primer 1283
3
gcgatcccca 10
4
10
DNA
Artificial Sequence
Description of Artificial Sequence primer
4
gtttcgctcc 10
5
25
DNA
Artificial Sequence
misc_feature
(23)..(25)
N= A, C, G, or T
5
tttttttttt ttgtttcgct ccnnn 25
6
25
DNA
Artificial Sequence
misc_feature
(23)..(25)
N= A,C,G or T
6
tttttttttt ttcccgtcag cannn 25
7
25
DNA
Artificial Sequence
misc_feature
(23)..(25)
N= A, C, G or T
7
tttttttttt ttgcgatccc cannn 25
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A nucleic acid analysis method is provided which includes the steps of using a primer to amplify the nucleic acid; providing an array of probes, each probe comprising a sequence identical to the primer and an adjacent sequence; applying fragments of the amplifier nucleic acid under hybridisation conditions to the array, effecting enzymatic chain extension of any probe where the adjacent sequence matches that of a hybridised fragment of the amplified nucleic acid; and observing the location of probes of the array while chain extension has taken place.
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FIELD OF THE INVENTION
This invention relates generally to fuel delivery systems for internal combustion engines and more particularly to an improved carburetor.
BACKGROUND OF THE INVENTION
Carburetors are widely used to produce and control the mixture of fuel and air delivered to an operating engine. Current carburetors utilize one or more needle valve assemblies to meter the quantity of fuel in the fuel and air mixture. The needle valve assemblies have a pin or needle threadably received in a bore of the carburetor and rotatable to vary the location of a conical end of the needle relative to an annular seat to vary and control the area between the needle and the seat through which fuel flows. One of the major problems with needle valve assemblies is that a fuel flow change can and usually does occur after the needle valve assembly has been adjusted. This fuel flow change is caused by axial and radial movement after adjustment of the conical tip of the needle relative to the seat which may be caused by vibrations, temperature changes, installation of a limiting cap and other physical side loading of the needle. Radial movement of the needle relative to the valve seat decreases the gap between the needle and the valve seat adjacent one portion of the needle and increases the gap on the opposite portion of the needle which can drastically affect the fuel flow characteristics through the needle valve assembly.
Another problem with the needle valve assemblies is the size of the metering orifice. The annular fuel flow area between the needle and valve seat is generally on the order of about 0.001 inches to 0.002 inches wide. Most particles such as dirt or aluminum flakes within the carburetor are too large to pass through this gap and may at least partially clog the fuel flow area causing the engine to run leaner than desired.
Also, to limit the extent to which the end user can vary the fuel flow rate through a needle valve assembly, a limiter cap or the like has to be installed on the needle to limit the extent to which it can be rotated. These limiter caps increase the cost to manufacture and assemble the needle valve assemblies and may cause the needle valve to shift relative to its seat as the caps are installed after adjustment and thereby unintentionally alter the fuel flow rate of the valve assembly.
Additionally, current carburetors typically have at least a low fuel mixture needle valve, a high fuel mixture needle valve and an idle air adjustment screw. Adjustment of these components permits calibration or tuning of the carburetor to provide a fuel and air mixture to the engine at speeds ranging from idle speed to wide open throttle. However, adjustment of the carburetor is relatively complex and difficult for unskilled power equipment operators. When the user adjusts the idle or the high mixture needle, the fuel flow will change to either a richer or a leaner condition. Resulting from this mixture change, undesirable engine performance may occur such as acceleration lag, under running during deceleration, instability of the engine at idle speeds, increased exhaust emissions, and improper or less than optimum fuel to air ratios and engine performance.
SUMMARY OF THE INVENTION
A single screw carburetor is provided having an idle nozzle and a main nozzle each with a fixed flow area and an idle speed adjustment screw adjustable by the user. The idle and high speed fuel flows are controlled by the idle nozzle and the main nozzle, respectively. The user can adjust the engine speed only by adjustment of the idle speed adjustment screw which changes the position of the carburetor throttle valve to control the air flow through the carburetor. This provides a more consistent fuel and air mixture to improve performance of the engine and better control engine emissions by preventing the user from changing the fuel and air mixture ratio to a mixture which is either too lean or too rich for the optimum operation of the engine.
The single screw carburetor facilitates adjustment of the engine idle speed by the user and eliminates the complex calibration of carburetors having needle valve assemblies and the subsequent fuel flow changes which occur in use of the needle valve assemblies after calibration. Further, the limited idle speed adjustment permitted by the user prevents the user from adjusting the carburetor so that the engine runs too lean or too rich and maintains the engine emissions within the limits set by current emissions legislation. In this way, the carburetor is inherently tamper-proof Further, the idle nozzle and main nozzle may be machined orifices directly in the carburetor body or they may be separate inserts fitted into bores in the carburetor. This reduces the number of parts of the carburetor as compared to carburetors utilizing needle valve assemblies and, therefore, the cost to manufacture and assemble this single screw carburetor is reduced.
Objects, features and advantages of this invention include providing a carburetor which facilitates adjustment of the idle speed by the operator, eliminates adjustment by the operator of the fuel to air ratio, eliminates the use of needle valve assemblies, reduces the number of parts in the carburetor, provides a generally fixed fuel to air ratio of the mixture delivered to the engine, assures stable engine performance, easily meets the tamper resistant requirements of current emissions legislation, provides a consistent fuel flow from one carburetor to another, is of relatively simple design and economical manufacture and assembly, and has a long, useful life in service.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of this invention will be apparent from the following detailed description of the preferred embodiments and best mode, appended claims and accompanying drawings in which:
FIG. 1 is an end view of a carburetor embodying the invention;
FIG. 2 is a bottom view of the carburetor of FIG. 1;
FIG. 3 is a cross sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a cross sectional view taken along line 4--4 of FIG. 2;
FIG. 5 is a cross sectional view of an idle nozzle without a check valve;
FIG. 6 is a cross sectional view of a main fuel nozzle; and
FIG. 7 is a cross sectional view of a modified main nozzle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in more detail to the drawings, FIGS. 1 and 2 illustrate a carburetor 10 having a main body 12 with a mixing passage 14 in which a throttle valve 16 is mounted on a shaft 18 rotatable by a lever 20. A fuel pump 22 in the body 12 receives fuel from a fuel inlet 24 and delivers fuel to a chamber 26 through an inlet valve (not shown) controlled by a fuel metering diaphragm 28 such as shown and described in U.S. Pat. No. 5,262,092, the disclosure of which is incorporated herein by reference in its entirety. Generally, the fuel chamber 26 is defined between one side of the diaphragm 28 and the main body 12 of the carburetor 10 and an air chamber 30 is defined between the other side of the diaphragm 28 and a cover plate 32. Preferably, the air chamber 30 communicates with the atmosphere through a hole 33 in the cover plate. The diaphragm 28 is responsive to a differential pressure across the diaphragm 28 to actuate a valve assembly (not shown) to control the delivery of fuel from the fuel pump 22 to the fuel chamber 26.
As shown in FIGS. 3 and 4, the mixing passage 14 may have a venturi shape with a reduced diameter central portion or throat 15 in which a pressure drop is created by air flow through the mixing passage 14. Air flow through the mixing passage 14 is controlled by the throttle valve 16. The throttle valve 16 is rotated in the mixing passage 14 between a first position substantially closing and generally transverse to the axis of the mixing passage 14 and a second, fully open position generally parallel to the axis of the mixing passage 14 and permitting a substantially unrestricted flow of air through the mixing passage 14. The first position of the throttle valve 16 corresponds to engine idle speed and the second position corresponds to what is commonly referred to as "wide open throttle". Desirably, a spring 34 yieldingly biases the throttle lever 20 and hence, biases the throttle valve 16 to its idle position.
An idle speed adjustment screw 36 is threadably received in the carburetor body 12 and has a conical tip 38 on its free end. The tip 38 provides an adjustable stop engaged by an arm 40 attached to one end of the throttle valve shaft 18 when the throttle valve 16 is in its first or idle position. Rotation of the idle speed adjustment screw 36 changes the location of the tip 38 relative to the arm 40 to change the position at which the arm 40 bears on the tip 38 and thereby adjusts the first position of the throttle valve 16 and hence the idle speed of the operating engine.
Liquid fuel in the fuel chamber 26 is supplied to a low speed or idle nozzle 50 and a high speed or main nozzle 52 received in passages 54 and 56 formed in the main body 12. The idle nozzle 50 communicates with the mixing passage 14 through three separate passages 58, 60, 62. The first passage 58 opens into the mixing passage 14 downstream of the throttle valve 16 when it is in its first or idle position. Second and third passages 60, 62 open into the mixing passage 14 upstream of the throttle valve 16 when it is in its first or idle position. The main nozzle 52 preferably communicates directly with the mixing passage upstream of the throttle valve 16.
As best shown in FIGS. 4 and 5, the idle nozzle 50 is preferably an insert fitted into the passage 54 and has a fuel passage 66 formed therethrough and having an inlet end 68 leading to a tapered or venturi portion 70 which opens into an outlet 72 of the passage 66. Alternatively, the idle nozzle may be an orifice machined directly in the carburetor body 12. If desired, a check valve 74 (FIG. 4) may also be provided adjacent the outlet of the passage 66 to facilitate purging of air from the carburetor to improve starting of the engine and to prevent reverse fuel flow through the idle nozzle.
As best shown in FIGS. 4 and 6, the main nozzle 52 is an insert fitted into the passage 56 which is in communication with the mixing passage 14 upstream of the throttle valve 16. The main nozzle 52 has a passage 76 formed therethrough having an inlet end 78 leading to a tapered or venturi portion 80 which opens into an outlet side 82 of the nozzle 52 Alternatively, the main nozzle 52 may be an orifice machined directly in the carburetor body 12. The main nozzle 52 may be of substantially any configuration sufficient to provide the desired fuel flow characteristics therethrough. A check valve 83 is provided adjacent the main nozzle outlet 82 to prevent reverse fluid flow from the mixing passage 14 through the main nozzle 52. The check valve is preferably carried by the main nozzle as shown in FIG. 6 and has a valve disc 85 which bears on an annular valve seat 87 to close the main nozzle 52. A perforate retainer 89 limits the displacement of the valve disc 85 from the valve seat 87 when fuel and/or air are discharged from the main nozzle 52 into the mixing passage 14. Such a check valve 83 prevents reverse flow through the main nozzle 52 and removal of fuel from the main circuit during engine idle and slightly open throttle conditions.
In another embodiment, the idle and main nozzles 50, 52 may be threadably received in tapped bores in the carburetor body 12 or in separate inserts themselves fitted in the carburetor body. For example, as shown in FIG. 7, a main nozzle assembly 52' has a body 90 with a fixed orifice 92 threadably received in a retainer 94 press fit in the passage 56 of the carburetor body 12. A check valve 96 is preferably carried by the retainer 94.
Operation
When the engine is idling, the throttle valve 16 is in its first position substantially restricting the flow of air through the mixing passage 14. The low air flow velocities upstream of the throttle valve 16 are not sufficient to induce fuel flow from the main nozzle 52. The first passage 58 communicating with the idle nozzle 50 is subjected to a vacuum or a pressure drop caused by the cranking of an operating engine. As a result thereof, the passage 54 containing the idle nozzle 50 receives fuel from the fuel chamber 26 which flows through the idle nozzle 50, the first passage 58 and into the mixing passage 14 whereupon the fuel is combined with air and the fuel and air mixture is delivered to the operating engine.
When the engine throttle lever 20 is moved to cause an increased engine operating speed, the throttle valve 16 is rotated within the mixing passage 14. As viewed in FIG. 3, the throttle valve 16 rotates counterclockwise from its first position toward its second or wide open throttle position. As the throttle valve 16 initially opens, fuel is supplied to the mixing passage through both the first passage 58 and at least the second passage 60 and usually the third passage 62 which function as acceleration ports to provide additional fuel to the mixing passage 14 as the engine is accelerated from an idle or low operating speed to a higher operating speed. When the throttle valve 16 is opened sufficiently towards its wide open throttle position, an increased pressure drop is produced at the main nozzle 52. This pressure drop at the main nozzle 52 draws fuel from the fuel chamber 26 through the main nozzle 52 for delivery into the air stream flowing through the mixing passage 14 to provide a fuel and air mixture to the operating engine.
The passages 66, 76 formed through the idle nozzle 50 and the main nozzle 52 are constructed to provide a metered flow of fuel into the mixing passage 14 to provide the desired fuel to air mixture ratio as desired for the operation of the engine. Desirably, this fuel to air mixture ratio remains essentially constant throughout use of the carburetor 10 and is within acceptable limits to provide stable engine performance and acceptable exhaust emissions levels from the operating engine. Therefore, with the fixed orifice idle and main nozzles 50, 52, the carburetor 10 according to this invention provides a desirable fuel to air ratio mixture to an operating engine over engine speeds ranging from idle to wide open throttle. Desirably, this fuel to air ratio of the mixture cannot be altered by the user and does not require high and low fuel mixture needle valve assemblies which are difficult to calibrate or adjust, and which are subject to becoming clogged or displaced to provide inconsistent fuel flow rates therethrough in use.
The only adjustment which can be made externally of the carburetor 10 by the user is to the idle speed adjustment screw 36 which permits slight variation of the first position of the throttle valve 16 to vary and adjust the engine idle speed. This adjustment of the screw 36 permits the user to control the speed at which the engine idles by changing the first position of the throttle valve 16 to control the air flow and thus the rate of flow of fuel drawn through the idle nozzle 50 and into the mixing passage 14. Thus, with a single adjustment screw 36, the user can control the idle speed of the engine to provide for the stable operation of the engine. The fuel to air mixture ratio remains generally constant and cannot be altered by the user. Thus, the carburetor 10 eliminates the complex adjustments associated with multiple needle valve assemblies and the engine performance and emission problems associated with improper carburetor adjustment made by the user.
The carburetor 10 according to this invention has relatively few parts, is easy to adjust by the end user, is tamper-proof and provides an essentially constant fuel to air ratio mixture sufficient for the stable operation of the engine. Further, the carburetor 10 according to this invention is extremely versatile in that interchangeable idle nozzles 50 and main nozzles 52 of different sizes may be inserted into the carburetor main body 12 to change the fuel flow characteristics of the carburetor 10 so that the carburetor 10 may be used with different engines.
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A carburetor having an idle nozzle and a main nozzle each with a fixed flow area and an idle speed single adjustment screw adjustable by the user. The idle and high speed fuel flows are controlled by the idle nozzle and the main nozzle, respectively. The user can adjust the engine speed only by adjustment of the idle speed adjustment screw which changes the position of the carburetor throttle valve to control the flow through the carburetor. This provides a more consistent fuel and air mixture to improve the performance of the engine and better control engine emissions by preventing the user from changing the fuel and air ratio to a mixture which is either too lean or too rich for the steady and low level exhaust emission operation of the engine.
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This is a continuation of copending application Ser. No. 07/531,783 filed on Jun. 1, 1990, now abandoned.
The present invention relates to bucket attachments for connection to the arm structure and hydraulic system of a mobile machine such as a skid-steer loader and, more particularly, to a vibrating bucket screen attachment for such a mobile machine.
BACKGROUND OF THE INVENTION
The national shoreline of the United States is 32,344 miles long, excluding Alaska and Hawaii. See the National Shoreline Study, U.S. Army Corps of Engineers, 1971. Although sixty percent of the shoreline may have been undeveloped in 1971, 40% had been classified as either devoted to public recreation, private recreation or non-recreational developed. Thirty percent or about 10,983 miles of the shoreline meets the criteria of a beach where, according to the Army Corps of Engineers, a beach is defined as the area with sand between high and low tide. Of course, the 10,983 miles of beach shoreline does not include the numerous beaches found adjacent to inland lakes and rivers such as the Great Lakes or Mississippi River.
Beaches exist in a variety of types. For example, open beaches with widths of over one hundred yards may run for over a mile. Smaller beaches, especially around retirement communities, may be secluded and dotted with palm trees. Some beaches are soft, others are hard. Some beaches include coral sand, others comprise volcanic or glacial sand.
The cleaning of beaches is a slow and difficult task, whether accomplished by hand or machine. When a beach is hand-cleaned, only the larger, visible items such as pop and beer cans are found. Smaller items such as nails or hairpins remain dangerously hidden in the sand. Manually labor is typically employed to clean the private secluded beaches because the large, complex beach cleaning machines are prohibitively expensive. Moreover, the massive beach cleaning machines are difficult to maneuver where beach areas include obstructions such as trees, boulders and docks.
SUMMARY OF THE INVENTION
A feature of the present invention is the provision in a vibrating bucket screen attachment for picking up litter from a sandy beach and for connection to the arm structure and hydraulic system of a mobile machine such as a skid-steer loader, of an inner vibrating screen mounted in an outer, primary excavating bucket and spaced above a cutting edge of a sand-scooping blade and a bottom portion of the primary bucket which engages and slides on the beach.
Another feature is the provision in such a vibrating bucket screen attachment, of the screen being resiliently mounted in the primary bucket.
Another feature is the provision in such a vibrating bucket screen attachment, of means for adjusting the amplitude of the vibrations of the screen.
Another feature is the provision in such a vibrating bucket screen attachment, of an adjustable blade which may be disposed to penetrate the sand at different depths.
Another feature is the provision in such a vibrating bucket screen attachment, of a harp-type screen that includes screen wires running parallel to each other with no cross-over screen wire such that sand is screened more quickly.
Another feature is the provision in such a vibrating bucket screen attachment, of support means on the frame for supporting the attachment relative to the the beach and being adjustable to aid in disposing the cutting edge of the blade at a prescribed depth.
Another feature is the provision in such a vibrating bucket screen attachment, of a roller broom disposed adjacent to the blade for sweeping sand and litter onto the screen, and of the roller broom being swingable to an out-of-the-way position.
Another feature is the provision in such as vibrating bucket screen attachment, of an electromagnet traversing the screen adjacent to the cutting blade for picking up small pieces of metallic litter which otherwise would pass through the screen.
An advantage of the present invention is that it is inexpensive relative to other beach cleaning machines.
Another advantage is that beaches are cleaned quickly. The present bucket screen attachment cleans about one hundred feet per minute while traversing a six foot span and while picking up items as small as bobby pins.
Another advantage is that litter is cleanly separated from the sand. The present bucket attachment conveys sand from a scooping blade onto a screening bucket spaced from the surface of the beach and isolated via the resilient mounts from the primary bucket. Such spacing and isolation permit a free unhindered vibration for quick separation of the sand from the litter.
Another advantage is that the inner vibrating bucket screen is readily mountable in and removable from the primary excavating bucket. A set of typically four resilient mounts are easily aligned to provide for the quick connection.
Another advantage is ease of operation. Skis or wheels on the primary excavating bucket permit the operator of the skid-steer loader to easily dispose the cutting edge of the blade at a uniform depth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the vibrating bucket screen attachment connected to the arm structure and hydraulic system of a skid-steer loader.
FIG. 2 is a detail section view at lines 2--2 of FIG. 1.
FIG. 3 is a detail section view at lines 3--3 of FIG. 1.
FIG. 4 is a detail rear elevation view at lines 4--4 of FIG. 1.
FIG. 5 is a detail bottom elevation view of the bucket screen attachment of FIG. 1.
FIG. 6 is a detail, elevation cut away view at lines 5--5 of FIG. 1.
FIG. 7 is side elevation view of an alternate embodiment of the invention showing transverse hinge mechanisms.
FIG. 7a is a cross-section partial view of one of the transverse hinge mechanisms.
FIG. 8 is a partial perspective view of an alternate embodiment of the invention showing an adjustable blade for penetrating the beach at various depths.
FIG. 9 is a partial perspective view of an alternate embodiment of the invention showing wheels for supporting the attachment relative the beach.
FIG. 10 is a perspective view of an alternate embodiment of the invention showing a harp-type screen.
FIG. 11 is a detailed partially broken away view of a portion of the harp-type screen shown in FIG. 10, and of another harp screen embodiment.
FIG. 12 is partial view of a punch plate steel screen utilized for screening black dirt.
FIG. 13 is a partial view of an alternate embodiment of the invention showing a roller broom disposed adjacent to the blade and swingable by a hydraulic cylinder to an out-of-the-way position.
FIG. 14 is a front elevation view of the roller broom of FIG. 13 with bristles.
FIG. 14a is a front view of a roller broom with resilient strips.
FIG. 15 is a cross-section of a roller broom with tension mounted tines.
FIG. 16 is a perspective view of an alternate embodiment of the invention showing a telescoping rake mountable on the bucket for raking seaweed from a shoreline.
FIG. 17 is a perspective view of a preferred embodiment of the vibrating screen bucket attachment.
FIG. 18 is a side elevation, partially broken away, partially phantom view of the attachment of FIG. 17.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the present vibrating bucket screen attachment is generally indicated by reference numeral 10 and includes as its principal components a primary excavating bucket or frame 11, an inner bucket screen 12 with a vibrator 13, an elongate blade 14 with a cutting edge 15, and a pair of runners or skis 16.
The attachment 10 is connectable to a mobile machine such as a skid-steer loader 20. The skid-steer loader 20 includes a pair of bucket or lift arms 21 with distal connecting ends 22 for connection to the attachment 10. The lift arms 21 are operated by a pair of lift hydraulic cylinders 23. A pair of dump or tilt hydraulic cylinders 24 are pivotably connected to the lift arms 21 and to the attachment 10 via distal piston ends 25.
The primary excavating bucket 11 includes a one-piece integral frame comprising a generally rectangular rear plate 31 integrally formed with a pair of generally triangular side plates 32 extending forwardly from the rear plate 31. The rear plate 31 includes two pairs of rigid apertured ears 33 for connection to the arm structure of the skid-steer loader 20. Upper apertured portions of the ears 33 are connected to the distal ends 25 of the tilt hydraulic cylinders 24 via pin connectors 42. Lower apertured portions of the ears 33 are connected to the distal ends 22 of the lift arms 21 via pin connectors 43.
An angled flange 35 extends rearwardly from an upper portion of the rear plate 31 and runs parallel to and opposite of a bottom edge 36 of the rear plate 31. The flange 35 is formed integrally with a pair of oblique, outwardly extending angled flanges 37 on the side plates 32. Opposite of the oblique flanges 37, the side plates 32 include inwardly extending flanges 38. Each of the inwardly extending flanges 38 includes a bottom surface portion 39 which engages and slides on the beach. Although use of the skis 16 is preferred, the attachment 10 may be utilized without skis 16 with the bottom portions 39 engaging and sliding on the beach.
The triangular side plates 32 are held in a spaced apart relationship by the rear plate 31 and the blade 14, which may be rigidly affixed between inner front portions of the plates 32. An open bottom portion 40 is provided between the flanges 38 of the side plates 32 to allow sand screened by the screening bucket 12 to fall back to the beach.
The pair of skis 16 are adjustably affixed to the primary bucket 11 via respective, front and rear slots 50, 51. Each of the slots 50, 51 is generally vertically formed in its respective side plate 32. Pin connectors 52 of the bracket-like ski mounts 53 extend through slots 50, 51 to affix the skis 16 to the primary bucket 11. A raising or lowering of the ski mounts 53 in the slots 50, 51 dispose the cutting edge 15 of the blade 14 at a prescribed depth relative the surface of the beach on which the skis 16 slide. Typically, the cutting edge 15 of the blade 14 lies in the same plane as the bottom surface portions 39 of the flanges 38. Accordingly, if the cutting edge 15 traverses the beach at a two inch depth, the bottom surface portions 39 follow at such a two inch depth.
The inner vibrating screen bucket 12 includes a generally rectangular horizontal floor portion bounded by front and rear angle iron support members 70 and 71 and side angle iron support members 72, 73 which are rigidly affixed between the front and rear support members 70, 71. Flat steel standing or bars or strips 74 are rigidly connected between the front and rear support members 70, 71. Reinforcing corner gussets 75 are rigidly affixed in the four corners of the floor portion. A rectangular floor section of screen cloth 76 is supported by and affixed to the support members 70-73, bar 74 and gussets 75.
The inner vibrating screen bucket 12 further includes a rear bucket portion bounded by rear, lower support member 71 of the floor portion, and upper angle iron support member 80, and outer generally upright angle iron support members 81, 82, which are rigidly affixed between support members 71, 80. Reinforcing corner gussets 83 are rigidly affixed in the four corners of the rear bucket portion. A bent plate 84 for mounting the vibrator 13 is rigidly affixed between the lower and upper support members 81, 80. A pair of oblique, reinforcing angle iron support members 85.1 are affixed between upper portions of the bent plate 84 and lower gussets 83. It should be noted that the rear screen bucket portion and angle irons 81, 82 are tilted slightly forwardly relative to the rear plate 31 of the primarily bucket 11. A rectangular rear section of screen cloth 85 is affixed to and supported by the support members 71, 80, 81, 82, gussets 83, bent plate 84, and oblique support members 85.1.
The inner vibrating screen bucket 12 further includes generally triangular side portions bounded by respective side, lower support members 72, 73, respective outer, rear support members 81, 82, and oblique, downwardly and forwardly extending support members 90, and front upright angle iron support members 91. Support members 82, 91 are rigidly affixed between support members 72, 90. Generally triangular side sections of screen cloth 92 are affixed to and supported by their respective support members 72, 73, 81, 82, 90, 91.
The sections of screen cloth 76, 85, 92 are typically integrally connected to each other to be formed of one piece. The screen cloth may be of a cross-over type screen as shown in FIG. 6. The screen gauge typically ranges from one-eighth to three inches.
The inner vibrating screen bucket 12 is typically mounted in the primary bucket 11 via a set of four resilient mounts 100. Each of the mounts 100 include an apertured angle bracket 101 rigidly affixed such as by welding to one of the oblique support members of the screen bucket 12 and an apertured angle bracket 102 affixed to one of the oblique flanges 37 of the primary bucket 11. A threaded rod 103 with lock nuts 103.1 mount a pair of resilient, compression springs 104. The springs 104 are disposed o either side of the angle bracket 101 connected to the inner screen bucket 12. With the mounts 100 connected to the oblique support members 90 of the screen bucket 12, the compression springs 104 bear against the angle brackets 102 on the flanges 37 on the primary bucket 11 and the angle brackets 101 on the inner screen bucket 12, and washers 105 on a top portion of the threaded rod 103.
It should be noted that the attachment 10 may include an additional pair of rear, lower resilient mounts 100. As shown in FIGS. 2 and 4, angle brackets 101 are connected to lower gussets 75 of the inner screen bucket 12 and angle brackets 102 are connected to the rear plate 31 of the primary bucket 11. One compression spring 104 extends between the angle brackets 101, 102; the other compression spring 104 is mounted between angle bracket 101 connected to the screen bucket 12 and a washer 105 on top of a threaded rod 103.
The lock nuts 103.1 of the resilient mounts 100 may be turned up or down on the threaded rod 103 to control the amplitude of the vibrations of the screen bucket 12. When the springs 104 are compressed by adjustment of the lock nuts 103.1, the amplitude of the vibrations decreases. When the springs 104 are decompressed, the amplitude of the vibrations is increased. It should be noted that the amplitude of vibrations at a frontward portion of the screen bucket 12 may be increased relative to a rearward portion of the screen by either decreasing the compression of the forwardly disposed mounts 100 or increasing the compression of the rearwardly disposed mounts 100. Likewise, the amplitude of vibrations at a rearward portions of the screen bucket 12 may be increased relative the front portion by adjustment of the forward and rearward mounts 100.
The vibrating screen bucket 12 further includes the vibrator 13 which is mounted on the bent plate 84. The vibrator 13 includes a housing 110 and hydraulic feed and return lines 111, 112, which run from the hydraulic system of the skid-steer loader 20 to the vibrator 13. The feed line 111 includes a variable speed flow control valve 113 for increasing the frequency of the vibrations of the vibrating screen bucket 12. The vibrator 13 includes a Char-Lynn® hydraulic motor 114 bearing a Model No. 128-0012-002 available from Power Systems in Eden Prairie, Minn. The motor 114 drives a shaft 115 mounted in pillow block bearings 116. The bearings 116 and motor 114 are set on braces 117 in the housing 110. The vibrator 13 further includes a flex-coupling 118 and an eccentric or off-center weight 119 on the shaft 115. The motor 114 may be driven at 500-1400 rpm with 1-5 gallons of hydraulic fluid per minute for 500-1400 vibrations per minute of the vibrating bucket 12. An electrically operated vibrator may also be used.
The vibrating screen bucket 12 further includes an electromagnet 120 on a front portion of the screen cloth floor section 76. The electromagnet 120 extends between the lower support members 72, 73. Leads 121 extend from the electromagnet 120 to the skid-steer loader 20. The electromagnet 120 picks up small items such as nails which otherwise may pass through the screen cloth floor section 76.
The blade 14 is affixed between lower, front ends of side plates 32 and is triangular in cross-section. The blade 14 includes an elongate oblique flat piece 130 formed of steel or a hardened metal and includes the elongate cutting edge 15. An elongate bottom flat piece 131 and an elongate upright flat piece 132 are affixed to flat piece 130 and are affixed at right angles to each other. The blade 14 may be enclosed at both ends to prevent the entry of sand.
In operation, the inner vibrating bucket 12 is readily set in the primary bucket 11 by aligning the angle brackets 101 of the vibrating bucket 12 with the angle brackets 102 of the primary bucket 11. The brackets 101, 102 are then connected with the threaded rods 103, lock nuts 103.1, and compression springs 104. The prescribed amplitude of the vibrations of the screen bucket 12 is subsequently set by turning the lock nuts 103.1. The variable speed control 113 is adjusted to set the desired frequency of the vibrations. The altitude of the skis 16 relative to the cutting edge 15 is typically set so that the cutting edge 15 and bottom surface portions 39 and the flanges 38 dig into the beach at a two inch depth.
The primary bucket 11 is then connected to the skid-steer loader 20. The lift arms 21 and tilt cylinders 24 are connected to the ears 33 and the hydraulic lines 111, 112 are connected to the vibrator 13, which is turned on. The skid-steer loader 20 is then driven on the beach to be cleaned with the tilt arms 21 bringing the skis 16 to engage and slide on the surface of the beach. As the beach is traversed as such, the cutting edge 15 digs into the beach and sand and litter flows up oblique portion 130, over electromagnet 120, and on to the vibrating floor screen portion 76, and perhaps the vibrating side screen portions 92. The vibrations of the screen portions 76, 92 facilitate the screening of the sand, which passes through the screen portions 76, 92 and falls back to the beach. Litter remains in the screen bucket 12, and metallic items may cling to the electromagnet 120. The electromagnet 120 is operable from the cab of the skid-steer loader 20 so that if larger metallic items adhere to the front of the bucket 12 and obstruct the scooping of sand, the electromagnet 120 may be turned off until the larger metallic item is conveyed to the rear of the screen bucket 12. When it is desired to dump collected litter from the screen bucket 12, the skid-steer loader 20 is driven to a dumpster and the lift arms 21 and tilt cylinders 24 are operated to dump the bucket 12.
It should be noted that the sand typically passes through the floor portion before it has travelled about one-third of the distance from the front support member 70 to the rear support member 71 of the screen bucket 12. This result is obtained when the gauge of the criss-cross screen cloth is 7/16 inches, the sand screened is of the glacial type, the hydraulic vibrating frequency is at 500-1400 vibrations per minute, the amplitude of the vibrations is set at 3/8 inches and the skid-steer loader is being driven at 2 mph.
As shown in FIGS. 4 and 7, an alternate embodiment of the invention includes a screen bucket 12 hinged to the primary bucket 11 via a transverse hinge 140 on a central portion of the screen bucket 12. Such an embodiment includes steel pipe or tube sections 141 welded to central bottom portions of the support members 72, 73 of the screen bucket 12. Rubber tube or hydraulic hose sections 142 are disposed axially in the steel tube sections 141 to suppress vibrations and cushion the vibrating screen bucket 12 from the primary bucket 11. The length of tubes 141, 142 is approximately equal to the distance between support members 72, 73. A rod 143 extends axially through the the rubber tube sections 142 and through each of the side plates 32 to which the rod 143 is rotatably connected. Such a transversely hinged screen bucket may minimize the amplitude of the vibrations about the central portion of the screen and maximize the amplitude of the vibrations at the front and rear portions of the screen.
Another embodiment of the invention includes a screen bucket 12 hinged to the primary bucket 11 via a transverse hinge 145 mounted on a front portion of the screen bucket 12. Except for the location, the hinge 145 is identical to hinge 140. The hinge 145 is fixed to the front portion of the screen bucket 12 below the electromagnet 120 and adjacent to the blade 15. At such a location, the hinge 145 may minimize the amplitude of vibrations at the front of the screen bucket 12 and maximize the vibrations at a rear portion of the screen bucket 12.
As shown in FIG. 8, an adjustable blade 150 is mounted between front portions of the side plates 32. The blade 150 is typically a one-piece plate with an oblique portion 151 and opposing side portions 153. The oblique portion 152 includes a cutting edge 154. Each of the side portions 153 includes a curvilinear slot 155 and is connected to the front portions of its respective side plate 32 via a pivot pin 156 and a removable pin connector 157 in the slot 155. The blade 150 is pivotable about pivot 156 such that the cutting edge 154 is disposed at the prescribed depth relative the skis 16 or bottom surface portions 39 of flanges 38. With only the cutting edge 154 and a lower section of the oblique portion 151 engaging the beach, resistance between the attachment 10 and the beach is minimized.
As shown in FIG. 9, an alternate embodiment of the invention includes wheels 160 instead of skis 16. The wheels 160 are mounted on each of the side plates 32 via mounts 161. Each of the mounts 161 include pin connectors 162 cooperating with slots 163 formed in side plates 32. Such independent mounting of the wheels 160 allows the primary bucket 111, and blade 150, or blade 14, to be disposed horizontally, or at an angle, relative to the surface of the beach. The wheels 160 are typically utilized on the harder beaches. The skis 16 are typically utilized on soft sand.
As shown in FIGS. 10 and 11, an alternate embodiment of the invention includes a harp-type screen bucket 170. The floor portion 171 of such a bucket includes no cross-over wires; the screen cloth includes only wires running parallel to each other and forming elongate slots therebetween from a front support member 172 to a rear support member 173. The distance between each of the wires is typically one-eighth to seven-sixteenths inches depending on the type of sand to be screened. With no cross-over wires, sand is screened more quickly. To show one type of harp screen, the Gellhaus U.S. Pat. No. 4,162,968 is hereby incorporated by reference.
A pair of lock nuts 174, 175 on threaded pin 176 form a tension adjustment means for pulling each of the wires 171 taut. An end of each of the wires 171 is set in one of the pins 176. The pins 176 and wires 171 extend through apertures in the cross support members 172, 173. The side and rear portions of the screen bucket 170 may include respective solid plates or walls 176.1, 176.2. A rear portion of the screen bucket 170 includes a vibrator 13 mounted on the plate 84. When a seven-sixteenth inch harp-type screen is utilized, the attachment 10 may clean one-half acre to one and one-half acres of coral sand per hour with the cutting edge 14 disposed two inches into the sand. Another type of harp screen includes a cloth 177.1 crimped into an elongate edge 177 of an elongate U-channel 178. A take-up bar 179 is typically disposed in the U-channel 178. The take-up bar 179 is adjustably mounted to side portions 176.1 via a pin 180 in a horizontal slot such that the harp screen 171.1 is drawn taut as a whole.
As shown in FIG. 12, an alternate embodiment of the invention includes a steel punch plate screen 180 with square apertures 181. Such a punch plate screen 180 is typically utilized for screen black dirt. As an alternative to the square apertures 181, a punch plate with round apertures may be utilized.
As shown in FIG. 13, another alternate embodiment of the invention includes a roller or power broom 190 swingably mounted on a front portion of the primary bucket 11. One end 191 of the broom 190 is mounted on an L-shaped mount 192 pivotally connected to the flange 37 of one of the side plates 32. One end of the L-shaped mount 192 is pivotally affixed to a piston end 193 of a hydraulic cylinder 194, which in turn is pivotally affixed to one of the side plates 32 of the primary bucket 11. The other end of the power broom 190 may be connected in a like manner to the other side plate 32. The power broom 190 further includes an electric motor 195. The length of the broom 190 is approximately equal to the width of the screen bucket 12. Pivotal supports 196 on both of the flanges 37 engage the L-shaped mount 192 to support the broom 190 and align the circumference of the fiberglass bristles 197 with the surface of the beach and adjacent to the cutting edge 15 of the blade 14. The broom 190 is utilized typically on hard sand to sweep litter and its accompanying sand into the screen bucket 12. The broom 190 is swingable to an out-of-the-way position by retracting the piston ends 193.
As shown in FIG. 14, the fiberglass bristles 197 are disposed on a shaft 198 which is typically driven at 50 rpm. Alternatively as shown in FIG. 14A, resilient rubber-like straps or strips 199 are mounted on the shaft 198. Two or more sets of diametrically extending strips 199 may extend from the shaft 198. As shown in FIG. 15, a number of disks 199.1 are rigidly mounted on the power broom shaft 198 and include circumferentially disposed pins 199.2. Each of the pins 199.2 mounts a tension spring-like tine 199.3, each of Which includes an end bearing against the shaft 198. Such tines 199.3 may be used in thatching operations.
As shown in FIG. 16, another alternate embodiment of the invention includes an extendable rake 200. The rake 200 includes a row of projecting teeth 201, and two front and rear telescoping portions 202, 203. The rear telescoping portion 203 is pivotally affixed to the rear plate 31 of the primary bucket 11. Two braces 205 extend from the rear portion 203 to be pivotally affixed to the rear plate 31. The telescoping portions 202, 203 include alignable holes 206 for receiving a pin 207. The rake 200 may be extended 10-30 feet beyond the blade 14 to, for instance, rake seaweed from a shoreline. The rake 200 may be swingable via the pivotal connections to an out of the way position such that the screening bucket 12 may be used. In this embodiment, the vibrator 13 is typically connected to a rear portion of the screen bucket 12, and extends through an opening formed in the rear of the primary bucket 11.
As shown in FIG. 17, a preferred attachment 210 includes a primary excavating bucket 211 which is typically formed of a frame of 2"×2"×10 gauge steel square tubing. A rear portion of the frame includes upper and lower horizontal members 212, 213 with vertical members 214, 215 connected between the members 212, 213. Members 214, 215 include ears for attachment to a mobile machine such as a skid-steer loader. Each of the end portions of the frame of the bucket 211 includes an oblique, upper member 216 and an integral lower member 217 with a rear upright portion 218, a bottom portion 219 for engaging a beach, and a curved front portion 220 which may decrease resistance of the attachment 210 as it traverses a beach. A front cross member 221 is connected between forward portions of the bottom portions 219.
A blade 225 is mounted between the front curved portions 220 and to the front cross member 221. The blade 225 includes an oblique plate 226 with a 10° sloping portion 227 and a greater sloping portion 228. Blade portion 227 includes a cutting edge 229. A right-angled blade portion 230 rigidly connects the plate 226 to the cross member 221.
An inner vibrating bucket 235 is typically formed of a frame of 1"×1"×10 gauge steel square tubing. A rear plate 236 is framed by rectangular tubular frame 237. Each of two generally triangular end plates 238 are framed by a generally triangular, end, tubular frame 239 with upper tubing 240, rear tubing 241 and lower tubing 242. The vibrator 13 is mounted on a plate affixed to an upper central portion of the rear plate 236. The inner bucket 235 further includes front and rear cross members 245, 246 rigidly connected between lower tubing members 242. A harp-type screen 247 is connected between the cross members 245, 246.
A set of four resilient mounts 250 connect the buckets 211, 235 and provide vibration suppressing means for suppressing vibrations of the inner vibrating bucket 235 relative to the outer excavating bucket 236. Each of the oblique upper members 216 include a frontward angle bracket 251 and each of the upper tubing portions 240 include a cooperating frontward angle bracket 252. Frontward resilient bumper pads or grommets 253 are mounted between flat portions of the brackets 251, 252 via removable pin connectors 254.
Two of the resilient mounts 250 are disposed on rear portions of the buckets 211, 235. Each of the rear tubing portions 241 of the inner bucket 235 includes an angle bracket 260 and the horizontal lower member 213 of the outer bucket 211 includes a pair of angle brackets 261. Rearward bumper pads 253 on pin connectors 254 are disposed between flat portions of the brackets 260, 261. The amplitude of the vibrations of the inner bucket 235 is adjusted by turning the pin connectors 254 such that the respective brackets 251, 254 and 260, 261 are drawn together to squeeze the bumper pads 253 therebetween.
It should be noted that as well as cleaning debris from beaches, the present invention may be utilized for screening roots and lumps out of black dirt for use in yards and nurseries, especially with the punch plate screen 180; for cleaning lawns of sticks and stones, especially with the broom implements having fiberglass bristles 197, straps 199, and thatching tines 199.3; for picking up nails and metal mixed with debris on parking lots, scrap yards and lumber years, especially with the electromagnet embodiment 120; for picking up balled up oil and grease; for picking up undesirable rocks and debris at parks and desert land; for picking up dead fish and seaweed at the shoreline; for scarifying and then picking up dead or undesirable sod from yards; for scarifying blacktop or concrete driveways and then removing the undesirable oversized pieces from the road base; for sweeping highways and road shoulders, especially with the fiberglass bristles 197 and straps 199; and for picking up oranges, grapefruit, and pecans from groves.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof; therefore, the illustrated embodiment should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
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The present vibrating bucket screen attachment for cleaning beaches and for being mounted on mobile machines such as skid-steer loaders includes an outer excavating bucket with a sand-scooping blade and runners on the outer bucket for supporting the outer bucket relative to the beach. An inner vibrating screen bucket is resiliently mounted in the excavating bucket and includes a hydraulically operated vibrator. Resilient bumper pad mounts disposed between the inner and outer buckets suppress the vibrations of the inner vibrating bucket relative the outer excavating bucket. A floor screen portion of the inner bucket is mounted above bottom, sand-engaging portions of the outer bucket such that the screen portion is spaced from the surface of the beach to vibrate freely during the separation of sand from litter.
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BACKGROUND OF THE INVENTION
The present invention relates to geological well logging, and more particularly to methods and apparatus for testing geologic formations.
Various wireline instruments and techniques are employed in logging of uncased boreholes to measure the properties of drilled section and the fluids contained in the rock interstices for evaluating the productive capabilities of petroleum reservoir formations. After running electrical, sonic, nuclear, and other wireline logs to identify zones of interest in a borehole, a wireline formation tester may be lowered for measuring subsurface formation and hydrostatic pressures and for taking diagnostic fluid samples. At selected depths, a back-up shoe is set against one side of the borehole to press a probe or "snorkel tube" into, or tightly against, the formation on the opposite side. This provides a good seal for allowing a fluid sample from the formation to collect in a sampling chamber free of any drilling fluid.
The ability to collect a sample and the rate at which the fluid sample is recovered depend upon, among other factors, the formation's permeability, or degree to which the interstices or pores are interconnected, at the snorkel tube. In homogeneous clean sandstones and unfractured limestones, the permeability is substantially uniform in all directions, consequently, the orientation of the snorkel tube in the borehole will not affect the flow rate. In fractured formations, on the other hand, the permeability varies significantly around the borehole. Therefore, the orientation of the probe against the formation will affect the amount of recovery and the sample recovery rate.
Prior art testers make no provision for positioning the snorkel tube in the area of greatest permeability. In fact, some formation testers by their very design consistently place the snorkel tube in areas of the formation where there is least permeability. Consequently, little or no sample is obtained or the time consumed in obtaining a satisfactory quantity of a diagnostic fluid sample is unnecessarily long, and costly in terms of manhours. Even if the snorkel tube were, by chance, positioned in the area of highest permeability, its orifice communicates with a very small area of the formation, thus further limiting the sample recovery rate.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved formation tester for better and more rapid recovery of diagnostic fluid samples from subsurface formations.
Another object of the invention is to provide a formation tester for geological logging in which diagnostic fluid samples are recovered from areas of high permeability of a borehole in a fracture zone of interest.
Still another object of the invention is to provide an improved method for sampling liquid and gas samples in subsurface formations at a preferred orientation of a sampling probe.
A further object is to provide an improved probe for sampling a large area of a borehole in a fracture zone of interest.
Yet another object of the invention is to provide apparatus which can be readily adapted to present formation testing devices for orienting a sampling probe in a borehole in the area of highest permeability, and which is reliable and inexpensive to manufacture and maintain.
Briefly, these and other objects and aspects of the invention are accomplished with a wireline formation tester electrically controlled from the surface and lowered to a fracture zone of interest in an uncased or open borehole for measuring and recording fluid pressures and for recovering fluid samples through a probe positioned at the area of maximum permeability. The tester includes a generally elongate housing and a power-operated cylindrical sampling probe which is laterally extended against the borehole wall. Pressure readings are taken as desired, and fluid samples recovered in collecting chambers. A pair of arms symmetrically extendable from opposite sides of the housing in a longitudinal plane 90° displaced from the probe, urge against the opposite walls of the borehole before extending the probe. In a generally elliptical or oblong borehole the extended arms rotate the housing to a position where they contact the sides of the borehole which are farthest apart and generally align with the long axis of the borehole. The sampling direction will, therefore, always be along the short axis of the borehole where there is maximum permeability in the formation. An alternative embodiment of the sampling probe includes an elongate aperture transverse to the length of the housing for exposing a greater sampling area of optimum permeability for improved fluid sample recovery.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of these and other objects and aspects of the invention, reference may be made to the following detailed description taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a perspective view in cross-section with a borehole on the left flank of a plunging fold of a schematically illustrated geologic structure;
FIG. 2 is a perspective view of a borehole in the upper right quadrant of a schematically illustrated geologic, domal structure;
FIG. 3 is a plan view of the structure of FIG. 1 at the borehole;
FIG. 4 represents a dipmeter log of a typical sand and shale section of a borehole superimposed with interpretive notations;
FIG. 5 is a schematic representation in elevation of a formation tester according to the invention entirely positioned within a fractured, elliptical borehole;
FIG. 6 is an elevation view of the formation tester of FIG. 5 taken along the line 6--6;
FIG. 7 is a cross-sectional view of the formation tester of FIG. 5 taken along the line 7--7;
FIG. 8 is a schematic representation in elevation of an alternate embodiment of a formation tester according to the invention positioned within a borehole;
FIG. 9 is a frontal view of an alternate embodiment of a sampling probe according to the invention for a formation tester; and
FIG. 10 is a cross-sectional view of the probe of FIG. 9 taken along the line 10--10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Structural deformation as applied to consolidated sedimentary or metamorphic rocks create fractures which are oriented in definite patterns in relation to bedding planes and to the resultant structure, i.e. dip, strike, and plunge of the flexure or fold. Referring to the geologic structure of FIG. 1, a simple anticlinal fold of sand and shale strata is shown about an axis F--F plunging to the left from a horizontal datum. This produces a definite pattern of fractures in the shale related to the flexure created by the fold. The intersection of the fracture planes and the shale bedding planes is at approximately 90° and forms elongate fissile shale or splinters S, often referred to as pencil structures, longitudinally oriented with the fold axis F--F. As the axis of the fold changes direction, the long axes of splinters S precisely follow. This is illustrated in the domal fold of FIG. 2.
Splinters S are disproportionately enlarged in FIG. 1 to illustrate their generally square cross-sectional configuration, and even if crushed to microscopic dimensions, the square configuration remains reflecting that the weak fracture planes always intersect the bedding planes at 90° and are dominant to the bedding planes. For example, common roofing slate which is metamorphosed shale splits on fracture planes and not on bedding planes. This fracture phenomenon frequently impedes drilling operations because of extreme sloughing of the splinters into the borehole and potential stuck pipe. These adverse conditions notwithstanding, such formations are valid candidates for exploration rather than undisturbed layercake deposits offering no hydrocarbon traps.
FIG. 1 shows a fractured, subsurface formation on the flank of the plunging fold disturbed by a drill bit on a vertical axis D as causing sloughing from two opposite sides of a borehole B in the direction perpendicular to the elongate orientation of the splinters. As illustrated in FIG. 3, splinters S shown in dotted outline slough off from the top and bottom sides of borehole B diagram leaving a generally elliptical or oblong configuration with a long axis m perpendicular to the length of splinters S and a width on the short axis n the same as or near the drill bit diameter. By analogy, imagine a stack of pencils, representing the splinters, piled on a desk in the same alignment. If the desk were bumped, the stack would collapse with the pencils moving sidewise perpendicular to their alignment. The splinters in a borehole have similar preferential direction of movement resulting in a generally elliptical borehole whenever a fracture formation is disturbed.
From earlier observations, it has been shown that the long axis of a borehole on the flank of a plunging fold will always have an alignment which will deviate from updip an amount proportional to the plunge. If there is no plunge, the resultant circular elongation on the flank of the fold will be oriented with its long axis aligned with the vertical plane of the updip angle. From studies of formations overlying salt domes where the uplift or heave resulted in a domal structure such as illustrated in FIG. 2, the fracturing created a radial pattern of splinters S in which the intersections of their fracture planes with the bedding plane produced splinters coincident with the dip at a particular flank. Accordingly, the elliptical or oblong borehole always orients with the short axis pointing updip, no matter where encountered. Where a structural dip determined by a dipmeter was questionable, it can be resolved by observing the orientation of the borehole ellipse. Although the short axis also defines the downdip direction, the updip direction must be selected from two possibilities. Enough seismic data are usually available to determine which is which.
An actual dipmeter log in FIG. 4, abridged for clarity, corroborates the above-described relationship of fractures to structure in a shale and sand section. The caliper orientation chart on the left is a record of the distance across the borehole on conventional well logging calipers 1-3 and 2-4 on axes 90° apart; and the dipmeter or "tadpole" chart on the right is a record of the true dip angle and the azimuth of the updip angle of a measured plane determined from resistivity measurements. For ease of interpretation, the caliper measurements in scaled lines have been added to the chart for selected depths in the orientation read from the corresponding azimuth record. It will be noted that the orthogonal caliper measurements in sand between 10,650 and 10,700 ft. and from 10,900 to 11,100 ft. are substantially equal indicating a circular borehole. This is as expected since there would be no sloughing off of fissiled shale splinters. However, in the shale strata between 10,700 to 10,900 ft., there is a discrete increase in length across calipers 1-3 indicating an elliptical borehole; and at 10,800 ft., for example, the azimuth of calipers 2-4 is approximately West-Southwest (and East-Northeast) which is in substantial agreement with the azimuth of the structural dip indicated by the tadpole plot of the dipmeter.
Having thusly shown that the elliptical orientation of the borehole bears a direct relationship to fracture alignment and structure, it follows that the preferred direction for optimum recovery of diagnostic fluid samples is along the short axis of the borehole where the probe is exposed to areas of maximum permeability. Most prior art formation testers, to the contrary, align the sampling probe with the long axis of the borehole. This inherently taps the sides of the splinter structures, rather than the ends where there is the greatest permeability, and consequently fastest and greatest recovery.
The present invention in contradistinction provides for recovering fluid samples from a selected depth in a borehole at the area of maximum permeability. Referring now to the embodiment of FIGS. 5, 6, and 7 wherein like characters designate like or corresponding parts throughout the several views, there is shown a formation tester 10 according to the invention lowered to a fracture formation zone of interest in a borehole by and depending from a cable, not shown, and operatively extended for receiving a fluid sample. Except as otherwise described herein, the fluid pressure measuring and sampling components of the tester may be of conventional design such as disclosed in the publications "Formation Multi-Tester (FMT) Principles, Theory, and Interpretation", 5M 10/87 AT87-071 9575, 1987, by Western Atlas International, Houston, Texas, and "Open Hole Repeat Formation Tester `RFT`", compiled by E. Havard, Spring, 1982, by Schlumberger, Houston, Tex.
Tester 10 includes a spindle or housing 12 with a laterally slidable sampling probe 14 of circular cross section at the exposed orifice which communicates with pressure transducers and sample collecting chambers, not shown, in housing 12. A resilient pad 16 mounted on a packer plate 18, fixed to the outer end of probe 14, seals the probe and formation interface to prevent sample contamination from drilling fluids and other slurry. Hydraulically operated pistons 20 at the ends of plate 18 radially extend the probe into contact with the formation, and similarly actuated pistons 24 extend a backup shoe 22 in the opposite direction of probe 14. With the probe positioned at the desired depth and orientation, pressure simultaneously applied to pistons 20 and 24 force probe 14 and backup shoe 22 against the opposite sides of borehole B. The pistons are hydraulically operated by electrical signals transmitted by wire along the cable from a control center (not shown) at the well site.
With formation tester 10 positioned as shown in FIG. 6, fluid pressures, flow rates and samples of the formation fluid at probe 14 may be taken in response to signals electrically transmitted from the control center. After completing measuring and sampling, the hydraulic pressures applied to pistons 20 and 22 are reversed to retract packer plate 18 and backup shoe 22 from the sides of the formation. Tension springs 28 are provided as supplementary forces to plate 18 and backup shoe 22 to insure positive retraction in the event of a failure of hydraulic pressure while probe 14 is in the borehole. Formation testers with plural sample collecting chambers (not shown) in the housing 12 permit several samples to be taken at the same location or at other depths.
The orientation or azimuth of housing 12 and probe 14, as noted above, is critical at fractured formations. In clean granular formations, such as nonlaminated sand, fluids within the interstices will flow at the same rate in any direction; hence, probe orientation is irrelevant since the permeability around the borehole is substantially uniform. In fractured formations, however, the borehole is generally elliptical or oblong with the permeability highest across the opposite surfaces intersecting the short axis of the borehole. The present invention orients probe 14 at these surfaces for improving the sample recovery amount and rate.
In the embodiment of FIGS. 5, 6, and 7, this is accomplished with a pair of oppositely arched springs 32, each connected at one end to a collar 34 fixed to housing 12 and the other end connected to a collar 36 slidable along the length of housing 12, as shown in dotted outline in FIG. 6. Springs 32 are preferably displaced above or below the probe 14 so that advantage can be taken of the maximum ellipticity expressed in shale bounding the interval to be sampled. The dotted outline represents the expansion of springs 32 as tester 10 passes through, for example, a sand zone having a borehole equal to the diameter of the drill bit or smaller than the drill bit because of mud cake on the sides of the borehole. When tester 10 reaches an elliptical shape in the borehole, springs 32 (if not already aligned with the major axis of the ellipse), will impart a torque to the housing 12 in a direction aligning probe 14 with the minor axis. In the event that springs 32 are precisely aligned on the minor axis, a slight displacement may be necessary in order to develop the torque required to initiate rotation and alignment toward the major axis.
Springs 32 are fixed to housing 12 90° displaced from the axis of probe 14. Consequently, when springs 32 align with the surface intersecting the major axis, probe 14 aligns with one of the surfaces intersecting the short axis of the elliptical bore, as shown in FIG. 7. At this position, probe 14 is at the formation area of optimum permeability to afford better pressure measurements and fluid sampling. Better recovery is also achieved in fractured carbonate zones where total effective porosity is extremely small and restricted to fractures.
An alternate embodiment for springs 32 is illustrated in FIG. 8. Probe 14 is oriented along the minor axis of an elliptical borehole by a pair of opposed shoes 32', hydraulically extendable from a housing 12' by pistons 38 and radially displaced 90° from probe 14. At the sampling zone of interest, shoes 32' are first extended against the formation wall causing housing 12' to rotate and align probe 14 and shoe 22 on the short axis. Plate 18 and shoe 22 may then be extended to abut the opposed sides. This arrangement would be especially desirable in highly-fractured carbonate zones.
The circular cross-sectional area at the tip of probe 14 being relatively small, limits the sampling area for the fluid recovery. The present invention provides in the alternate embodiment of FIGS. 9 and 10 a slotted probe 40 in which tube 42 telescopes from housing 12 in the same manner as probe 14 but includes a flared end 44 forming an elongated aperture or slot 46 in an arcuate flange 48. In its simplest form, probe 40 resembles an oblate funnel. The curvature of flange 48 approximates the curvature of the borehole at the probe position and can be fitted at the surface to conform to bit size and anticipated borehole configuration; however, a resilient packer seal 50 may be fixed to the face of flange 48 to accommodate both circular and elliptical bore configurations of a drill hole.
Some of the many advantages of the invention should now be readily apparent. For example, a formation tester is provided which self-orients the sampling probe at the area of optimum permeability for optimum recovery of diagnostic fluid samples from subsurface formations, and which can be readily adapted to existing formation testers. A method is disclosed which assures optimum recovery of fluid samples by orienting the probe along the fracture planes of a formation. A novel probe is also provided which greatly enlarges the surface area sampled at a given position of the formation tester.
It will be understood, of course, that various changes in the details, steps, and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.
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Apparatus and method are disclosed for testing and sampling fluid in an oblong borehole of fracture zones in the area maximum permeability for more efficient recovery and testing in a given sampling period. The tester includes a pair of oppositely extending arms urged against the sides of the borehole causing the tester to rotate until a sampling probe oriented 90° from the arms aligns with the short axis of the borehole. A probe is also disclosed having an elongate slot oriented perpendicular to the borehole for covering a greater horizontal sampling area.
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